Removing and installing ABS control unit J104/ABS hydraulic unit N55, LHD vehicles — VW

🧭 Before you start

Fits: platform code 138

• Opens: brake fluid

Don't miss

• Do not bend the brake lines in the area of the hydraulic unit! — Read out and note the existing control unit code.
• Risk of damage to the coolant pipe.Do not attempt to reshape the coolant pipe. — Unscrew bolts (1, 2 and 3), and carefully swing coolant line forwards slightly.
• Do not remove brake pedal depressorV.A.G 1869/2.
• Mark remaining brake lines (brake calipers) (1 to 4), then unscrew them and seal threaded holes.
• Before installing bracket of ABS hydraulic unit N55 into console, spray rubber dampers with silicone lubricantD 007 000 A2.

📋 Procedure

1. ⚠ Do not bend the brake lines in the area of the hydraulic unit! — Read out and note the existing control unit code.
2. Note or request radio code on vehicles with coded radio if necessary.
3. Disconnect battery Electrical system27Battery; Disconnecting and reconnecting battery.
4. Remove engine cover panel 10Engine cover; Removing and installing engine cover panel.
5. Unscrew coolant lines leading to turbocharger (1)(arrows), and lay them to right side.

6. Unbolt heat shield (1)(arrows), and remove it.
7. Remove catalytic converter 26Emission control; Assembly overview – emission control.
8. Remove intake connecting pipe together with regulating flap control unit 24Intake manifold; Assembly overview – intake manifold.
9. Remove charge air hose 21Charge air system; Assembly overview - charge air system.
10. Clamp off hose from coolant expansion tank and pull it off.
11. Unscrew bolt (1) for air pipe (4).
12. Release hose clip (2), and pull air pipe off turbocharger.
13. Press together catch on crankcase breather hose (3), and pull off hose. Remove air pipe.
14. Disconnect connectors (upper arrow) from charge pressure positioner V465(2).
15. Disconnect breather line (2)20Plug-in connectors; Disconnecting plug-in connectors.
16. Release locking lug (3) in direction of arrow, and remove activated charcoal filter (1) upwards.
17. Place activated charcoal filter (1) together with breather line (arrow) and line (2) on engine.
18. Unscrew bolt (4), and turn filler neck for washer fluid reservoir (2) forwards.
19. Open clip (3), and pull connector (5) off coolant expansion tank (1).
20. Unscrew bolts (arrows), and place coolant expansion tank (1) on engine with hoses still connected.
21. Remove bracket of washer fluid reservoir filler neck from engine mounting and body.
22. Unbolt double clamp and rubber clamp of refrigerant line from longitudinal member.
23. Release connectors, and pull all connectors simultaneously off ignition coils.
24. Release fasteners (arrow), remove wiring duct upwards from bracket, and press it towards front.
25. ⚠ Risk of damage to the coolant pipe.Do not attempt to reshape the coolant pipe. — Unscrew bolts (1, 2 and 3), and carefully swing coolant line forwards slightly.
26. Remove actuators for camshaft adjustment for cylinder no. 1 and cylinder no. 2 15Valve gear; Assembly overview – valve gear.
27. Seal both openings using suitable plugs from engine bung setVAS 6122.
28. Remove air duct 21Turbocharger; Assembly overview - turbocharger.
29. Seal turbocharger with engine bung setVAS 6122.
30. Remove noise insulation General body repairs, exterior66Noise insulation; Removing and installing noise insulation.
31. Unclip fuel lines from coolant expansion tank.
32. Unscrew securing bolts (2), and lay fuel filter to one side.
33. Unscrew bolt (4), and turn filler neck for washer fluid reservoir (2) forwards.
34. Open clip (3), and pull connector (5) off coolant expansion tank (1).
35. Unscrew bolts (arrows), and place coolant expansion tank (1) on engine with hoses still connected.
36. Remove bracket of washer fluid reservoir filler neck from engine mounting and body.
37. Extract refrigerant using air conditioner service station. Only after this has been done, open refrigerant circuit.
38. Unbolt double clamp and rubber clamp of refrigerant line from longitudinal member.
39. Unscrew refrigerant line from expansion valve 87Refrigerant circuit; system overview – refrigerant circuit.
40. Remove measuring tube leading to pressure differential sender G50526Emission control; Assembly overview – emission control.
41. Remove heat shield from emission control module.
42. Using release tool T10236, lever heat shield for fuel lines (1) off weld stud, and push it towards front as far as it will go.
43. Pull cover off plenum chamber bulkhead and unclip brake lines.
44. Remove heat shield (if installed).
45. Release connector in direction of (arrow 1).
46. Disconnect connector in direction of (arrow 2).
47. Apply brake pedal depressorV.A.G 1869/2.
48. Fit bleeder bottle hoses to front left and rear left brake caliper bleeder valves.
49. Open bleed valve.
50. Depress brake pedal at least 60 mm using brake pedal actuatorV.A.G 1869/2.
51. Close front left and rear left bleeder valves.
52. Do not remove brake pedal depressorV.A.G 1869/2.
53. Place sufficient lint-free cloths under the control unit and hydraulic unit.
54. First identify the two brake master cylinder brake lines (A and B) and unscrew from the hydraulic unit.
55. Seal threaded holes immediately using sealing plugs from assembly part kit, part no.5Q0 698 311.
56. Mark remaining brake lines (brake calipers) (1 to 4), then unscrew them and seal threaded holes.
57. Fit dust caps of bleeder valves onto brake lines.
58. Unscrew hexagon fitted bolt from retainer.
59. Pull hydraulic unit together with control unit and retainer sideways out of rubber dampers of bracket, and turn it upside down.
60. Unbolt retainer from hydraulic unit in engine compartment, and remove it.

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