Anti-Lock Brake System (roadster) Audi TT 8J

ABS REPAIR INFORMATION

ABS Mark 60

Note. ABS malfunctions have no effect on the brake system. However, a change in braking behavior should be checked.

Vehicles with ABS Mark 60 do not have a mechanical brake pressure regulator. A specially coordinated software program in the control module determines brake pressure allocation at the rear axle.

1. Before performing repair work on the anti-lock brake system, determine the cause of the malfunction using On-Board Diagnostics (OBD).
2. The connector at the hydraulic control unit may only be disconnected if the ignition is switched off.
3. When installing a new hydraulic control unit, it must be coded Vehicle diagnosis, testing and information System VAS 5051.
4. Bleed brake system after opening. Refer to «BRAKE SYSTEM BLEEDING»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__brake-system-bleeding) . To do this, use the Brake Charger/Bleeder Unit V.A.G 1869 or Brake Charger/Bleeder Unit VAS 5234.
5. Absolute cleanliness is required when working on the anti-lock brake system, it is not permitted to use any products which contain mineral oil, such as oils, greases etc.
6. Thoroughly clean all unions and the adjacent areas before loosening. Do not use aggressive cleaning agents such as brake cleaner, fuel, thinners or similar chemicals.
7. Place parts that have been removed on a clean surface and cover.
8. Carefully cover over opened components or seal, if repairs are not carried out immediately. Use sealing plugs from repair kit.
9. When the brake system is open, do not work with compressed air and do not move the vehicle.
10. Only use lint-free cloths.
11. Only use genuine parts in their original packaging.
12. Only unpack replacement parts immediately prior to installation.
13. During the final road test, ensure that a ABS-controlled brake test is performed at least once (pulsation must be felt at the brake pedal).
14. When painting, electronic control module can be exposed to a maximum temperature of. 95 °C only briefly, and to a maximum of 85 °C for longer periods (approximately 2 hours).

VAS 5051, CONNECTING AND SELECTION FUNCTIONS

Special tools and workshop equipment required

1. Vehicle diagnostic, testing and information System VAS 5051

Connect diagnostic cable connector to diagnostic connection.

Scheme 22

Switch VAS 5051 on -arrow-.

Scheme 23

The VAS 5051 is ready for use when a picture (photo) of a vehicle is displayed.

Switch on ignition.

Touch the field / the button on the screen: Guided Fault Finding.

Select one after another

1. Brand
2. Model
3. Model year
4. Version
5. Engine Code

Confirm entered data.

Wait until VAS 5051 has checked all control modules in vehicle.

Press the Go to button and select the "Function/component selection" function.

Now, follow the displays on screen to begin the desired functions.

