ABS Control Module -J104- AND ABS Hydraulic Unit -N55-, REMOVING AND INSTALLING, 4-CYLINDER DIESEL ENGINE WITH EMISSIONS CONTROL MODULE: Removing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Configuration

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Component Location

The ABS Control Module -J104- is attached to the ABS Hydraulic Unit -N55- and is located inside the engine compartment on the right side.

ABS Hydraulic Unit -N55- with ABS Control Module -J104-
Brake booster with tandem brake master cylinder

WARNING: Do not bend the brake lines near the ABS Hydraulic Unit -N55- !

-- Get the coding from the ABS Control Module -J104- and write it down.

Use the Vehicle Diagnostic Tester.

Chassis
Brake System
Anti-lock braking system ABS/EDL/ASR/ESP Mark 60 EC
Function
Check Coding in the ABS control module J104

NOTE: To perform work sequence, the Ground (GND) cable must be disconnected from battery. Check if a coded radio is installed. If so, obtain anti-theft coding beforehand.

CAUTION: Risk of damaging electronic components when disconnecting the battery.

Observe the steps for disconnecting the battery.

-- Disconnect the battery. Refer to REMOVAL AND INSTALLATION .

-- Remove the engine cover. Refer to [For transmission(s) 02E, 02Q] [For engine(s) CVCA, CJAA] Removal and Installation [For engine(s) CPRA, CPKA, CPLA, CPPA] Removal and Installation [For engine(s) CVCA] Removal and Installation [For engine(s) CCTA, CBFA] Removal and Installation [For engine(s) CBUA] Removal and Installation .

Fig 2: Engine Cover

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CAUTION: The bracket for attaching the engine cover to the cylinder head could break if removed incorrectly. Always remove the engine cover according to the following procedure.

-- Pull the engine cover -arrows- upward in the given sequence.

-- Reach as far as possible under the engine cover.

-- Remove the nuts -arrows- and then remove the heat shield -1- from the diesel particulate filter.

Fig 3: Locating Heat Shield Nuts

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-- Open the clips -arrows- and remove the upper toothed belt cover.

Fig 4: Removing Upper Toothed Belt Guard

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-- Unclip the wires on the cover.

-- Remove the noise insulation or impact guard. Refer to DESCRIPTION AND OPERATION .

WARNING:

The reducing agent can irritate skin, eyes and the respiratory system.
If the fluid comes into contact with skin, rinse the affected area immediately with plenty of water.
If necessary, consult a physician.

CAUTION:

Protect the connectors, for example with a plastic bag or cable ties, before coating with reducing agent. The connectors could be damaged because the reducing agent has a tendency to seep and it crystallizes.

Seal all openings on the line and the connections immediately with plugs to prevent contaminants from entering. Even tiny particles can cause serious damage to the system.

Make sure the reducing agent does not come into contact with clothing or the vehicle body.

If this occurs, wash immediately with clean water and then dry with a lint-free cotton cloth.

If the reducing agent has already crystallized, use warm water and a sponge.

Reducing agent that is not removed will crystallize and can damage the affected surface.

-- Release and disconnect the connector -4- on the Reducing Agent Injector -N474- -2-.

Fig 5: Identifying Connector

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NOTE: Securing clamp -1- for the Reducing Agent Injector -N474- must not be opened.

-- Release the securing device -3- in direction of -arrow 1-.

-- Remove the coupling in direction of -arrow 2- without special equipment and without >>sharply pulling<< on it.

-- Remove the tunnel bridge. Refer to REMOVAL AND INSTALLATION .

-- Remove the clamping sleeve -1-.

Fig 6: Front Cross Member

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-- Remove the right underbody trim panel. Refer to DESCRIPTION AND OPERATION .

-- Remove the NOx Sensor 2 Control Module -J881-. Refer to [For engine(s) CPRA, CPKA, CPLA, CPPA] Description and Operation [For engine(s) CVCA] Description and Operation [For engine(s) CCTA, CBFA] Description and Operation [For engine(s) CBUA] Description and Operation [For transmission(s) 02E, 02Q] [For engine(s) CVCA, CJAA] Description and Operation .

-- Loosen the nuts -arrows- and remove the exhaust pipe -1-.

Fig 7: Identifying Exhaust Pipe Nuts

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-- Remove the bracket bolts -arrows-.

Fig 8: Bracket For Exhaust System

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-- Remove the exhaust pipe with the Reducing Agent Injector -N474-, the NOx Sensor Control Module 2 -J881- and the Exhaust Door Control Unit -J883-.

-- Release and remove connectors -1 through 3-.

Fig 9: Disconnect The Black

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-- Guide the wires out.

-- Remove the particulate filter mount bolts -1-.

Fig 10: Identifying Particulate Filter Bracket Bolt

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-- Raise the vehicle.

-- Loosen the clamp -1- for the turbocharger/particulate filter connection and remove it.

Fig 11: Identifying Turbocharger/Particulate Filter Clamp

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NOTE: The illustration shows the clamp bolt -1- from underneath. This can also be installed from above in some cases.

-- Release and disconnect the connector -2- from the Differential Pressure Sensor -G505-.

Fig 12: Identifying Bolt

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-- Remove the bolt -4-.

