Hydraulic Unit, Brake Booster/brake Master Cylinder, Assembly Overview

Volkswagen Passat B5 - Hydraulic unit, brake booster/brake master cylinder Page 1 / 49
45 - 5
Hydraulic unit, brake booster/brake master cylinder,

assembly overview
ABS Bosch 5.3 up to model year 1999 - Vehicles up to
VIN 3B X 600 000
With the following versions: ABS; ABS/EDL and

ABS/EDL/ASR
Brake booster
On gasoline engines the

vacuum required is taken
from the intake manifold.
To produce vacuum with

diesel engines, a vacuum
pump is equipped.
Functional check:
Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 2 / 49
- With engine switched off,

depress brake pedal firmly
several times (to exhaust
the vacuum in the unit).
- Depress brake pedal with

average foot pressure, hold
and start engine. If the
booster unit is working
properly, the pedal will be
felt to give slightly under
foot (booster assist
becomes effective).
- If faulty, replace
completely.
Removing and installing

47-8, Brake booster,
removing and installing
(Vehicles up to model year
1999)
Spring
Self-locking nut, 9 Nm
Threaded stud
Rubber bushing
Control module

separately 45-5, ABS
Control Module, removing
and installing separately
Remove and install together

with hydraulic unit 45-5,
Control module and
hydraulic unit, removing and
installing
T 20 torx socket head bolt, 8 Nm
ABS hydraulic unit
Note different versions:
ABS Front Wheel Drive

(FWD)
ABS/EDL front and All

Wheel Drive (AWD) 45-5,

Connecting tandem brake
master cylinder to hydraulic
unit for ABS/EDL front and
all wheel drive, as well as
ABS/EDL/ASR front wheel
drive
ABS/EDL/ASR Front Wheel

Drive (FWD) 45-5,
Connecting tandem brake
master cylinder to hydraulic
unit for ABS/EDL front and
all wheel drive, as well as
ABS/EDL/ASR front wheel
drive

45-5, Control module and
installing
Brake line connection
Hydraulic unit to right front

brake caliper
Hydraulic unit to left front

brake caliper
Brake line
Brake master
cylinder/secondary piston
circuit to hydraulic unit
Brake line
Brake master
cylinder/primary piston circuit
to hydraulic unit
Hydraulic unit to left rear

brake caliper

Hydraulic unit to right rear

brake caliper
Bracket
Hex head bolt, 9 Nm
Bracket
T 45 torx socket head bolt, 25

Nm
Self-locking hex nut, 49 Nm
Tandem brake master cylinder
With seal
Cap
Brake fluid reservoir
Connecting brake lines from tandem master cylinder to ABS

hydraulic unit
A - Secondary piston circuit

B - Primary piston circuit
1 - Hydraulic unit to left rear brake caliper
2 - Hydraulic unit to right rear brake caliper
3 - Hydraulic unit to right front brake caliper
4 - Hydraulic unit to left front brake caliper
Connecting tandem brake master cylinder to hydraulic unit

for ABS/EDL front and all wheel drive, as well as
ABS/EDL/ASR front wheel drive

ABS Control Module, removing and installing separately
Special tools, testers and auxiliary items required
Torque Wrench (5-60 Nm) VAG1783
- For vehicles equipped with coded anti-theft radio, note

radio code, obtain if necessary.
- Disconnect battery.
- Remove left front wheel.

- Remove left front wheel housing liner
Repair Manual, Body Exterior, Repair Group 66, Wheel

housing liner
- Loosen power steering fluid reservoir.
- Remove tank for windshield washer system
Repair Manual, Electrical Equipment, Repair Group 92,

Windshield washer system
- Thoroughly clean control module, hydraulic unit and

surrounding area.
- Vacuum clean control module, hydraulic unit and

surrounding area in order to prevent dirt and moisture from
entering the unit.
- Disengage connector - arrow 1 - and disconnect -

arrow 2 - from control module.
- Disengage and disconnect harness connector - 1 - .
- Remove bolts - 1 - and pull control module - 2 - off

hydraulic unit without canting.
- Clean sealing surface - 2 - using plastic scraper - 1 -

enclosed.
- Check valves - 3 - for damage.
Note:
Do not use aggressive cleaning agents (use

cleaning agent enclosed).
Check sealing surface for damage (visual check).
Caution!
No moisture or particles of dirt must penetrate in

interior of control module.
If sealing surface or contact tags are damaged,

hydraulic unit must be replaced.
Excessive shaking (e.g. dropping, impact) may destroy

the control module. Control module must then no
longer be used.
- Carefully slide control module - 1 - onto hydraulic unit -