Scheme 24

1. ASR/ESP Control Lamp -K155- Component Location: In Tachometer. Blinks When Driving If Esp/Asr Engages Regularly. Comes On When Ignition Is Switched On And Goes Out After A Short Self-Check. Comes On If There Is An Esp System Malfunction. Comes On If There Is An Abs System Malfunction Because Esp And Abs Work Together. Comes On When Esp Is Switched Off. Comes On During Sensor Programming If: The Battery Was Disconnected And Connected. Vehicle Was Started With Jump Start. The Battery Is Too Weak. After The Sensor Programming Procedure, The Light Goes Out After Driving A Short Distance.
2. Brake Pad Wear Indicator Lamp -K32- Component location: In center display field. Lights up when the brake pad wear limit is reached. Refer to «TECHNICAL DATA»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#general-technical-data-brake-system-roadster) .
3. Warning Light for Brake System -K118- Component location: In tachometer. Lights up with parking brake engaged. Lights up if there is an ABS system malfunction. Blinks when brake fluid is too low.
4. ABS Warning Lamp -K47- Component location: In tachometer. Lights up for several seconds when ignition is switched on and goes out after an automatic ABS system self-check if there are no malfunctions in the ABS system. There is an ABS malfunction if the indicator light: Does not light up when ignition is switched on. Does not go out after a few seconds. Lights up while driving. ABS malfunctions have no effect on the brake system. However, a change in braking behavior should be considered. If there is an ABS system malfunction, the ESP indicator light comes on as well because both systems work together.
5. ASR/ESP Button -E256- Component location: In the center console.
6. Right Rear ABS Wheel Speed Sensor -G44- /Left Rear ABS Wheel Speed Sensor -G46- 8 Nm
7. Steering Angle Sensor -G85- Location on steering column between steering wheel and steering column switch. Removing and installing, refer to «STEERING ANGLE SENSOR»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__steering-angle-sensor) .
8. Diagnostic Connection Component location: Cover in driver footwell.
9. Brake Pedal Removing and installing, refer to «BRAKE PEDAL»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#mechanical-components-brake-system-roadster__brake-pedal) .
10. Right Front ABS Wheel Speed Sensor -G45- /Left Front ABS Wheel Speed Sensor -G47- Removing and installing, refer to «FRONT ABS WHEEL SPEED SENSOR»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__front-abs-wheel-speed-sensor) . 8 Nm
11. Brake Booster Removing and installing, refer to «BRAKE BOOSTER»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__brake-booster) . NOTE: If the vehicle has a TFSI engine, then the noise amplifier must be removed and installed. Refer to «NOISE AMPLIFIER, TFSI»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__noise-amplifier-tfsi) . The noise amplifier is inside the engine compartment in front of the brake booster. With integrated Brake Booster Vacuum Sensor -G483- Brake booster vacuum sensor installation depends on model Brake booster vacuum sensor, removing and installing, refer to «BRAKE BOOSTER VACUUM SENSOR, WITH OPTIMIZED HYDRAULIC BRAKE VACUUM (OHBV) BOOSTING»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__brake-booster-vacuum-sensor-with-optimized) . NOTE: Brake booster vacuum sensor is only installed on vehicles with optimized hydraulic brake vacuum boosters.
12. Brake Master Cylinder With attached brake light switch. Removing and installing, refer to «BRAKE MASTER CYLINDER»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__brake-master-cylinder) . NOTE: If the vehicle has a TFSI engine, then the noise amplifier must be removed and installed. Refer to «NOISE AMPLIFIER, TFSI»(/audi/tt/8j-2006-2010/remont/mechanical-hydraulic/#hydraulic-components-brake-system-roadster__noise-amplifier-tfsi) . The noise amplifier is inside the engine compartment in front of the brake booster.
13. Brake Light Switch Removing and installing, refer to «BRAKE LIGHT SWITCH»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__brake-light-switch) . Removing and installing, TT RS, refer to «BRAKE LAMP SWITCH, TT RS»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__brake-lamp-switch-tt-rs) The brake light switch is not adjusted. Component location: At brake master cylinder. 5 Nm
14. ABS Control Module with ESP -J104- Component location: In right of engine compartment on ABS hydraulic unit. Do not disconnect connector before successfully completing On Board Diagnostic (OBD). Switch ignition off before separating connector. Removing and installing, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic) . TFSI engine, removing and installing, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT, TFSI»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic) . CAUTION: Disconnecting ABS control module and hydraulic unit is not permitted.
15. ABS Hydraulic Unit -N55- Component location: In tight of engine compartment, on ABS control module. Removing and installing, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic) . TFSI Engine, removing and installing, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT, TFSI»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic) . The ABS Hydraulic Pump -V64-, the ABS Hydraulic Unit -N55- and the ABS Control Module with ESP -J104- comprise the hydraulic control unit. With integrated Brake Pressure Sensor 1 -G201-. The brake pressure sensor cannot be replaced.
16. ESP Sensor Unit -G419- 9 Nm Component location: On center console in front of selector lever. Combined sensor for Transverse Acceleration Sensor -G200- and for Rotation Rate Sensor -G202-. On AWD vehicles, also Longitudinal Acceleration Sensor -G251-. Removing and installing, refer to «ESP SENSOR UNIT»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__esp-sensor-unit) .

