2.5L Engine
ABS Control Module and ABS Hydraulic Unit
Special tools, testers and auxiliary items required
• Torque wrench (V.A.G 1331)
• Torque wrench (V.A.G 1410)
• Brake pedal actuator (V.A.G 1869/2)
• Hose clamp pliers (VAS 6340)
Plug (1H0 698 311 A)
Install the transportation protection after removing the ABS hydraulic unit (N55).
The warranty on the ABS hydraulic unit will not be honored if there is no transportation protection.
1 Transport protection for valve domes (foam)
2 Sealing plugs M10
3 Sealing plugs M12
Removing
• Component location: The ABS control module (J104) is attached to the ABS hydraulic unit and is located inside the engine compartment on the right side.
1. ABS hydraulic unit with ABS control module
2. Brake booster with tandem master cylinder
Do not bend the brake lines near the ABS hydraulic unit!
- Get the coding from the ABS control module and write it down.
Use the Vehicle Diagnostic Tester.
• Chassis
• Brake System
• Anti-lock braking system ABS/EDS/ASR/ESP Mark 60 EC
• Function
• Check coding in the ABS control module J104
• Disconnect battery ground strap for all further work. See if a coded radio is installed. Get the anti-theft code beforehand, if necessary.
Danger of causing damage to electronic components when disconnecting the battery.
• Complete the steps for disconnecting the battery.
- Disconnect the connector - 1 - and intake hose - 2 -.
- Remove the bolts - 3 - and the intake hose.
- Remove the engine cover from the fasteners first at the front - arrow 1 -, then at the rear on the right side - arrow 2 - and finally at the rear on the left side - arrow 3 - with a quick pull.
- Carefully remove the engine cover at the rear.
- Remove the nuts - 1 - and remove the heat shield - 2 -, if equipped.
- Disconnect the connector from the ABS control module - in direction of arrow -.
- Insert (V.A.G 1869/2).
- Attach the bleeder bottle bleed hose - 1 - to the left front brake caliper bleed valve.
- Open the bleed valve.
- Attach the bleeder bottle bleed hose - 1 - to the left rear brake caliper bleed valve.
- Open the bleed valve.
- Depress the brake pedal at least 60 mm with the (V.A.G 1869/2).
- Close left front and left rear bleeder valves.
Do not remove (V.A.G 1869/2).
- Place a lint-free cloth under the ABS control module and the ABS hydraulic unit.
• Make sure no brake fluid gets onto contacts.
- First mark both brake lines - A - and - B - on the master cylinder and then remove them from the ABS hydraulic unit.
- Seal brake lines and threaded holes with sealing plugs (1H0 698 311 A).
- Mark brake lines - 1 - through - 4 - and then remove them.
- Seal brake lines and threaded holes with sealing plugs (1H0 698 311 A).
- Remove the hex bolt form the bracket - arrow -.
- Remove the ABS hydraulic unit with the ABS control module and the bracket sideways in - direction of arrow - from the rubber bushings on the console.
- Turn the ABS hydraulic unit with the ABS control module upside down.
- Remove the bracket from the ABS hydraulic unit inside the engine compartment.
- Remove ABS hydraulic unit with ABS control module.
Installing
Install in reverse order of removal. Note the following:
• Remove the plugs on the new ABS hydraulic unit only when installing the brake line.
• Brake fluid will leak out if the plugs are removed too early from the ABS hydraulic unit. The system will then not have sufficient brake fluid and will not adequately bled.
When installing the mount, make sure the rubber insulation does not push out of the bracket. Make sure the ABS hydraulic unit is secure after installing it otherwise malfunctions can occur.
- Make sure the rubber buffers fit correctly in the mounts when installing the engine cover.
Before installing the engine cover, make sure the 4 mounting elements (ball sockets) are correctly positioned; adjust them if necessary. Otherwise the engine cover will get damaged.
- Connect the battery.
- Remove (V.A.G 1869/2).
- Bleed the brake system. Refer to => [ Brake System, Bleeding ] Service and Repair.
• Perform a basic setting on the steering angle sensor (G85) , the transverse acceleration sensor (G200) and the brake pressure sensor (G201) after installing the ABS control module and the ABS hydraulic unit.
Use the Vehicle Diagnostic Tester.
• Chassis
• Brake System
• Anti-lock braking system ABS/EDS/ASR/ESP Mark 60 EC
• Function
• Sensor basic setting (G85/ G200/ G201/ G251)
If a new ABS control module was installed, it must be coded.
Use the Vehicle Diagnostic Tester.
• Chassis
• Brake System
• Anti-lock braking system ABS/EDS/ASR/ESP Mark 60 EC
• Function
• ABS Control Module J104, coding
Tightening Specification
