Control Module And Hydraulic Unit

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
Hose clamps, up to 25 mm 3094

Special tools and workshop equipment required

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Transport protection for valve domes (foam)

2 - Sealing plug M 10

3 - Sealing plug M 12

Removing

NOTE:

Component location: The control module is bolted to the hydraulic unit and is located at right in the engine compartment.

WARNING:

Do not bend the brake lines near the hydraulic unit.

-- Read and note the present control module coding.

-- If the vehicle has a coded radio, get the radio code from the customer before beginning.

-- Disconnect battery. Refer to [For engine(s) BPY,BLV,CCTA,CBFA] Removal and Installation .

-- Remove engine cover.

6-Cylinder Gasoline Engine

-- Disconnect knock sensor and vacuum hose valve connectors at rear of intake manifold. Unclip wiring harness from retainers on coolant pipe and lay it aside.

-- Remove vacuum hoses on rear of intake manifold, remove from retainers and set aside completely.

-- Loosen right rear coolant pipe from left and rear of engine.

-- Disconnect both coolant hoses on reservoir with 3094.

-- Now remove both coolant hoses on reservoir and then set them as far aside as possible with coolant pipe.

All Vehicles

-- On vehicles with heat shield, remove heat shield.

-- Press the red securing clip in -direction of arrow- toward the rear.

Fig 2: Identifying Direction Of Pressing Red Securing Clip Toward Rear

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-- Release and remove connector from control module in -direction of arrow-.

Fig 3: Identifying Direction To Remove Connector From Control Module

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-- Insert V.A.G 1869/2.

-- Attach bleeder hose of bleeder bottles to left-front and left-rear brake caliper bleeder valves and open bleeder valves.

-- Operate brake pedal using V.A.G 1869/2 at least 60 mm.

-- Close left front and left rear bleeder valves.

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

-- Place sufficient lint-free cloths under the control module and hydraulic unit.

NOTE:

Make sure that brake fluid does not come in contact with the terminals.

-- First, mark both brake lines from master cylinder and remove from the hydraulic unit.

-- Plug the brake lines and threaded holes immediately with sealing plugs from the repair kit Part No. 1H0 698 311 A.

-- Mark, unfasten and plug the remaining brake lines (brake calipers).

All Vehicles

-- Lift the hydraulic unit with control module up and out of the dampers -arrow-.

Fig 4: Identifying Hydraulic Unit And Control Module Removed From Dampers

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Installing

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 and unit may not be sufficiently filled or adequately bled.

When installing the hydraulic unit, make sure the damper rubber is not pushed out of the console.

-- Install in reverse order of removal.

Fastening sequence of brake lines:

Fig 5: Identifying Connection Of Brake Lines From Dual Master Brake Cylinder To Hydraulic Unit -- On Hydraulic Unit

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-- Remove V.A.G 1869/2.

-- Bleed the brake system. Refer to BRAKE SYSTEM, BLEEDING .

-- Enter radio code.

-- Code the ABS control module -J104- with the Vehicle Diagnostic Tester in "Guided Fault Finding".

A Steering Angle Sensor -G85-, Transverse Acceleration Sensor -G200-, Longitudinal Acceleration Sensor -G251- and Brake Pressure Sensor 1 -G201- basic setting must be done.

Tightening Specifications
Hydraulic unit hex bolt to bracket	10 Nm
Brake lines with the ABS unit:
Brake lines 1 through 4 (brake calipers)	14 Nm
Brake lines 5 and 6 (brake master cylinder)
Diameter 8.5 mm	17 Nm
Diameter 6 mm	14 Nm