Control Module and Hydraulic Unit Mark 60, Removing and Installing

Control module and hydraulic unit Mark 60, removing and installing




Special tools and equipment
^ VAG 1331 Torque wrench
^ VAG 1410 Torque wrench
^ VAG 1869/2 Brake pedal depressor

Location:
The control module is bolted to the hydraulic unit and is located on left in the engine compartment.

WARNING! Do not bend the brake lines in the area of the hydraulic unit!

Removing:
- Request radio code on vehicles with coded radio if necessary.
- Disconnect battery.

Remove air cleaner





- Pull connector -2- off mass air flow sensor.
- Release spring-type clip -1- on air duct hose with pliers VAG 1921 and pull hose off air cleaner.
- Remove air cleaner bolts -3- and take out air cleaner -4-.





- Release control module connector (arrow -1-) and pull off (arrow -2-).
- Install brake pedal loading device VAG 1869/2.
- Connect bleeder bottle hose to left front brake caliper and left rear caliper bleed screw and open bleed screws.
- Depress brake pedal at least 60 mm (2.36 in.) with brake pedal depressor VAG 1869/2.
- Close left front and left rear caliper bleeder screws.
- Do not remove brake pedal depressor VAG 1869/2 from brake pedal.
- Place sufficient lint-free cloths under the control module and hydraulic unit.

Make sure no brake fluid gets on contacts.





- Disconnect brake lines -1- from hydraulic unit to brake master cylinder and tie up
- Disconnect remaining brake lines on hydraulic unit.
- Seal brake lines and threaded holes with plugs from repair kit Part No. 1 H0 698 311 A.
- Remove bolts (arrows) from hydraulic unit/control module bracket.
- Remove hydraulic unit with control module.

Removing control module from hydraulic unit
- Place the hydraulic unit with control module down on a clean flat surface.





- Remove E 5 hex socket head bolt -arrows- from hydraulic pump.

CAUTION! The hydraulic pump must not be separated from the hydraulic unit.





- For this reason, tighten the hydraulic pump with the red bracket -1- from the repair kit and two sealing plugs -2- on the hydraulic unit.





- Separate hydraulic unit with hydraulic pump from control module by carefully lifting off joint -1-.





When pulling off control module, make sure that the hydraulic unit valve dome does not contact the control module solenoid valves.
Cover control module magnetic coils with a lint-free cloth.
After separating control module and hydraulic unit use transportation protection for valve dome.
The contact pin -2- which is supplied as a replacement part along with the control module can only be clipped in once and then it cannot be removed.

Installing

Note:
^ Only remove sealing plugs on new hydraulic unit when the corresponding brake line is going to be installed.
^ If the sealing plugs are removed too early, brake fluid can escape, it can no longer be guaranteed that the module is sufficiently filled or adequately bled.

When assembling the control module and hydraulic unit, be sure that the hydraulic unit valve dome does not come in contact with the control module solenoid valves.
- Using new bolts, install control module to hydraulic unit. Do not tighten more than a max. 4 Nm (35 in. lb).
- Bolt ABS module to bracket.
Do not tighten bolts completely. Attaching the individual brake lines is made easier.
- After tightening brake lines, tighten hydraulic unit.
- Further installation is carried out in the reverse sequence.
- Remove brake pedal depressor VAG 1869/2.
- Bleed brake system.
- Enter radio code.
- Code ABS control module (w/EDL) -J104-.
- Basic settings must be performed when replacing ABS control module (w/EDL) -J104-.

Tightening Torques: