Removing ABS control unit J104 and ABS hydraulic unit N55 — VW

Removing
ABS control unit
J104
and
ABS hydraulic unit
N55
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1410
Brake pedal depressor
V.A.G 1869/2
Sealing plugs repair kit, Part No. 1H0 698 311 A
After removing
ABS hydraulic unit
N55
, fit transport protection for contact pins.
Without transport protection, the warranty for the
ABS hydraulic unit
N55
will not be recognised.
1
Transport protection for contact pins (foam)
2
Sealing plug M10
3
Sealing plug M12
Removing
Location:
The
ABS control unit
J104
is bolted to the
ABS hydraulic unit
N55
and is located on the right in the engine compartment.
WARNING
Do not bend the brake lines in the area of the
ABS hydraulic unit
N55
Read out and note the existing control unit code
Chapter
.
Note or request radio code on vehicles with coded radio if necessary.
Disconnect battery
Electrical system
Rep. gr.
27
Disconnecting and reconnecting battery
.
1.4l TSI engine
Remove engine cover
A
and heat shield
B
.
Remove pressure pipe and intake connecting pipe with regulating flap control unit
2
4-cyl. injection engine (1.4l direct injection engine, turbocharger and compressor)
Rep. gr.
24
Injection system; Part I - assembly overview - intake manifold
.
Remove charge air hose
1
4-cyl. injection engine (1.4l direct injection engine, turbocharger and compressor)
Rep. gr.
21
Charge air system
.
Clamp off hose from coolant expansion tank and pull it off.
Vehicles with diesel engine
Remove engine cover in
direction of arrow
.
1.9l diesel engine
Remove connecting hose to intake pipe
4-cylinder diesel engine (2 valve)
Rep. gr.
21
Removing and installing charge air system with turbocharger
.
Remove intake manifold flap motor V157
4-cylinder diesel engine (2 valve)
Rep. gr.
23
Removing and installing mixture preparation - injection
.
1.6l and 2.0l diesel engine
Remove upper part of timing belt guard by detaching clasps
arrows
.
Remove plenum chamber middle bulkhead
General body repairs, exterior
Rep. gr.
50
Assembly overview - plenum chamber bulkhead
.
Remove connecting pipe between intake hose and turbocharger.
All diesel engines with diesel particulate filter
Unscrew
exhaust gas pressure sensor
, separate electrical connectors,
Rep. gr.
26
Assembly overview - front exhaust pipe with particulate filter
.
Remove clamp
1
.
Unscrew bolts of particulate filter
2
to
5
Exhaust system
Rep. gr.
26
Removing and installing particulate filter with front exhaust pipe
.
Lower particulate filter.
Continuation for all vehicles
Remove heat shield (if installed).
Release connector from
ABS control unit
J104
in direction of arrow
1
and pull it off
2
.
Apply
brake pedal depressor
V.A.G 1869/2
.
Connect bleeder bottle hose to front left brake caliper bleeder valve and rear left brake caliper bleeder valve and open bleeder valves.
Depress brake pedal at least 60 mm using
brake pedal depressor
V.A.G 1869/2
.
Close front left and rear left bleeder valves.
Do not remove
brake pedal depressor
V.A.G 1869/2
.
Place sufficiently lint-free cloths under
ABS control unit
J104
and
ABS hydraulic unit
N55
.
Ensure no brake fluid gets onto contacts.
First mark the two brake master cylinder brake lines
A and B
and unscrew from
ABS hydraulic unit
N55
.
Immediately seal brake lines and threaded holes with seal plugs from repair set Part No. 1H0 698 311 A.
Mark brake lines (brake caliper)
1 to 4
, unscrew and seal with plugs from repair kit Part No. 1H0 698 311 A.
Turn hexagon fitted bolt out of retainer.
Pull off
ABS hydraulic unit
N55
with
ABS control unit
J104
and retainer sideways from damper rubbers of bracket and turn upside down.
Unbolt bracket from
ABS hydraulic unit
N55
in engine compartment and remove.
Remove
ABS hydraulic unit
N55
with
ABS control unit
J104
.