Hydraulic unit/ABS control module, removing and installing

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Fig 1: Identifying Special Tools - Hydraulic unit/ABS control module, removing and installing

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Special tools and equipment

Additional required information sources

Component location:

The ABS control module is bolted together with the hydraulic unit and is located in the engine compartment, left side.

CAUTION:

Brake lines in the area of the hydraulic unit should not be bent!

Removing

Fig 2: Identifying Air Cleaner Assembly

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Disconnect electrical connector -1- of Mass Air Flow MAF sensor from air filter tube.
Remove bolts -2- at air filter -3- and move filter to left side.
On vehicles with Diesel engines, remove relay panel above brake booster.
Remove as much brake fluid as possible from brake fluid reservoir using a brake bleeder bottle.

Insert brake pedal depressor VAG 1869/2 or equivalent.
Activate brake pedal booster with brake pedal depressor.
Connect bleeder bottle hose to bleed screw of left front brake caliper and open bleed screw.
Close left front bleed screw.

Fig 3: Releasing ABS Control Module Connector

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Release ABS control module connector (arrow -1-) and remove (arrow -2-).
Place plastic covering under control module and hydraulic unit. Do not use rags.

NOTE: Do not let brake fluid enter electrical connectors.

Fig 4: Locating Hydraulic Unit To Brake Master Cylinder Brake Lines, Brake Lines And Threaded Holes

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Disconnect brake lines from hydraulic unit to brake master cylinder (arrows) and suspend with wire.
Disconnect remaining brake lines from hydraulic unit.
Seal brake lines and threaded holes (arrows) using plugs from repair kit, Part No. 1H0 698 311 A.

Fig 5: Identifying Hydraulic Unit Bolts

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ABS control module, removing from hydraulic unit

Fig 6: Identifying ABS Control Module Bolts

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Fig 7: Identifying ABS Control Module Separated

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NOTE:

When removing the control module make sure that the hydraulic unit valve dome does not contact the control module solenoid valves.
Cover the control module magnet coils with a plastic cover. Do not use rags.
After separating the control module and hydraulic unit use transportation protection for the valve dome.

Installing

NOTE:

Only remove the sealing plugs on the new hydraulic unit just before installing the corresponding brake line.
If the sealing plugs are removed from the hydraulic unit too early, brake fluid can escape. It can then no longer be guaranteed that the unit 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 max. 4 Nm (35 in. lb).
Re-connect electrical connector for hydraulic pump motor.
Install ABS unit to bracket.

NOTE: Hand-tighten bolts at first to make attaching the individual brake lines easier.

Tightening Torques:
Control module to hydraulic unit	max. 4 Nm (35 in. lb)
Hydraulic unit to bracket	8 Nm (70 in. lb)
Nut for brake master cylinder to brake booster	20 Nm (15 ft. lb)
Brake lines at ABS unit:
Thread M10 x 1	14 Nm (10 ft. lb)
Thread M12 x 1	14 Nm (10 ft. lb)
Nut to body	20 Nm (15 ft. lb)
Cap nut to body	20 Nm (15 ft. lb)