ABS Control Module -J104- /ABS Hydraulic Unit -N55-, REMOVING AND INSTALLING, WITH 4-CYLINDER ENGINE AND ABS MARK 70 ABS/ASR: Removing

WARNING: This page is about a different variant/trim than selected.

Fig 1: Configuration

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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- !

NOTE:

The battery ground cable must be disconnected for the following procedure. Check if a coded radio is installed. If necessary, obtain anti-theft code beforehand.

CAUTION:

Danger of causing damage to electronic components when disconnecting the battery.

Follow the steps for disconnecting the battery.

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Remove engine cover near in direction of -arrows-.

Fig 2: Engine Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Observe the given sequence -1 through 4-.

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

CAUTION:

The bracket for attaching the engine cover to the cylinder head could break if removed incorrectly. Always follow these steps to remove 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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 4: Removing Upper Toothed Belt Guard

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 5: Disconnect The Black

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 6: Identifying Particulate Filter Bracket Bolt

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Loosen the clamps and remove the hoses from the particulate filter. Refer to OVERVIEW - EMISSIONS CONTROL (CPLA, CPPA, CPKA, CPRA) or OVERVIEW - EMISSIONS CONTROL SYSTEM (DDSA, DDSB) .

-- Raise the vehicle.

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

Fig 7: Identifying Turbocharger/Particulate Filter Clamp

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

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

Vehicles with Absorption Catalytic Converter

-- Disconnect the exhaust system between the particulate filter and the absorption catalytic converter. Refer to OVERVIEW - EMISSIONS CONTROL (CPLA, CPPA, CPKA, CPRA) or OVERVIEW - EMISSIONS CONTROL SYSTEM (DDSA, DDSB) .

-- Disconnect the exhaust system after the absorption catalytic converter. Refer to OVERVIEW - EMISSIONS CONTROL (CPLA, CPPA, CPKA, CPRA) or OVERVIEW - EMISSIONS CONTROL SYSTEM (DDSA, DDSB) .

Continuation for All Vehicles

-- If equipped, remove the EGR pipe from the particulate filter. Refer to OVERVIEW - EMISSIONS CONTROL (CPLA, CPPA, CPKA, CPRA) or OVERVIEW - EMISSIONS CONTROL SYSTEM (DDSA, DDSB) .

-- Disconnect the exhaust system. Refer to OVERVIEW - MUFFLER (CPLA, CPPA, CPKA, CPRA) or OVERVIEW - MUFFLER (DDSA, DDSB) .

-- Remove the exhaust system bracket from the subframe -arrows-.

Fig 8: Heat Shield Bolts

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 9: Identifying Bolts And Drive Axle Cover

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the right drive axle form the flange, lay it down and secure it. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Remove the nuts -1-.

Fig 10: Identifying Nuts And Particulate Filter Bracket

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the nuts -2- using the : T10384 .

-- Remove bracket for particulate filter -3-.

-- Seal all openings using the : VAS6122 .

-- 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.

-- If equipped, remove the nut -1- and remove the heat shield -2-.

Fig 11: Identifying Nuts And Heat Shield

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

Fig 12: Identifying Direction To Release And Remove Connector From Control Module

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the : VAG1869/2 .

Fig 13: Identifying Brake Pedal Depressor V.A.G 1869/2

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove front left caps -1-.

Fig 14: Identifying Bleeder Screw Cap

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove rear left caps -1-.

Fig 15: Identifying Bleeder Screw Cap (Rear)

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

Use a suitable bleeder hose

It must fit tightly on the bleeder valve so that no air can get into the brake system

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

Fig 16: Identifying Bleed Valve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the breather valve.

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

Fig 17: Identifying Bleed Valve

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Open the breather valve.

-- Push the brake pedal at least 60 mm using the : VAG1869/2 .

-- Close the left front and left rear bleeder valves.

Do not remove the : VAG1869/2 .

-- Place enough lint-free cloths under the ABS Control Module -J104- and the ABS Hydraulic Unit -N55-.

Make Sure No Brake Fluid Gets on the Contacts

CAUTION:

Do not confuse the brake lines when connecting them to the ABS Hydraulic Unit -N55-. Mark the lines in their installed position before removing them.

-- Mark brake lines -A and B- from brake master cylinder.

Fig 18: Identifying Brake Lines

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Remove the brake lines -A and B- from the ABS Hydraulic Unit -N55-.

-- Immediately seal the threaded holes with the plugs from the assembly repair kit.

-- Close brake lines immediately using Sealing Plugs or with suitable plugs from the : VAS6122 .

-- Mark brake lines (brake calipers) -1 to 4-, unscrew and seal.

-- Immediately seal the threaded holes with the plugs from the assembly repair kit.

-- Close brake lines immediately using Sealing Plugs or with suitable plugs from the : VAS6122 .

-- Remove the ABS Hydraulic Unit -N55- and the ABS Control Module -J104- in direction of -arrow- and pull upward out of the shock absorbers.

Fig 19: Identifying Hydraulic Unit With Control Module Upward Removed Out Of Shock Absorbers

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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

-- Remove the bracket in the vehicle from the hydraulic unit -arrows- (only on engines with too little clearance between the cross panel and engine).

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

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