-- Remove the bolt -3-.

-- Remove the Differential Pressure Sensor -G505- and move it to the side.

-- Free up the diesel lines from the bracket for the Differential Pressure Sensor -G505-. Refer to [For engine(s) CVCA, CJAA] Description and Operation [For engine(s) CBFA, CPRA, CPKA, CPLA, CBUA, CCTA, CPPA] Description and Operation .

-- Remove the bolts -1-.

NOTE: Lower the Differential Pressure Sensor -G505- and the bracket.

-- Remove the bolts -arrows-.

Fig 13: Identifying Bolts

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-- Release and disconnect the connector -3-.

-- Unclip the Exhaust Pressure Sensor 1 -G450- -1- on the bracket -2-.

-- Remove the bracket -2-.

-- Loosen the clamp and remove the hoses -4- from Exhaust Pressure Sensor 1 -G450- -1-.

-- Remove the nut -arrow- to remove the bracket -1- on the upper cylinder head.

Fig 14: Identifying Nut And Bracket

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-- Disconnect the wiring harness from the Exhaust Gas Temperature Sensor -- and remove it in direction of -arrow-.

Fig 15: Identifying Connector For Exhaust Gas Temperature Sensor

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-- Remove Exhaust Gas Temperature Sensor -- -arrow-.

Fig 16: Identifying Exhaust Gas Temperature Sensor 4

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-- Remove the Exhaust Gas Temperature Sensor --.

CAUTION: Danger of causing damage to the decoupling element.

-- Secure the decoupling element with the Transportation Lock T10404 -arrow-.

Fig 17: Identifying Decoupling Element

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-- Loosen the clamp -2- on the Exhaust Gas Recirculation (EGR) pipe -1- and remove.

Fig 18: Identifying Clamp And Nuts

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-- Remove the bolts -1- and remove the drive axle cover -2-.

Fig 19: Identifying Bolts And Drive Axle Cover

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-- Remove the right drive axle form the flange, lay it down and secure it. Refer to REMOVAL AND INSTALLATION .

-- Remove the nuts -1-.

Fig 20: Identifying Nuts And Particulate Filter Bracket

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-- Remove the nuts -2- and remove the particulate filter bracket -3-.

-- Push the particulate filter downward so that it lays on the subframe.

Fig 21: Turn The Particulate Filter 180 Degrees

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-- Close all openings using the Engine Bung Set VAS6122.

NOTE: The particle filter must not be removed from the vehicle.

-- Lower the particulate filter just enough so that it touches the steering gear.

NOTE: Pay attention to the Exhaust Gas Temperature Sensor -- and the Heated Oxygen Sensor -- when lowering onto the cables in order to avoid any damage.

-- Remove the nuts -1- and remove the heat shield -2-, if equipped.

Fig 22: Identifying Nuts And Heat Shield

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-- Disconnect the connector from the ABS Control Module -J104- in direction of -arrow-.

Fig 23: Identifying Direction To Release And Remove Connector From Control Module

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-- Install the Brake Pedal Actuator VAG1869/2.

Fig 24: Identifying Brake Pedal Depressor V.A.G 1869/2

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-- Attach the bleeder bottle bleeder hose -1- to the left front brake caliper bleeder valve.

Fig 25: Identifying Bleed Valve

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-- Open the bleeder valve.

-- Attach the bleeder bottle bleed hose -1- to the left rear brake caliper bleeder valve.

Fig 26: Identifying V.A.G 1869/2

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-- Open the bleeder valve.

-- Push the brake pedal with the Brake Pedal Actuator VAG1869/2 at least 60 mm.

-- Close left front and left rear bleeder valves.

Do not remove the Brake Pedal Actuator VAG1869/2.

-- Place a lint-free cloth under the ABS Control Module -J104- and the ABS Hydraulic Unit -N55-.

Make Sure No Brake Fluid Gets Onto Contacts.

-- First, mark both brake lines from master cylinder -A and B-.

Fig 27: Identifying Brake Lines (Brake Caliper) -1- To -4- And Brake Lines (Master Cylinder) -A To B-

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-- Remove the break line from the ABS Hydraulic Unit -N55-.

-- Seal the threaded holes immediately with plugs from the assembly part set part number 5Q0 698 311.

-- Close brake lines immediately using Sealing Plugs 1H0 698 311 A or with suitable plugs from the Engine Bung Set VAS 6122.

-- Mark brake lines -1 through 4- and then remove them.

-- Seal the threaded holes immediately with plugs from the assembly part set part number 5Q0 698 311.

-- Close brake lines immediately using Sealing Plugs1H0 698 311 A or with suitable plugs from the Engine Bung Set VAS 6122.

-- Remove the hex bolt form the bracket -arrow-.

-- Remove the ABS Hydraulic Unit -N55- with the ABS Control Module -J104- and the bracket sideways in direction of -arrow- from the rubber bushings on the console.

-- Turn the ABS Hydraulic Unit -N55- with the ABS Control Module -J104- upside down.

-- Remove the bracket from the ABS Hydraulic Unit -N55- inside the engine compartment.

-- Remove the ABS Hydraulic Unit -N55- with the ABS Control Module -J104-.