2 - . Make sure valves do not cant.
- Control module housing edge must glide over offset on

hydraulic unit.
Note:
Use new bolts.
A new control module may be assembled on an

already used hydraulic unit a maximum of two times
in order to guarantee the seal of the elastic gaskets.
A control module which was once in driving

operation must not be installed a second time.
- Press control module onto hydraulic unit and install new

bolts - 1 and 2 - evenly (do not tighten) until control
module makes contact evenly on hydraulic unit.
- Install bolts - 1 to 6 - until making contact, do not

tighten.
- Now tighten bolts in the specified sequence to tightening

torque of 2.5 Nm.
- Install harness connector - 1 - .
- Code radio.
- If control module is codeable, code control module

Coding control module using Vehicle Diagnosis, Testing
and Information System VAS 5051 , via "Guided Fault
Finding" .
Tightening torque:
Control module to hydraulic unit 2.5 Nm
Control module and hydraulic unit, removing and installing
Torque wrench V.A.G 1331

Brake pedal loading device V.A.G 1869/2
Location:
The control module is bolted to the hydraulic unit and is

located in the engine compartment, on the left side.
Warning!
Do not bend the brake lines in the area of the hydraulic

unit!
Removing
- Note or request radio code on vehicles with coded radio if

necessary.
- Release control module connector - arrow 1 - and pull

off - arrow 2 - .
- Connect bleeder bottle hose to left front brake caliper

bleeder screw and open bleeder screw.
- Install brake pedal loading device V.A.G 1869/2 .
- Depress brake pedal with brake pedal loading device

V.A.G 1869/2 .
- Close left front bleeder screw.
- Place sufficient lint-free cloths under control module and

hydraulic unit.
- Disconnect brake lines from the hydraulic unit.
- Plug brake lines and threaded holes with sealing plugs

from the repair kit Part No. 1H0 698 311 A.
- Remove nuts on hydraulic unit bracket - arrows - .
- Remove hydraulic unit with control module.
Installing
Note:
Remove sealing plugs on new hydraulic unit when

the corresponding brake line is going to be
connected.
If the sealing plugs are removed too early, brake

fluid can escape, and can no longer be guaranteed
that the unit is filled or adequately bled.
- Installation is in reverse order of removal.
- Bleeding brake system 47-4, Braking system,

bleeding .
- Enter radio code.
- If control module can be coded, then code control module

Coding the control module with the Vehicle diagnostic,
test and information system. in "Guided Fault Finding"
Tightening torques:
Brake lines to ABS module:
Thread M 10 x 1 14 Nm
Hydraulic unit hex to bracket Item - 3 -
ABS Bosch 5.3 from model year 2000 - Vehicles from VIN
3B Y 000 001
With the following versions: ABS; ABS/EDL and

ABS/EDL/ASR
Tandem brake booster

As of model year 2001,

vehicles with a gasoline
engine and automatic
transmission are equipped
with a brake vacuum pump
47-6, Brake system
vacuum pump V192 .

pump is equipped.
Functional check:


becomes effective).
completely.

(vehicles as of model year
2000)
To left rear brake caliper
Marked on hydraulic unit

with "HL"
To right rear brake caliper

with "HR"
Brake line
Brake master
Brake line
Brake master
to hydraulic unit
Brake line
To left front brake caliper

with "VL"
Hex nut, 12 Nm
Threaded stud
Rubber bushing
Control module and hydraulic

unit
Control Module, removing

and installing separately
45-5, ABS Control Module,
separately
Control module and

installing 45-5, Control
module and hydraulic unit,
Brake line
To right front brake caliper

with "VR"
Bracket
Hex head bolt, 9 Nm
Bracket
Application Parts
Catalog
Rubber bushing
Hex head bolt

Tandem master cylinder
Cannot be repaired. If faulty,

replace.

47-7, Brake master cylinder,
(Vehicles as of model year
2000)

Nm
Sealing plug
Moisten with brake fluid and

press into brake fluid
reservoir
Sealing ring
Cap
Vacuum hose
Insert into brake booster unit
Seal ring
Connecting tandem master cylinder brake lines to hydraulic

unit for ABS/EDL front and all wheel drive (AWD), as well
as ABS/EDL/ASR front wheel drive (FWD)

ABS Control Module, removing and installing separately
- For vehicles equipped with coded anti-theft radio, note

radio code, obtain if necessary.
- Remove left front wheel.
- Remove left front wheel housing liner
Repair Manual, Body Exterior, Repair Group 66, Wheel

housing liner
- Loosen power steering fluid reservoir.
- Remove tank for windshield washer system
Repair Manual, Electrical Equipment, Repair Group 92,