Note. The ABS sensor ring/rotor is installed in the respective wheel bearing unit and should not be replaced.

Scheme 25

1. Brake Lines -DK- marking, Brake master cylinder/primary piston circuit to hydraulic unit. -HL- marking, to left rear brake caliper. -VR- marking, to right front brake caliper. -VL- marking, to left front brake caliper. -HR- marking, to right rear brake caliper -SK- marking, brake master cylinder/secondary piston circuit to hydraulic unit. 14 Nm After securing brake lines to hydraulic unit, perform output diagnostic test mode. Use Vehicle Diagnosis, Testing and Information System VAS 5051 for this.
2. ABS Control Module with ESP -J104- Component location: In right of engine compartment on ABS hydraulic unit. Removing and installing, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic) . TFSI Engine, removing and installing, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT, TFSI»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic) . Removing and installing, TT RS, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT, TF RS»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic) CAUTION: Disconnecting ABS control module and ABS hydraulic unit is not permitted. They may only be replaced completely (control module and hydraulic unit).
3. ABS Hydraulic Unit -N55- Component location: In right of engine compartment, on ABS control module. Removing and installing, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic) . TFSI Engine, removing and installing, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT, TFSI»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic) . Removing and installing, TT RS, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT, TF RS»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic)
4. Bracket Removing and installing together with hydraulic unit and control module, refer to «ABS CONTROL MODULE AND ABS HYDRAULIC UNIT»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__abs-control-module-and-abs-hydraulic) .
5. Bolt Bracket to hydraulic unit. 8 Nm.
6. Bracket With rubber buffer
7. Nut

FRONT ABS WHEEL SPEED SENSOR ASSEMBLY OVERVIEW

Note. The ABS sensor ring/rotor is installed in the respective wheel bearing unit and should not be replaced. Refer to Description and Operation .

Scheme 26

1. Right Front ABS Wheel Speed Sensor -G45- /Left Front ABS Wheel Speed Sensor -G47- Removing and installing, refer to «FRONT ABS WHEEL SPEED SENSOR»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__front-abs-wheel-speed-sensor) .
2. Bolt 8 Nm

REAR ABS WHEEL SPEED SENSOR ASSEMBLY OVERVIEW, FWD

Note. The ABS sensor ring/rotor is installed in the respective wheel bearing unit and should not be replaced. Refer to Description and Operation .

Scheme 27

1. Bolt 8 Nm
2. Right Rear ABS Wheel Speed Sensor -G44- /Left Rear ABS Wheel Speed Sensor -G46- Removing and installing, refer to «REAR ABS WHEEL SPEED SENSOR, FWD»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__rear-abs-wheel-speed-sensor-fwd) .

REAR ABS WHEEL SPEED SENSOR ASSEMBLY OVERVIEW, AWD

Note. The ABS sensor ring/rotor is installed in the respective wheel bearing unit and should not be replaced. Refer to Description and Operation .

Scheme 28

1. Right Rear ABS Wheel Speed Sensor -G44- /Left Rear ABS Wheel Speed Sensor -G46- Removing and installing, refer to «REAR ABS WHEEL SPEED SENSOR, AWD»(/audi/tt/8j-2006-2010/remont/anti-locktraction-control/#anti-lock-brake-system-roadster__rear-abs-wheel-speed-sensor-awd)
2. Bolt 8 Nm

FASTENER TIGHTENING SPECIFICATIONS

BRAKE LIGHT SWITCH

Removing

Note. The brake light switch is installed on the brake master cylinder. The brake light switch is not adjustable.

Disconnect electrical connector -1-.

Scheme 29

Remove brake light switch retaining bolt -2- from brake master cylinder.

Remove brake light switch down from brake master cylinder and remove switch upward from retaining tab.

Installing

Installation is performed in the reverse order of removal. Make sure that top of switch is seated correctly in retaining tab when doing so.

Note. The brake light switch is not adjustable.

