VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing control unit and hydraulic unit, LHD

Removing and installing control unit and hydraulic unit, LHD

Special tools and workshop equipment required
Torque wrench -V.A.G 1331-
Torque wrench -V.A.G 1410-
Brake pedal depressor -V.A.G 1869/2-

 
     
Sealing plugs, assembly part no. 5Q0 698 311
1 -  Sealing plug M10
2 -  Sealing plug M12
Removing
Location:
 

Removing and installing control unit and hydraulic unit, LHD

The control unit is bolted to the hydraulic unit and is located on right of the engine compartment.
Do not bend the brake lines in the area of the hydraulic unit!
–  Read out and note the existing control unit code.
–  If vehicle has a coded radio, note radio code or, if necessary, request it.
–  Observe safety precautions when working on the high-voltage system → Chapter.
–  Observe the risk classification of the high-voltage system → Electric drive; Rep. gr.00.
–  Disconnect battery → Electrical system; Rep. gr.27.
–  Remove catalytic converter → Rep. gr.26.
 

Removing and installing control unit and hydraulic unit, LHD

–  Remove heat shield -1- if present.
–  To do this, unclip heat shield -1- from bracket -2--arrow-.
 

Removing and installing control unit and hydraulic unit, LHD

–  Press down retainer catch -arrow A-.
 

Removing and installing control unit and hydraulic unit, LHD

–  Release electrical connector -arrow B-.
–  Pull off electrical connector -1-.
 

Removing and installing control unit and hydraulic unit, LHD

–  Apply brake pedal depressor -V.A.G 1869/2-.
 

Removing and installing control unit and hydraulic unit, LHD

–  Connect hose of bleeder bottle -1- to bleeder valve of front left brake caliper.
–  Open bleeder valve.
 

Removing and installing control unit and hydraulic unit, LHD

–  Connect hose of bleeder bottle -1- to bleeder valve of rear left brake caliper.
–  Open bleeder valve.
–  Depress brake pedal at least 60 mm using brake pedal depressor -V.A.G 1869/2-.
–  Close front left and rear left bleeder valves.
–  Do not remove brake pedal depressor -V.A.G 1869/2-.
  Note
Ensure no brake fluid gets onto contacts.
–  Pull cover off bulkhead and unclip brake lines.
–  First identify both brake lines from brake master cylinder and unscrew from hydraulic unit.
–  Seal threaded holes immediately using sealing plugs from the assembly part kit, part no. 5Q0 698 311.
–  Mark, unscrew and seal threaded holes of remaining brake lines (brake calipers).
 

Removing and installing control unit and hydraulic unit, LHD

–  Pull hydraulic unit together with control unit upwards out of dampers -arrow-.
Installing
Install in reverse order. Note the following points:
  Note
Remove sealing plugs from new hydraulic unit only when the corresponding brake line is to be fitted.
If sealing plugs are removed too early from the hydraulic unit, brake fluid can escape, and it can then no longer be guaranteed that the unit can be sufficiently filled and bled.
When installing the hydraulic unit, ensure that rubber dampers are not pressed out of bracket.
 

Removing and installing control unit and hydraulic unit, LHD

Tightening sequence of brake lines:
–  Remove brake pedal depressor -V.A.G 1869/2-.
–  Bleed brake system → Chapter.
–  Code radio.
–  Code control unit -J104- using → Vehicle diagnostic tester in "Guided Fault Finding".
To do this, carry out basic setting of the steering angle sender -G85-, the lateral acceleration sender -G200-, the longitudinal acceleration sender -G251- and the brake pressure sender -G201-.
Specified torques
→ Chapter „Assembly overview - control unit and hydraulic unit, LHD vehicles“
→ Rep. gr.26
Battery → Electrical system; Rep. gr.27
Front bleeder valves → Chapter „Assembly overview - front brake caliper“
Rear bleeder valves → Chapter „Assembly overview - rear brake caliper“
 

Removing and installing control unit and hydraulic unit, LHD

Assembly overview - control unit and hydraulic unit, RHD vehicles
1 -  Brake servo and brake master cylinder Assembly overview → Chapter. Checking brake servo → Vehicle diagnos ...

Removing and installing control unit and hydraulic unit, RHD vehicles
Special tools and workshop equipment required Torque wrench -V.A.G 1331- Torque wrench -V.A.G 1410- Brake pedal depressor -V.A.G 1869/2- ...

Other materials:

Assembly overview - manually operated anti-dazzle interior mirror, without rain and light sensor -G397- and front camera for driver assist systems -R242-
1 -  Retaining plate Retaining plate for mirror base Glued to windscreen Removing and installing → Chapter 2 -  Interior mirror Manually operated Removing and installing → Chapter ...

General information
Repair instructions for repair work on ABS The ABS brake system is divided diagonally. The servo-assistance is effected pneumatically by the vacuum brake servo unit. Vehicles with ABS are not fitted with a mechanical brake pressure regu ...

Steering rack
To achieve the desired results when performing repairs on the steering rack it is important to work with the greatest possible care and cleanliness, and to use proper tools in good condition. Also note the basic rules on safety when performing repair pro ...

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