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Speed sensor wire, replacing Audi TT 8N

Brake System 11 illustrations ~1322 words

Speed sensor wire, replacing

Note. Always use repair kit VAS 1978 for repairs on wiring harnesses and connectors.

Special tools and equipment

Scheme 45

Scheme 45: Speed sensor wire, replacing
Scheme 45: Speed sensor wire, replacing
  1. Wiring harness repair kit VAS 1978

Removing

  1. Remove wheel housing liner.
  1. Release connector on wheel speed sensor and disconnect wiring.
  2. Remove interior side panel trim.

Scheme 46

Scheme 46
Scheme 46
  1. Pull insulating grommet (arrow) off wiring connection.

Scheme 47

Scheme 47
Scheme 47
  1. Cut speed sensor wiring with wire strippers VAS 1978/3 and remove defective wiring.

Installing

Install in reverse sequence; note the following points

Scheme 48

Scheme 48
Scheme 48
  1. Strip 15 mm of insulation off the end of the wire using wire strippers from VAS 1978/3 and bend back the bare part of the wire over half its length.
  2. Run in new wheel speed sensor wiring.

Scheme 49

Scheme 49
Scheme 49
  1. Clip in speed sensor wiring (arrows).

Note. Make sure sensor wire is not twisted in wheel housing.

  1. Cut 2-pin connector off new speed sensor wiring with wire stripper pliers.
  2. Strip 15 mm of insulation from end of wire with wire strippers and bend back half.
  3. Connect speed sensor wiring with aid of suitable crimp connector from wiring harness repair kit VAS 1978.

Note. The instructions supplied with wiring repair kit VAS 1978 normally do not permit repairs to the wiring of the ABS system. However, this only applies to the screened wiring in the system.

Scheme 50

Scheme 50: Exploded view
Scheme 50: Exploded view

1 - ABS wheel speed sensor

  1. Removing and installing. Refer to «Speed sensor, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)
  2. Before installing speed sensor, clean inner surface of hole and coat speed sensor all around with lubricant paste G 000 650
  3. Replacing speed sensor wire. Refer to «Speed sensor wire, replacing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

2 - Hex socket-head bolt 8 Nm

3 - Trailing arm

4 - Backing plate

5 - Hex bolt, 10 Nm

6 - Brake disc

  1. Application. Refer to «Application of PR Nos./brakes»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

7 - Phillips-head screw

  1. Tightening torque. Refer to «Exploded view»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

8 - Wheel hub with rotor

  1. Checking rotor. Refer to «Rotor, checking»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)
  2. Only replace complete
  3. Removing and installing

9 - Snap ring

10 - Wheel bearing

  1. Removing and installing

Removing

Scheme 51

Scheme 51: Speed sensor, removing and installing
Scheme 51: Speed sensor, removing and installing
  1. Open cover -2- above connector for speed sensor.
  2. Unplug electrical connector -1-.

Scheme 52

Scheme 52
Scheme 52
  1. Remove bolt -1-.
  2. Pull speed sensor out of trailing arm.

Installing

Install in reverse sequence; note the following points

  1. Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with solid lubricant paste G 000 650.

Tightening torque

ComponentNm
Speed sensor to trailing arm8
  1. Remove bolt -1-.
  2. Pull speed sensor out of trailing arm.
  3. Remove wheel.
  4. Rotate brake disc and check rotor for damage or dirt.
  1. If rotor is damaged, remove wheel hub with rotor and replace.
  1. Install speed sensor. Refer to «Speed sensor, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system) .

Note. Always use repair kit VAS 1978 for repairs on wiring harnesses and connectors.

Special tools and equipment

  1. Wiring harness repair kit VAS 1978

Removing

  1. Open cover -2- above connector for speed sensor.
  2. Unplug electrical connector -1-.
  3. Remove interior side panel trim.
  1. Pull insulating grommet (arrow) off wire connection.
  1. Cut speed sensor wiring with wire strippers VAS 1978/3 and remove defective wiring.

Installing

Install in reverse sequence; note the following points

  1. Strip 15 mm of insulation off the end of the wire using wire strippers VAS 1978/3 and bend back the bare part of the wire over half its length.
  2. Run in new wheel speed sensor wiring.

Scheme 53

Scheme 53
Scheme 53
  1. Clip in speed sensor wiring -arrows-.

Note. Make sure sensor wire is not twisted in wheel housing.

  1. Plug in electrical connector -1- and close cover -2-.
  2. Cut 2-pin connector off new speed sensor wiring with wire stripper pliers.
  3. Strip 15 mm of insulation from end of wire with wire strippers and bend back half.
  4. Connect speed sensor wiring with aid of suitable crimp connector from wiring harness repair kit VAS 1978.

Note. The instructions supplied with wiring repair kit VAS 1978 normally do not permit repairs to the wiring of the ABS system. However, this only applies to the screened wiring in the system.