BRAKE LAMP SWITCH, TT RS

Removing

Note. The brake light switch is installed on the brake master cylinder. The brake light switch is not adjusted.

Remove the engine cover -1-.

Scheme 30

Remove bolts -arrows- and remove the air guide.

Scheme 31

Remove the bolts -arrows- and remove the air filter housing.

Scheme 32

Disconnect electrical connector -1-.

Remove brake light switch retaining bolt -2- from brake master cylinder.

Remove brake light switch down from brake master cylinder and remove switch upward from retaining tab.

Installing

Install in reverse order of removal. Make sure that top of switch is seated correctly in retaining tab when doing so.

Note. The brake light switch is not adjusted.

Install the air filter housing and tighten the bolts -arrows-.

Install the air guide and tighten the bolts -arrows-.

Install the engine cover.

ESP SENSOR UNIT

After the ESP sensor unit is replaced, basic setting (calibration) must be performed on

1. Transverse Acceleration Sensor -G200
2. Rotation Rate Sensor -G202
3. On AWD vehicles, Longitudinal Acceleration Sensor -G251

Removing

Note. The ESP sensor unit is installed on the center console under the selector lever trim.

Remove center console trim. Refer to Removal and Installation .

Disconnect electrical connector.

Remove bolts.

Remove the ESP sensor unit upward.

Installing

Installation is the reverse of removal, with special attention to the following

Calibrate transverse acceleration sensor and, on AWD vehicles, longitudinal acceleration sensor. For this, use the Vehicle diagnostic, testing and information System VAS 5051.

On display, select

1. Chassis
2. Brake system (Repair group 01;45)
3. 01 - On Board Diagnostic (OBD) capable systems
4. 03 - Brake electronics ABS/ESP Mark 60

Select desired function on display.

1. Calibrate transverse acceleration sensor.
2. Calibrate longitudinal acceleration sensor (only AWD vehicles).

Perform ESP driving and system test.

STEERING ANGLE SENSOR

Removing

Set the wheels to the straight ahead position.

Remove airbag unit and steering wheel. Refer to Removal and Installation .

Scheme 33

1 - Coil Ring With Slip Ring

Clipped onto switch for turn signals, high/low beam headlamps and light signal.

2 - Steering Angle Sensor -G85

Clipped to coil ring with slip ring.

Remove driver side compartment. Refer to Removal and Installation .

Remove steering column switch module. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation .

Installing

Installation is performed in the reverse order of removal.

Install airbag unit and steering wheel. Refer to Removal and Installation .

Steering Angle Sensor, Calibrating

Note. Use Vehicle Diagnosis, Testing and Information System VAS 5051 for this.

On display, select

1. Chassis
2. Brake system (Repair group 01;45)
3. 01 - On Board Diagnostic (OBD) capable systems
4. 03 - Brake electronics ABS/ESP Mark 60

Select desired function on display

1. ABS/ASR/ESP Control Module, Functions
2. Steering Angle Sensor calibration.

Perform the ESP driving and system tests.

BRAKE BOOSTER VACUUM SENSOR, WITH OPTIMIZED HYDRAULIC BRAKE VACUUM (OHBV) BOOSTING

Note. If the vehicle has a TFSI engine, then the noise amplifier must be removed and installed. Refer to NOISE AMPLIFIER, TFSI . The noise amplifier is inside the engine compartment in front of the brake booster.

Note. Vehicles that draw the vacuum for the brakes from the intake manifold and vehicles with mechanical vacuum pumps do not have a Brake Booster Vacuum Sensor -G483-.

Special tools and workshop equipment required

1. Vehicle diagnostic, testing and information System VAS 5051

Note. The brake booster vacuum sensor does not require calibration after replacing. The electrical test is described in Guided Fault Finding.

Removing

Note. If the vehicle has a TFSI engine, then the noise amplifier must be removed and installed. Refer to NOISE AMPLIFIER, TFSI . The noise amplifier is inside the engine compartment in front of the brake booster.

