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Brake, brake mechanics > < Connecting brake lines from the master brake cylinder to the hydraulic unit - Vehicles with right-hand drive

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Removing and installing control unit and hydraulic unit - Vehicles with right-hand drive
Removing and installing control unit and hydraulic unit - Vehicles with right-hand drive
Special tools and workshop equipment required
t  Brake pedal load e.g. -V.A.G 1869/2-
Removing:
Fitting location:
The control unit is bolted to the hydraulic unit and is located on the left in the engine compartment.
  WARNING
The brake lines around the hydraulic unit must not be bent!
–  Read out and note the actual control unit coding → Vehicle diagnostic tester.
–  Remove engine cover.
–  Remove battery → Electrical System; Rep. gr.27.
–  Remove induction pipe and air filter → Engine; Rep. gr.23 or → Engine; Rep. gr.24.
–  Remove battery tray → Electrical System; Rep. gr.27.
–  Position brake pedal load e.g. -V.A.G 1869/2-.
–  Attach the bleeder hose of the bleeding bottle onto the bleeder screws of the front left and rear left brake caliper and open the bleeder screws.
–  Press down brake pedal with brake pedal load e.g. -V.A.G 1869/2- at least 60 mm.
–  Close front left and rear left bleeder screws.
  Note
Do not remove brake pedal load, e.g. -V.A.G 1869/2-.
–  Place sufficient non-fluffing cloths under the control unit and the hydraulic unit.
–  Extract as much brake fluid as possible from the brake fluid reservoir.
Make sure that no brake fluid gets onto the contacts of the plug connections.
   
–  Mark both brake lines from the master brake cylinder -A- and -B- and unscrew from the hydraulic unit.
–  Close the brake lines and threaded holes immediately with plugs from the repair kit -1H0 698 311 A-.
–  Mark the brake lines (for brake calipers) -1- to -4-, unscrew and close with plugs from the repair kit -1H0 698 311 A-.
  N45-10188
–  Release the plug at the control unit, -in direction of arrow 1-.
–  Disconnect the plug from the control unit in -direction of arrow 2-.
–  Pull hydraulic unit with control unit upwards and out of the rubber bearings. If the rubber bearings are pulled out of the console at the same time, place the bearings in the same position again → Item.
–  Unscrew the bracket from the ABS hydraulic unit.
Unscrew control unit from the hydraulic unit.
–  Place the hydraulic unit with the control unit upwards on a clean and level surface.
  N45-10189
–  Release screws -arrows-.
  S45-0165
–  Detach the control unit without tilting from the hydraulic unit -arrow-.
–  Carefully pull off all gasket rings from the valve domes of the hydraulic unit.
  WARNING
t  On a disconnected control unit, the printed circuit board is exposed.
t  No humidity and dirt particles must penetrate into the inside of the control unit.
t  The hydraulic pump must not be separated from the hydraulic unit.
–  Cover the solenoid coils of the control unit with a non-fluffing cloth.
After separating from the control unit and hydraulic unit use the transport protection for valve domes.
Mount new control unit onto the hydraulic unit.
  WARNING
Strong vibrations (e.g. fall, knock) can destroy the control unit. The control unit must no longer be used.
l  The surfaces must be cleaned before assembling.
  S45-0166
–  Push all the gasket rings -A- a little over the valve domes.
–  Position the control unit without tilting it onto the hydraulic unit.
Thus the gasket rings are brought into their end position.
–  Screw hydraulic unit and control unit with the enclosed new Torx screws.
  Note
t  A new control unit may only be installed maximum twice onto the remaining hydraulic unit, in order to ensure tightness of the elastic seal.
t  A control unit, which was once operational, must not be mounted a second time.
Installing:
  Note
t  Only then remove plugs from the new hydraulic unit when the relevant brake line is installed.
t  If the plugs were already removed from the hydraulic unit before the brake line is installed, then brake fluid may escape and adequate filling and bleeding can no longer be guaranteed.
–  Screw the bracket onto the hydraulic unit and tighten to the recommended tightening torque.
–  Moisten the bolt of the support → Item with lubricant, e.g. -D 007 000 A2-, before inserting into the rubber bearings.
  S45-0167
–  Connect the plug to the control unit against the -direction of arrow 2-.
–  Release the plug at the control unit, against the -direction of arrow 1-.
–  Insert the hydraulic unit with the control unit and bracket into the rubber bearings of the console.
–  Remove the plugs consecutively from the brake lines and the ABS control unit.
–  Screw the marked brake lines onto the hydraulic unit.
–  Install battery tray → Electrical System; Rep. gr.27.
–  Install induction pipe and air filter → Engine; Rep. gr.23 or → Engine; Rep. gr.24.
–  Install battery → Electrical System; Rep. gr.27.
  Note
If the battery earth strap is disconnected and connected, carry out certain additional operations → Electrical System; Rep. gr.27.
–  Position engine cover.
–  Remove brake pedal load e.g. -V.A.G 1869/2-.
–  Bleeding brake system → Chapter.
–  Code the control unit -J104- → Vehicle diagnostic tester.
  N45-10189
Tightening torques:
Control unit to hydraulic unit5.5 Nm
Screw for hydraulic unit to bracket 8 Nm
Brake lines to ABS unit: 
Thread M 10 x 114 Nm
Thread M 12 x 114 Nm

   

Brake, brake mechanics > < Connecting brake lines from the master brake cylinder to the hydraulic unit - Vehicles with right-hand drive