VW Golf manuals

Volkswagen Golf Service & Repair Manual: Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

Volkswagen Golf Service & Repair Manual / Brake system / ABS, ADR, TCS, EDL, ESP / Control unit and hydraulic unit / Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, 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
1 -  Sealing plug M10
2 -  Sealing plug M12
Removing
Location:
 

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

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.
–  Remove noise insulation → General body repairs, exterior; Rep. gr.66.
–  Remove front exhaust pipe → Rep. gr.26.
 

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

–  Disconnect connector -1-.
–  Loosen clamp -2- and push towards rear.
 

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

–  Remove bolts -1-.
–  Loosen bolt -2- and remove clamp.
–  Remove front exhaust pipe.
–  Remove right drive shaft → Running gear, axles, steering; Rep. gr.40.
–  Swing suspension strut towards rear and secure it in this position.
–  In vehicles with heat shield, remove heat shield.
–  Unclip line guide.
 

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

–  Press down retainer catch -arrow A-.
 

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

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

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

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

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

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

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

–  Connect bleed hose of bleed bottle -1- to bleed valve of rear left brake caliper.
–  Open bleed 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-.
–  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).
 

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

–  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.
–  Raise vehicle.
 

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

–  Unbolt bracket from hydraulic unit -arrows- in vehicle.
–  Swing suspension strut -1- to one side and then backwards. Then, fix it in this position using a wooden block -2-.
 

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

–  Thread hydraulic unit -3- out of vehicle through wheel housing.
Installing
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.
 

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

Tightening sequence of brake lines:
–  Remove brake pedal depressor -V.A.G 1869/2-.
–  Bleed brake system → Chapter.
–  Code radio.
–  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-.
Specified torques
→ 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
Drive shaft → Running gear, axles, steering; Rep. gr.40.
Lower suspension link → Running gear, axles, steering; Rep. gr.40.
Front bleed valves → Chapter „Assembly overview - front brake caliper“
Rear bleed valves → Chapter „Assembly overview - rear brake caliper“
 

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, diesel engine

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- ...

Removing and installing control unit and hydraulic unit, LHD vehicles, four-wheel drive, »R«
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:

Operation and safety notes for gas discharge bulbs
  Note Never change bulbs if you are not familiar with the appropriate procedures, safety precautions or tools.   WARNING Risk of death due to high voltage. ...

Safety precautions when working on the cooling system
Risk of scalding by hot coolant When the engine is warm, the cooling system is under pressure. Danger of scalding due to steam and hot coolant. –  Always wear safety gloves. –  Always wear safety goggles. –  ...

Assembly overview - poly V-belt drive, vehicles with air conditioner compressor
1 -  Poly V-belt Check for wear Before removing, mark direction of rotation with chalk or felt-tipped pen. Do not kink The length of the poly V-belt must be determined according to the → E ...

© 2016-2019 Copyright www.vwgolf.org