Abs Control Module And Abs Hydraulic Unit, TF RS

CAUTION:

Disconnecting ABS Control Module J104 and ABS Control Module J104 is not permitted.

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.

Fig 1: Brake Pedal Depressor VAG 1869/2 Inserted Between Brake Pedal And Driver's Seat

Courtesy of AUDI OF AMERICA, LLC

-- 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-.

Fig 2: Identifying Control Module Connector

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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

WARNING:

Do not bend or kink brake lines!

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

Fig 3: Identifying Master Brake Cylinder Lines

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-- 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-.

Fig 4: ABS Control Module And ABS Hydraulic Unit ABS/ESP Mark 60 Assembly Overview

Courtesy of AUDI OF AMERICA, LLC

-- 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.

WARNING:

Excessive shaking (e.g. dropping, impact) may destroy the control module. Control module must then no longer be used.

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

WARNING:

The hydraulic pump must not be separated from the hydraulic unit.

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.

Fig 5: ABS Control Module And ABS Hydraulic Unit ABS/ESP Mark 60 Assembly Overview

Courtesy of AUDI OF AMERICA, LLC

-- 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

WARNING:

If the brake line connections are interchanged, the ESP system will malfunction.

-- 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:

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

-- Select desired function on display.

J104- ABS/ASR/ESP Control Module Mark 60
J104- ABS/ASR/ESP Control Module, Functions
J104- Control module, coding

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

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

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

-- On display, select:

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

-- Select desired function on display.

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

-- Then perform the ESP driving and system tests.

WARNING:

Make sure the brakes are working correctly before driving the vehicle for the first time.