Volkswagen Golf Service & Repair Manual: 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- |
| Sealing plugs, assembly part no. 5Q0 698 311 |
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| Fitting location of ABS hydraulic unit -N55- and ABS control
unit -J104- in RHD vehicles: |
| 1 - |
Brake servo and brake master cylinder |
| 2 - |
ABS hydraulic unit -N55- and ABS control unit -J104- |
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 battery tray -1-
→ Electrical system; Rep. gr.27. |
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| – |
Apply brake pedal depressor -V.A.G 1869/2-. |
| – |
Remove noise insulation
→ General body repairs, exterior; Rep. gr.66. |
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| – |
Press down retainer catch -arrow A-. |
 Note
| The illustration shows installation position of ABS
hydraulic unit -N55- and ABS control unit -J104- on a LHD
vehicle. |
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| – |
Release electrical connector -arrow B-. |
| – |
Pull off electrical connector -1-. |
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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 sufficiently lint-free cloths under ABS control unit
-J104- and ABS hydraulic unit -N55-. |
Note
| Make sure no brake fluid gets onto electrical contacts on
ABS control unit -J104-. |
|
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|
| – |
First, mark the two brake lines -A-
and -B- coming from brake master
cylinder. |
| – |
Disconnect the two brake master cylinder brake lines
-A- and -B-
from ABS hydraulic unit -N55-. |
| – |
Seal threaded holes immediately using sealing plugs from the
assembly part kit with part no. 5Q0 698 311. |
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| – |
Mark and unscrew remaining brake lines (brake calipers).
Seal threaded holes -2-. |
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|
| – |
Pull off ABS hydraulic unit -N55--1-
together with bracket -2- in
-direction of arrow-. |
| – |
The rubber dampers -arrows-
will be pulled off the studs of bracket
-3- while doing so. |
| – |
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. |
| Do not bend the brake lines in the area of the ABS hydraulic
unit -N55- |
| Ensure that rubber dampers of retainer are not pressed out
of bracket when installing. After installation, check that the
ABS hydraulic unit -N55- is firmly seated, or malfunction can
occur. |
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| Tightening sequence of brake lines: |
| – |
Start brake line union screws in sequence
-1- through
-6-. |
| – |
Tighten break line union screws in sequence
-1- through
-6-. |
| – |
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,
RHD vehicles“ |
| Battery
→ Electrical system; Rep. gr.27 |
| Noise insulation
→ General body repairs, exterior; Rep. gr.66. |
| 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
ESD workplace -VAS 6613-
Torx bit T25
I ...
Other materials:
Rain sensor
Fig. 89 Windscreen wiper lever: setting
the rain sensor ①
Fig. 90 Sensitive surface of the rain sensor
First read and observe the introductory information
and safety warnings When the rain sensor is activated, it automatically controls
the frequency of the wiper intervals, depending o ...
General notes concerning repairs to vehicle electrical system
Caution
When batteries are disconnected and reconnected, the
procedure described in the workshop manual must be
strictly observed.
WARNING
...
Assembly overview - foot rest and floor covering, LHD vehicles
1 -
Foot rest
Removing and installing
→ Chapter
Must fully engage into bracket.
2 -
Nut
Qty. 3
2 Nm
3 -
Bracket
Removing and installing
→ Chapter
4&nbs ...
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Removing and installing control unit and hydraulic unit, LHD vehicles,
four-wheel drive, »R«
Separating control unit from hydraulic unit