Volkswagen Golf Service & Repair Manual: Removing and installing control unit and hydraulic unit, LHD vehicles,
diesel engine
| 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 |
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| Control unit is bolted to hydraulic unit
-1- and is located on right in
engine compartment. |
Risk of damage to brake lines if bent.Never excessively 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. |
| – |
Disconnect battery
→ Electrical system; Rep. gr.27 |
| – |
Remove engine cover panel. |
| Diesel engine with particulate filter: |
| – |
Remove noise insulation
→ General body repairs, exterior; Rep. gr.66. |
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| – |
If driveshaft heat shield is fitted, remove it
-arrows-
→ Running gear, axles, steering; Rep. gr.40. |
| On vehicles equipped with auxiliary heaters: |
| – |
Remove front exhaust pipe
→ Rep. gr.26. |
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| – |
Disconnect connector -1-. |
| – |
Loosen clamp -2- and push
towards rear. |
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| – |
Loosen bolt -2- and remove
clamp. |
| – |
Remove front exhaust pipe. |
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| – |
Unscrew both nuts -arrows- for
coolant line retainers -1- from
longitudinal member and from plenum chamber bulkhead. |
| – |
Pull retainers off studs. Then, pull down coolant line as
far as possible. |
| Continuation for all models: |
| – |
In vehicles with heat shield, remove heat shield. |
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| – |
Press down retainer catch -arrow A-. |
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| – |
Release electrical connector -arrow B-.
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| – |
Pull off electrical connector -1-.
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| – |
Apply brake pedal depressor -V.A.G 1869/2-. |
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| – |
Connect bleed bottle bleed hose -1-
to bleed valve of front left brake caliper. |
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| – |
Connect bleed hose of bleed bottle -1-
to bleed valve of rear left brake caliper. |
| – |
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-. |
| – |
Place sufficient lint-free cloths under the control unit and
hydraulic unit. |
 Note
| Ensure no brake fluid gets onto contacts. |
| – |
Pull cover off plenum chamber 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 with part no. 5Q0 698 311. |
| – |
Mark, unscrew and seal threaded holes of remaining brake
lines (brake calipers). |
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| – |
Pull hydraulic unit together with control unit upwards out
of dampers -arrow-. |
| – |
Carefully set down hydraulic unit together with control unit
in engine compartment. |
Note
| Lay down ABS hydraulic unit -N55- together with ABS control
unit -J104- ensuring it cannot fall down. |
| On vehicles equipped with auxiliary heaters: |
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| – |
Unbolt bracket from hydraulic unit
-arrows- in vehicle. |
| – |
Guide hydraulic unit out of vehicle. |
| Install in reverse order of removal, observing the
following: |
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 the rubber
dampers are not pressed out of bracket. |
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| Tightening sequence of brake lines: |
| – |
Remove brake pedal depressor -V.A.G 1869/2-. |
| – |
Bleed brake system
→ Chapter. |
| – |
Code ABS control unit -J104- using → Vehicle
diagnostic tester. |
| 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-. |
| → Chapter „Assembly overview - control unit and hydraulic unit,
LHD vehicles“ |
| Battery
→ Electrical system; Rep. gr.27 |
| Bolts for noise insulation
→ General body repairs, exterior; Rep. gr.66. |
| Front exhaust pipe
→ Rep. gr.26 |
| Pendulum support
→ Rep. gr.10 |
| Front bleed valves
→ Chapter „Assembly overview - front brake caliper“ |
| Rear bleed valves
→ Chapter „Assembly overview - rear brake caliper“ |
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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- ...
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:
2-pack epoxy primer surfacer
Designation:
2-pack epoxy primer surfacer -LLS MAX 220 M1-, beige
(250 ml)
2-pack epoxy primer surfacer -LLS MAX 220 M2-, beige
(400 ml)
Issued 03.2013
...
Removing and installing glove compartment cover
Removing
–
Remove glove compartment
→ Chapter.
–
Place glove compartment on a soft surface.
–
Move glove compartment lid to service position
U ...
Vacuum generation with manual vacuum pump -VAS 6213-
In certain cases, vacuum can be generated with the manual
vacuum pump -VAS 6213- instead of with the engine or the vacuum
pump.
–
To do this, connect manual vacuum pump -VAS 6213- to vacuum
hose from connection -B- on brake ...
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Removing and installing control unit and hydraulic unit, LHD vehicles,
petrol engines
Removing and installing control unit and hydraulic unit, LHD vehicles,
four-wheel drive, diesel engine