Control Module And Hydraulic Unit, Mark 70

NOTE:

Beginning with MY 09, the ESP sensor unit G419 is inside the ABS control module -J104-.

Beginning with MY 09, the ABS control module must be replaced if the ESP sensor unit is faulty.

Beginning with MY 09, the ABS control module must be calibrated if it was replaced.

Beginning with MY 09, the steering angle and the braking pressure are stored in the ABS control module and must be calibrated.

Special tools and workshop equipment required

Torque Wrench V.A.G 1331
Torque Wrench V.A.G 1410
Brake Pedal Actuator V.A.G 1869/2

Fig 1: Identifying Sealing Plug Repair Set, Part No. 1H0 698 311 A

Courtesy of AUDI OF AMERICA, LLC

After separating the control module from the hydraulic unit, always install transport protection on the hydraulic unit for the valve domes.

Warranties will not be covered for hydraulic units without transport protection.

1 - Transport protection for valve domes (foam)

2 - Sealing plugs M10 for brake lines and threaded bores

3 - Sealing plugs M12 for brake lines and threaded bores

Removing

-- If equipped, remove the covers at right rear of engine compartment.

-- Install the V.A.G 1869/2 between the brake pedal and driver seat. Depress the brake pedal a minimum of 60 mm.

Fig 2: Brake Pedal Depressor VAG 1869/2 Inserted Between Brake Pedal And Driver's Seat

Courtesy of AUDI OF AMERICA, LLC

-- Connect the hose of a bleeder bottle to the bleeder screws of the left front and left rear brake calipers, and open the bleeder screws.

NOTE:

This lowers the pressure in the hydraulic unit.

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

-- Do not remove V.A.G 1869/2.

-- Release control module harness connector -arrow 1- and pull off -arrow 2-.

Fig 3: Control Module Harness Connector

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Make sure that no brake fluid gets into the control module connector housing. This could lead to corrosion of the contacts and thereby cause the system to fail.

Clean a dirty connector housing thoroughly with compressed air.

-- To protect against escaping brake fluid, place a lint-free rag in the area under the control module and hydraulic unit.

Fig 4: Connector Housing With Compressed Air

Courtesy of AUDI OF AMERICA, LLC

-- Mark the brake lines.

NOTE:

The right air guide must be removed on TFSI vehicles.

-- Disconnect the tie up the brake lines on the hydraulic unit -1- leading to the master brake cylinder.

Fig 5: Brake Line From Hydraulic Unit To Brake Master Cylinder

Courtesy of AUDI OF AMERICA, LLC

-- Remove the remaining brake lines -2- from hydraulic unit.

CAUTION:

Do not bend the brake lines near the hydraulic unit.

-- Seal the brake lines and threaded bores with sealing plugs from the repair kit.

-- Pry the hydraulic unit with control module upward and off, see -arrows-.

Fig 6: Hydraulic Unit With Control Module

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts on the hydraulic unit mount -1- ; tightening specification: 8 Nm.

Fig 7: Bolts From Hydraulic Unit Bracket

Courtesy of AUDI OF AMERICA, LLC

Unfastening control module from hydraulic unit

-- Set hydraulic unit with control module upward onto a clean, level surface.

-- Remove inner Torx® bolts -arrows-.

Fig 8: Locating Control Module Torx Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Pull control module off from hydraulic unit -arrow- without angling.

Fig 9: Control Module Pulled Off From Hydraulic Unit Without Angling

Courtesy of AUDI OF AMERICA, LLC

-- Carefully pull off all sealing rings from valve domes of hydraulic unit.

CAUTION:

On a disconnected control module, circuit board is laid open.
No moisture or particles of dirt must penetrate in interior of control module.
The hydraulic pump must not be separated from the hydraulic unit.

-- Cover control module magnetic coils with a lint free cloth.

After separating the control module and hydraulic unit, use transport protection for valve body.

New Control Module, Installing

CAUTION:

Excessive shaking (for example dropping, impact) may destroy the control module. Control module must then no longer be used.

Surface must be cleaned before assembling.

-- Slide all sealing rings -A- slightly over the valve dome.