Disconnect electrical connector -1- on vacuum sensor -2-.

Scheme 34

Pull back OHBV circlip -1- and remove sensor -2- from brake booster.

Scheme 35

Installing

Note. If the vehicle has a TFSI engine, then the noise amplifier must be removed and installed. Refer to NOISE AMPLIFIER, TFSI . The noise amplifier is inside the engine compartment in front of the brake booster.

Installation is performed in the reverse sequence.

ABS CONTROL MODULE AND ABS HYDRAULIC UNIT

Special tools and workshop equipment required

1. Brake Pedal Actuator V.A.G 1869/2
2. Vehicle Diagnosis, Testing and Information System VAS 5051

Removing

Read the control module version and make a note of it.

Disconnect the battery. Be sure to get the radio code beforehand. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation .

Insert V.A.G 1869/2 between brake pedal and driver's seat by pressing brake pedal down at least 60 mm.

Scheme 36

Connect bleeder bottle hose to left front and left rear brake caliper bleeder screw.

Open left rear and left front brake caliper bleeder screws to reduce pressure in hydraulic unit.

Close left front and rear brake caliper bleeder screws.

Do not remove V.A.G 1869/2.

Release control module harness connector -arrow 1- and pull off -arrow 2-.

Scheme 37

Note. Make sure that no brake fluid enters control module connector housing. This could lead to corrosion of the contacts and thereby cause the system to fail. A contaminated housing must be carefully cleaned with compressed air.

To protect against escaping brake fluid, place a lint-free rag in the area under the control module and hydraulic unit.

Mark brake lines. Refer to ABS CONTROL MODULE AND ABS HYDRAULIC UNIT ABS/ESP MARK 60 ASSEMBLY OVERVIEW .

Disconnect the tie up the brake lines on the hydraulic unit -2- leading to the master brake cylinder.

Scheme 38

Remove the remaining brake lines -3- from hydraulic unit.

Note. Disconnecting hydraulic pump -1- from hydraulic unit is not permitted.

Seal brake lines and threaded holes with plugs from repair kit.

Carefully remove the hydraulic unit -2- together with the control module and bracket -4- from the rubber buffers in the bracket -6-.

Remove hydraulic unit from the vehicle.

Remove the bolts -5- from the bracket -4- and remove the bracket.

Set hydraulic unit with control module down on a clean surface.

Note. After removing control module and hydraulic unit, seal threaded holes and brake lines with sealing plugs - 1H0.698.311.A.

Installing

Installation is the reverse of removal, with special attention to the following

Note. For customer service, hydraulic unit is filled with brake fluid. If sealing plugs are removed before corresponding brake line is installed, brake fluid leaks out. If that is the case, sufficient brake system bleeding can no longer be ensured.

Tighten the bolts -5- on the bracket -4- to 8 Nm.

Carefully install the hydraulic unit -2- together with the control module and bracket -4- on the rubber buffers in the bracket -6-.

Note. Be careful not to press the rubber buffers through bracket when installing the unit.

Connect brake lines according to marking.

Tighten brake lines on hydraulic unit.

Connect the connector to the control module.

Bleed the brake system. Refer to BRAKE SYSTEM BLEEDING .

After securing brake lines to hydraulic unit, perform output diagnostic test mode.

Note. By performing the output check diagnosis, it can be determined if the line connections were interchanged.

Note. If ABS hydraulic unit was replaced, it must be coded. Use VAS 5051 for this.

On display, select

1. Chassis
2. Brake system (Repair group 01;45)
3. 01- On Board Diagnostic (OBD) capable systems
4. 03- Brake electronics ABS/ESP Mark 60

Select desired function on display

1. J104- ABS/ASR/ESP Control Module Mark 60
2. J104- ABS/ASR/ESP Control Module, Functions
3. J104- Control module, coding

The following sensors should also be calibrated after replacing control module

1. Steering Angle Sensor -G85
2. Sensor for transverse acceleration -G200
3. Brake Pressure Sensor 1 -G201
4. On AWD vehicles, longitudinal acceleration sensor -G251

Use VAS 5051 for this.

