Control Module And Hydraulic Unit

Special tools and workshop equipment required

Torque Wrench 5-50 Nm V.A.G 1331
Torque Wrench V.A.G 1410
Brake Pedal Actuator V.A.G 1869/2
Hose Clamps up to 25 mm Dia. 3094

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

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

1 - Transport protection for valve domes (foam)

2 - Sealing Plug M 10

3 - Sealing Plug M 12

Removing

Component location:

The control module is bolted to the hydraulic unit and is located at the 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 the battery. Refer to [For engine(s) CNNA, CCTA, CBFA] Removal and Installation .

-- Remove engine cover.

6-Cylinder Engine

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

-- Remove the rear coolant pipe to the side and behind the engine.

-- Disconnect the coolant hose on the reservoir with 3094.

-- Now remove the coolant hose on the 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 the 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 the 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.

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

-- First, mark both brake lines from the 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).

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

Fig 4: Hydraulic Unit And Control Module Removed From Dampers

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Installing

NOTE:

Do not remove sealing plugs at the 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 the 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 bracket.

-- Install in reverse order of removal.

Fastening sequence of brake lines:

Fig 5: 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 HYDRAULIC 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)
8.5 mm	17 Nm
6 mm	14 Nm