Fig 10: Identifying Sealing Rings Slid Over Valve Dome

Courtesy of AUDI OF AMERICA, LLC

-- Place control module without canting it onto hydraulic unit.

Sealing rings are then brought into their end position.

-- Bolt hydraulic unit and control module with new inner Torx® bolts supplied.

NOTE:

A new control module may be assembled on an already used hydraulic unit twice at maximum in order to guarantee the seal of the elastic gasket.

Do not install a used control module.

-- Remove the bolt -1-.

Fig 11: Phillips-Head Screw

Courtesy of AUDI OF AMERICA, LLC

-- Unclip line -2-.

-- Remove nut -1-, Tightening specification 20 Nm.

Fig 12: Nut From Bracket

Courtesy of AUDI OF AMERICA, LLC

Installing

Installation is in reverse order of removal, with special attention to the following:

NOTE:

Do not remove sealing plugs at new hydraulic unit until the corresponding brake line is about to be installed.

If the sealing plugs are removed too early, brake fluid can escape. If this occurs, unit may not be sufficiently filled or adequately bled.

-- When installing together the control module and hydraulic unit, make sure that the valve body of the hydraulic unit does not bind with the solenoid coils of the control module.

-- Connect the lines according to the markings. Refer to CONTROL MODULE AND HYDRAULIC UNIT, ANTI-LOCK BRAKE ITT MARK 70 ASSEMBLY OVERVIEW .

-- Fasten the ABS unit to the bracket.

NOTE:

Do not tighten bolts completely. This makes it easier to fasten the individual brake lines to the hydraulic unit.

-- Tighten all brake lines.

-- After fastening the brake lines, fasten the hydraulic unit.

NOTE:

If the vehicle has a TFSI engine, connect the right air guide.

-- Bleed the brake system. Refer to BLEEDING BRAKE SYSTEM, ITT ABS/ESP MARK 60/ ABS MARK 70 .

-- If the control module was replaced, it must be coded.

Use the vehicle diagnosis, testing and information system VAS 5051 B or VAS 5052.

-- Connect the vehicle diagnosis, testing, and information system and select the function test using functions/component selection. Refer to VAS 5951 B OR VAS 5052, CONNECTING AND SELECTING FUNCTIONS .

Then

-- "Chassis"

-- "Brake System"

-- "01- On Board Diagnostic (OBD) capable systems"

-- "J104- ABS/ASR/ESP Control Module Mark 60"

-- "J104- ABS/ASR/ESP Control Module, Functions"

-- "J104- Control module, coding"

-- After fastening the brake lines to the ABS hydraulic unit, perform the output check diagnosis. Vehicle diagnosis, testing and information system VAS 5051 B or VAS 5052

NOTE:

If the ABS control module -J104- is replaced, the following sensors must be calibrated:

Steering angle sensor -G85-

Transverse acceleration sensor -G200-

Brake pressure sensor 1 -G201-

Longitudinal acceleration sensor -G251- (only equipped on all-wheel drive vehicles)

Beginning with MY 09, the steering angle and the braking pressure are stored in the ABS control module and must be calibrated.

Afterwards, the ESP driving and system tests must be performed.

Use the vehicle diagnosis, testing and information system VAS 5051 B or VAS 5052.

-- Connect VAS 5051 B or VAS 5052 and select function/component selection. Refer to VAS 5951 B OR VAS 5052, CONNECTING AND SELECTING FUNCTIONS .

-- "Chassis"

-- "Brake System"

-- "01- On Board Diagnostic (OBD) capable systems"

-- "J104- ABS/ASR/ESP Control Module Mark 60"

-- "J104- ABS/ASR/ESP Control Module, Functions"

NOTE:

By performing the output check diagnosis, it can be determined if the line connections were interchanged.

Tightening Specifications

Component

Control module to ABS hydraulic unit

5.5⁽¹⁾

ABS hydraulic unit to mount

Brake lines to the ABS hydraulic unit

14 ⁽²⁾

⁽¹⁾	Replace bolts

⁽²⁾	For M10 and M12 connections