On display, select

1. Chassis
2. Brake System
3. 01- On Board Diagnostic (OBD) capable systems
4. 03- Brake electronics ABS/ESP Mark 60

Select desired function on display

1. J104- ABS/ASR/ESP Control Module Mark 60
2. J104- ABS/ASR/ESP Control Module, Functions

Then perform the ESP driving and system tests.

ABS CONTROL MODULE AND ABS HYDRAULIC UNIT, TFSI

Special tools and workshop equipment required

1. Brake Pedal Actuator V.A.G 1869/2
2. Vehicle Diagnosis, Testing and Information System VAS 5051

Removing

Read the control module version and make a note of it.

Disconnect the battery. Be sure to get the radio code beforehand. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation .

Insert V.A.G 1869/2 between brake pedal and driver's seat by pressing brake pedal down at least 60 mm.

Connect bleeder bottle hose to left front and left rear brake caliper bleeder screw.

Open left rear and left front brake caliper bleeder screws to reduce pressure in hydraulic unit.

Close left front and rear brake caliper bleeder screws.

Do not remove V.A.G 1869/2.

Lower vehicle.

Remove the engine cover.

Scheme 39

Open the clamp on the air guide hose with pliers and disconnect the hose.

Remove the clamp from the air guide with pliers.

Remove the air guide for the turbocharger.

Remove the air guide from the vehicle.

Release control module harness connector -arrow 1- and pull off -arrow 2-.

Note. Make sure that no brake fluid enters control module connector housing. This could lead to corrosion of the contacts and thereby cause the system to fail. A contaminated housing must be carefully cleaned with compressed air.

To protect against escaping brake fluid, place a lint-free rag in the area under the control module and hydraulic unit.

Mark brake lines. Refer to ABS CONTROL MODULE AND ABS HYDRAULIC UNIT ABS/ESP MARK 60 ASSEMBLY OVERVIEW .

Disconnect the tie up the brake lines on the hydraulic unit -2- leading to the master brake cylinder.

Remove the remaining brake lines -3- from hydraulic unit.

Seal brake lines and threaded holes with plugs from repair kit.

Note. Disconnecting hydraulic pump from hydraulic unit is not permitted.

Carefully remove the hydraulic unit -2- together with the control module and bracket -4- from the rubber buffers in the bracket -6-.

Remove hydraulic unit from the vehicle.

Remove the bolts -5- from the bracket -4- and remove the bracket.

Set hydraulic unit with control module down on a clean surface.

Note. After removing control module and hydraulic unit, seal threaded holes and brake lines with sealing plugs - 1H0.698.311.A.

Installing

Installation is the reverse of removal, with special attention to the following

Note. For customer service, hydraulic unit is filled with brake fluid. If sealing plugs are removed before corresponding brake line is installed, brake fluid leaks out. If that is the case, sufficient brake system bleeding can no longer be ensured.

Tighten the bolts -5- on the bracket -4- to 8 Nm.

Carefully install the hydraulic unit -2- together with the control module and bracket -4- on the rubber buffers in the bracket -6-.

Note. Be careful not to press the rubber buffers through bracket when installing the unit.

Connect brake lines according to marking. Refer to ABS CONTROL MODULE AND ABS HYDRAULIC UNIT ABS/ESP MARK 60 ASSEMBLY OVERVIEW .

Tighten brake lines on hydraulic unit.

Connect the connector to the control module.

Install the turbocharger air guide and close the clamps with pliers.

Install the turbocharger air guide.

Connect the air hose and close the clamp with pliers.

Install the engine cover.

Bleed the brake system. Refer to BRAKE SYSTEM BLEEDING .

After securing brake lines to hydraulic unit, perform output diagnostic test mode.

Note. By performing the output check diagnosis, it can be determined if the line connections were interchanged. If ABS hydraulic unit was replaced, it must be coded. Use VAS 5051 for this.