Scheme 54

Scheme 54: Exploded view
Scheme 54: Exploded view

1 - Right rear speed sensor rotor

  1. Rotor is welded to wheel hub
  2. Checking. Refer to «Rotor, checking»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system) and «Rotor, checking»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)
  3. Removing and installing

2 - Right rear ABS wheel speed sensor -G44

  1. Removing and installing. Refer to «ABS wheel speed sensor, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system) and «ABS wheel speed sensor, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

3 - Left rear ABS wheel speed sensor -G46

  1. Removing and installing. Refer to «ABS wheel speed sensor, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system) and «ABS wheel speed sensor, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

4 - Rotor for left rear speed sensor

  1. Rotor is welded to wheel hub
  2. Checking. Refer to «Rotor, checking»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system) and «Rotor, checking»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)
  3. Removing and installing

5 - Parking brake indicator light - K14

  1. Installation location: in instrument cluster

6 - ABS warning light -K47

  1. Installation location: in instrument cluster

7 - Warning light for brake system -K118

  1. Installation location: in instrument cluster in driver information system (DIS)

8 - Traction control indicator light -K86

  1. Installation location: in instrument cluster

9 - Brake light switch -F

  1. Removing and installing. Refer to «Brake light switch, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system__brake-light-switch-removing-and-installing)

10 - Rotor for left front ABS wheel speed sensor

  1. Rotor is welded to wheel hub
  2. Checking. Refer to «Rotor, checking»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)
  3. Removing and installing

11 - Left front ABS wheel speed sensor -G47

  1. Removing and installing. Refer to «ABS wheel speed sensor, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

12 - ABS hydraulic unit -N55- with ABS Control Module (w/EDL) -J104

  1. The hydraulic control unit comprises ABS hydraulic pump -V64-, hydraulic unit -N55- and ABS control module (w/EDL) -J104
  2. Removing and installing. Refer to «Control module and hydraulic unit, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system__control-module-and-hydraulic-unit-removing)

13 - Rotor for right front ABS wheel speed sensor

  1. Rotor is welded to wheel hub
  2. Checking. Refer to «Rotor, checking»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)
  3. Removing and installing

14 - Right front ABS wheel speed sensor -G45

  1. Removing and installing. Refer to «ABS wheel speed sensor, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

15 - Longitudinal acceleration sensor -G251

  1. Vehicles with all wheel drive only
  2. Installation location: A-pillar on passenger`s side
  3. Removing and installing. Refer to «Longitudinal acceleration sensor -G251- (vehicles up to approx. 08.01), removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system__longitudinal-acceleration-sensor-g251-vehicles-up)
  4. Integrated into ESP sensor unit -G419- from approx. 09.01. See «ESP sensor unit -G419- from approx. 09.01»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

16 - Sensor -2- for brake pressure -G214

  1. Removing and installing. Refer to «Brake pressure sensors, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

17 - Sender 1 for brake booster -1- -G201

  1. Removing and installing. Refer to «Brake pressure sensors, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

18 - Brake fluid level warning switch -F34

19 - Sensor for transverse acceleration -G200

  1. Removing and installing. Refer to «Sensor for transverse acceleration -G200- and Sender for rotation rate -G202- (vehicles up to approx. 08.01), removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system__sensor-for-transverse-acceleration-g200-and)
  2. Integrated into ESP sensor unit -G419- from approx. 09.01. See «ESP sensor unit -G419- from approx. 09.01»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

20 - Sender for rotation rate -G202

  1. Removing and installing. Refer to «Sensor for transverse acceleration -G200- and Sender for rotation rate -G202- (vehicles up to approx. 08.01), removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system__sensor-for-transverse-acceleration-g200-and)
  2. Integrated into ESP sensor unit -G419- from approx. 09.01. See «ESP sensor unit -G419- from approx. 09.01»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

21 - Anti-Slip control switch -E132

  1. Installation location: on center console

22 - ESP sensor unit -G419

  1. From approx. 09.01. See «ESP sensor unit -G419- from approx. 09.01»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)
  2. Removing and installing. Refer to «ESP sensor unit -G419-, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system__esp-sensor-unit-g419-removing-and)

23 - Steering angle sensor -G85

  1. Removing and installing. Refer to «Steering angle sensor -G85-, removing and installing»(/audi/tt/8n-1998-2003/remont/anti-locktraction-control/#brake-system)

24 - Parking brake warning light switch -F9

  1. Installation location: on parking brake lever module

Scheme 55

Scheme 55: ESP sensor unit -G419- from approx. 09.01
Scheme 55: ESP sensor unit -G419- from approx. 09.01

The ESP sensor unit -1- comprises of the senders listed below

  1. Sensor for transverse acceleration -G200
  2. Sender for rotation rate -G202
  3. Longitudinal acceleration sensor -G251- (all wheel drive vehicles only)