Removing and installing ABS control unit J104 and ABS hydraulic unit N55, hybrid vehicles and ABS Mark 60 EC (ABS/EDL/TCS/ESP) — VW

Removing and installing
ABS control unit
J104
and
ABS hydraulic unit
N55
, hybrid vehicles and ABS Mark 60 EC (ABS/EDL/TCS/ESP)
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Ring insert tool, open, AF 11 mm
V.A.G 1410/6
Universal joint
V.A.G 1410/7
Torque wrench
VAS 6854
Brake pedal depressor
V.A.G 1869/2
Assembly tool
V.A.G 1410/8
Hose clip pliers
VAS 6340
Bleeder bottle
Tool set for brake bleeding
VAS 6564
Sealing plugs, assembly part no. 5Q0 698 311
1
Sealing plug M10
2
Sealing plug M12
Sealing plug
1H0 698 311 A
Transport protection must be fitted after removal of
ABS hydraulic unit
N55
.
Without transport protection, the warranty for the
ABS hydraulic unit
N55
will not be recognised.
1
Transport protection for contact pins (foam)
2
M10 sealing plugs
3
M12 sealing plugs
Removing
Fitting locations:
Brake servo with tandem brake master cylinder
ABS hydraulic unit
N55
with
ABS control unit
J104
Caution
Do not interchange the brake lines when connecting tandem brake master cylinder to
ABS hydraulic unit
N55
. Mark installation position before removing brake lines.
Do not bend the brake lines in the area of the
ABS hydraulic unit
N55
Read out and note code of
ABS control unit
J104
.
Use
vehicle diagnostic tester
.
Running gear
Brake system
ABS/EDL/TCS/ESP Mark 60 EC anti-lock brake system
Function
Check code of ABS control unit J104
Note
Disconnect battery earth strap for all further work. Before doing so, check whether a coded radio is fitted in the vehicle. If there is one, first find out what the anti-theft code is.
Caution
There is a danger of electronic components being destroyed when battery is disconnected.
Take necessary measures before disconnecting battery.
Vehicles with 2.0 l petrol engine and turbocharger
Pull off engine cover upwards from fastening points
arrows
Rep. gr.
10
Engine cover; Removing and installing engine cover
.
Vehicles with 1.4 l petrol engine, turbocharger and supercharger:
Hold engine cover panel
3
at points
1
and lift it upwards in direction of
arrow
.
Pull engine cover panel in direction of
arrow
towards front out of retainer
2
.
Vehicles with diesel engine:
Pull off engine cover in areas marked with
arrows
.
Observe the indicated order,
1
to
4
Rep. gr.
10
Engine cover; Removing and installing engine cover
Grasp under engine cover as far as possible.
Continuation for all models:
If necessary, remove intake hose
2
Rep. gr.
24
Air filter; Assembly overview - air filter housing
.
To do this, loosen clamps
1
.
Seal openings with
engine bung set
VAS 6122
.
Apply
brake pedal depressor
V.A.G 1869/2
.
Pull off front left cap
1
.
Pull off rear left cap
1
.
Use suitable bleeder hose. It must sit tightly on bleeder valve so that no air can enter brake system.
Connect hose of bleeder bottle
1
to bleeder valve of front left brake caliper.
Open bleeder valve.
Connect hose of bleeder bottle
1
to bleeder valve of rear left brake caliper/wheel brake cylinder.
Open bleeder valve.
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
.
Vehicles with manual gearbox:
Unclip hydraulic line
1
from retainer
2
arrows
.
Continuation for all models:
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 lines
A
and
B
coming from brake master cylinder.
Detach brake lines
A
and
B
from
ABS hydraulic unit
N55
.
Seal threaded holes immediately using sealing plugs from the assembly part kit, part no. 5Q0 698 311.
Immediately seal brake lines with
sealing plugs
1H0 698 311 A
or suitable plugs from
engine bung set
VAS 6122
.
Mark and unscrew brake lines
1
to
4
.
Seal threaded holes immediately using sealing plugs from the assembly part kit, part no. 5Q0 698 311.
Immediately seal brake lines with
sealing plugs
1H0 698 311 A
or suitable plugs from
engine bung set
VAS 6122
.
Release connector on
ABS control unit
J104
in direction of
arrow 1
.
Pull off connector in direction of
arrow 2
.
Turn hexagon fitted bolt
3
out of retainer.
Pull
ABS hydraulic unit
N55
with
ABS control unit
J104
and bracket sideways out of damper rubbers in bracket.
Remove
ABS hydraulic unit
N55
together with
ABS control unit
J104
.
Installing
Install in reverse order. Note the following points:
Caution
Do not interchange brake lines when connecting them to the
ABS hydraulic unit
N55
. Observe the marked installation position.
Note
Do not remove sealing plugs from new
ABS hydraulic unit
N55
until respective brake line is about to be installed.
If sealing plugs are removed too early from the
ABS hydraulic unit
N55
, brake fluid can escape, and it can then no longer be guaranteed that the unit can be sufficiently filled and bled.
WARNING
When installing, ensure that rubber dampers are not pressed out of bracket. After installation, check that the
ABS hydraulic unit
N55
is firmly seated, or malfunction can occur.
Connect battery
Electrical system
Rep. gr.
27
Battery; Disconnecting and connecting battery
.
Remove
brake pedal depressor
V.A.G 1869/2
.
Bleed brake system
Chapter
.
After the
ABS control unit
J104
and the
ABS hydraulic unit
N55
have been installed, the
steering angle sender
G85
, the
lateral acceleration sender
G200
and the
brake pressure sender
G201
must be reset.
Use
vehicle diagnostic tester
.
Running gear
Brake system
ABS/EDL/TCS/ESP Mark 60 EC anti-lock brake system
Function
Reset senders (G85/ G200/ G201/ G251)
If a new
ABS control unit
J104
has been installed, it must be coded.
Use
vehicle diagnostic tester
.
Running gear
Brake system
ABS/EDL/TCS/ESP Mark 60 EC anti-lock brake system
Function
Code ABS control unit J104
Specified torques
Chapter
“
Assembly overview - control unit and hydraulic unit
”
Rep. gr.
23
Air filter; Assembly overview - air filter housing
Rep. gr.
10
Engine cover; Removing and installing engine cover