On display, select

1. Chassis
2. Brake system (Repair group 01;45)
3. 01- On Board Diagnostic (OBD) capable systems
4. 03- Brake electronics ABS/ESP Mark 60

Select desired function on display

1. J104- ABS/ASR/ESP Control Module Mark 60
2. J104- ABS/ASR/ESP Control Module, Functions
3. J104- Control module, coding

The following sensors should also be calibrated after replacing control module

1. Steering Angle Sensor -G85
2. Sensor for transverse acceleration -G200
3. Brake Pressure Sensor 1 -G201
4. On AWD vehicles, longitudinal acceleration sensor -G251

Note. Use VAS 505x for this.

On display, select

1. Chassis
2. Brake System
3. 01- On Board Diagnostic (OBD) capable systems
4. 03- Brake electronics ABS/ESP Mark 60

Select desired function on display

1. J104- ABS/ASR/ESP Control Module Mark 60
2. J104- ABS/ASR/ESP Control Module, Functions

Then perform the ESP driving and system tests.

ABS CONTROL MODULE AND ABS HYDRAULIC UNIT, TF RS

Hydraulic unit with control module, removing

Read the control module version and make a note of it.

Disconnect the battery. Be sure to get the radio code beforehand. Refer to [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Battery, Starter, Generator, Cruise Control .

Insert Brake Pedal Actuator V.A.G 1869/2 between brake pedal and driver's seat by pressing brake pedal down at least 60 mm.

Connect bleeder bottle hose to left front and left rear brake caliper bleeder screw.

Open left rear and left front brake caliper bleeder screws to reduce pressure in hydraulic unit.

Close left front and rear brake caliper bleeder screws.

Do not remove brake pedal loading device V.A.G 1869/2.

Lower vehicle.

Open the clamp on the air guide hose with pliers and disconnect the hose.

Remove the clamp from the air guide with pliers.

Remove the air guide for the turbocharger.

Remove the air guide from the vehicle.

Remove the coolant line for the coolant reservoir from the bulkhead.

Carefully move the coolant line to the side.

Release control module harness connector -arrow 1- and pull off -arrow 2-.

Note. Make sure that no brake fluid enters control module connector housing. This could lead to corrosion of the contacts and thereby cause the system to fail. A contaminated housing must be carefully cleaned with compressed air.

Loosen the cable tie for the wire leading to the connector and move the wire to the side.

To protect against escaping brake fluid, place a lint-free rag in the area under the control module and hydraulic unit.

Mark brake lines. Refer to item 1

Disconnect the tie up the brake lines on the hydraulic unit -2- leading to the master brake cylinder.

Remove the remaining brake lines -3- from hydraulic unit.

Seal brake lines and threaded holes with plugs from repair kit.

Note. Disconnecting hydraulic pump from hydraulic unit is not permitted.

Carefully remove the hydraulic unit -2- together with the control module and bracket -4- from the rubber buffers in the bracket -6-.

Remove hydraulic unit from the vehicle.

Remove the bolts -5- from the bracket -4- and remove the bracket.

Set hydraulic unit with control module down on a clean surface.

After removing control module and hydraulic unit, seal threaded holes and brake lines with sealing plugs - 1H0.698.311.A.

Installing

Installation is the reverse of removal, with special attention to the following

Note. For customer service, hydraulic unit is filled with brake fluid. If sealing plugs are removed before corresponding brake line is installed, brake fluid leaks out. If that is the case, sufficient brake system bleeding can no longer be ensured.

Tighten the bolts -5- on the bracket -4- to 8 Nm.

Carefully install the hydraulic unit -2- together with the control module and bracket -4- on the rubber buffers in the bracket -6-.

Be careful not to press the rubber buffers through bracket when installing the unit.

Connect brake lines according to marking. Refer to item 1

Tighten brake lines on hydraulic unit.

Connect the connector to the control module.

Secure the connector electric wire to the body using a cable tie.

Install the coolant line for the coolant reservoir in the bracket on the bulkhead.

Note. Attach the bracket to the bulkhead.

Install the turbocharger air guide and close the clamps with pliers.

Install the turbocharger air guide.

Connect the air hose and close the clamp with pliers.

Bleed the brake system. Refer to BRAKE SYSTEM BLEEDING .

After securing brake lines to hydraulic unit, perform output diagnostic test mode.

Use Vehicle Diagnosis, Testing and Information System VAS 505x for this.

Note. By performing the output check diagnosis, it can be determined if the line connections were interchanged.

If ABS Hydraulic Unit J104 was replaced, it must be coded.

Use Vehicle Diagnosis, Testing and Information System VAS 505x for this.

On display, select

1. Chassis
2. Brake system (Repair group 01;45)
3. 01 - On Board Diagnostic (OBD) capable systems
4. 03- Brake electronics ABS/ESP Mark 60

Select desired function on display.

1. J104- ABS/ASR/ESP Control Module Mark 60
2. J104- ABS/ASR/ESP Control Module, Functions
3. J104- Control module, coding

The following sensors should also be calibrated after replacing control module J104.

1. Steering Angle Sensor -G85
2. Sensor for transverse acceleration -G200
3. Brake Pressure Sensor 1 -G201
4. On AWD vehicles longitudinal acceleration sensor -G251

Use Vehicle Diagnosis, Testing and Information System VAS 505x for this.

On display, select

1. Chassis
2. Brake System
3. 01 - On Board Diagnostic (OBD) capable systems
4. 03- Brake electronics ABS/ESP Mark 60

Select desired function on display.

1. J104- ABS/ASR/ESP Control Module Mark 60
2. J104- ABS/ASR/ESP Control Module, Functions

Then perform the ESP driving and system tests.

FRONT ABS WHEEL SPEED SENSOR

Removing

Release connector on speed sensor and disconnect.

Remove bolt.

Remove speed sensor from wheel bearing housing.

Installing

Installation is the reverse of removal, with special attention to the following

Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with Polycarbamide grease G 000 650.

Turn the steering completely left and right, making sure that the speed sensor wiring has sufficient clearance.

REAR ABS WHEEL SPEED SENSOR, FWD

Removing

Release connector on speed sensor and disconnect.

Remove bolt.

Remove speed sensor from stub axle.

Installing

Installation is the reverse of removal, with special attention to the following

Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with Polycarbamide grease G 000 650

REAR ABS WHEEL SPEED SENSOR, AWD

Removing

Release connector on speed sensor and disconnect.

Remove bolt.

Pull speed sensor out from stub axle.

Installing

Installation is the reverse of removal, with special attention to the following

Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with Polycarbamide grease G 000 650.

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 40

1. Brake Pedal Actuator V.A.G 1869/2
2. Vehicle Diagnosis, Testing and Information System VAS 5051

See also:
• BRAKE SYSTEM BLEEDING
• TECHNICAL DATA
• BRAKE PEDAL
• BRAKE BOOSTER
• NOISE AMPLIFIER, TFSI
• BRAKE MASTER CYLINDER
• Description and Operation
• Description and Operation
• Removal and Installation
• Removal and Installation
• [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation
• [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation
• STEERING ANGLE SENSOR
• FRONT ABS WHEEL SPEED SENSOR
• BRAKE BOOSTER VACUUM SENSOR, WITH OPTIMIZED HYDRAULIC BRAKE VACUUM (OHBV) BOOSTING
• BRAKE LIGHT SWITCH
• BRAKE LAMP SWITCH, TT RS
• ABS CONTROL MODULE AND ABS HYDRAULIC UNIT
• ESP SENSOR UNIT
• REAR ABS WHEEL SPEED SENSOR, FWD
• REAR ABS WHEEL SPEED SENSOR, AWD
• ABS CONTROL MODULE AND ABS HYDRAULIC UNIT ABS/ESP MARK 60 ASSEMBLY OVERVIEW