Windshield washer system
- Thoroughly clean control module, hydraulic unit and

surrounding area.
- Vacuum clean control module, hydraulic unit and

surrounding area in order to prevent dirt and moisture from
entering the unit.
- Disengage connector - arrow 1 - and disconnect -

arrow 2 - from control module.
- Disengage and disconnect harness connector - 1 - .
- Remove bolts - 1 - and pull control module - 2 - off

hydraulic unit without canting.
- Clean sealing surface - 2 - using plastic scraper - 1 -

enclosed.
- Check valves - 3 - for damage.
Note:
Do not use aggressive cleaning agents (use

cleaning agent enclosed).
Check sealing surface for damage (visual check).
Caution!
No moisture or particles of dirt must penetrate in

interior of control module.
If sealing surface or contact tags are damaged,

hydraulic unit must be replaced.
Excessive shaking (e.g. dropping, impact) may destroy

the control module. Control module must then no
longer be used.
- Carefully slide control module - 1 - onto hydraulic unit -

2 - . Make sure valves do not cant.
- Control module housing edge must glide over offset on

hydraulic unit.
Note:
Use new bolts.
A new control module may be assembled on an

already used hydraulic unit a maximum of two times
in order to guarantee the seal of the elastic gaskets.
A control module which was once in driving

operation must not be installed a second time.
- Press control module onto hydraulic unit and install new

bolts - 1 and 2 - evenly (do not tighten) until control
module makes contact evenly on hydraulic unit.
- Install bolts - 1 to 6 - until making contact, do not

tighten.
- Now tighten bolts in the specified sequence to tightening

torque of 2.5 Nm.
- Install harness connector - 1 - .
- Code radio.
- If control module is codeable, code control module

Coding control module using Vehicle Diagnosis, Testing
and Information System VAS 5051 , via "Guided Fault
Finding" .
Tightening torque:
Control module to hydraulic unit 2.5 Nm
Control module and hydraulic unit, removing and installing
If the hydraulic unit is faulty the whole assembly must be

replaced. If the control module is faulty it can be replaced
separately from the hydraulic unit.
Location:

located in the engine compartment, on the left side.
Warning!

unit!
Removing

necessary.
- Release control module connector - arrow 1 - and pull

off - arrow 2 - .


V.A.G 1869/2 .
- Place sufficient lint-free cloths under the control module

and hydraulic unit.
- Detach brake lines from the hydraulic unit.

- Unfasten nuts on hydraulic unit bracket - arrows - .
Installing
Note:

the corresponding brake line is going to be installed.

that the unit is filled or adequately bled.
- Further Installation is in reverse order of removal.
- Bleed brake system 47-4, Braking system, bleeding .
- Enter radio code.
- Perform control module coding Coding the control

module with the Vehicle diagnostic, test and information
system. in "Guided Fault Finding"
Tightening torques:
Hydraulic unit nut to bracket Item - 7 -
ABS/EDL/ASR/ESP Bosch 5.3, assembly overview, up to

model year 1999 - Vehicles up to VIN 3B X 600 000
With seal
Cap
Brake line
Brake master
to hydraulic pump for traction
control
Identification on the
hydraulic pump for traction
control "HZ"
Brake booster


pump is equipped.
Functional check:


becomes effective).
completely.

(Vehicles up to model year
1999)

with "HL"

with "HR"
Rubber bushing
Hex head bolt, 9 Nm

Brake line
Brake master

with "HZ2"
Brake line
Hydraulic unit to hydraulic

pump for traction control

with "VLP"
control "HE"
Brake line

with "VL"
Hex nut
8 mm with 12 Nm
6 mm with 9 Nm
Threaded stud
Brake line

with "VR"
ABS hydraulic unit
Bracket
Bracket
Hydraulic pump for traction

control
Brake pressure sensor
Always replace together with

the hydraulic pump for
traction control.
Connection for brake fluid from

brake fluid reservoir
control "BA"
Connection for the hydraulic

Torx socket head bolt T45, 25

Nm
Connection of brake lines from tandem master cylinder and

the hydraulic pump for traction control to the hydraulic unit
for ABS/EDL/ASR and ESP
A - Hydraulic unit to hydraulic pump for traction control

- Marked on hydraulic unit with VLP
- Identification on the hydraulic pump for traction control
HE
B - Hydraulic unit to master cylinder secondary piston
circuit
- Marked on hydraulic unit with HZ2
- Marked on hydraulic unit with VL
- Marked on hydraulic unit with VR

- Marked on hydraulic unit with HR
- Marked on hydraulic unit with HL
ABS Hydraulic Unit N55 with Hydraulic pump for traction

control V156 , removing and installing

The ABS hydraulic unit N55 and the hydraulic pump for
traction control V156 are located in left side of engine
compartment.
1 - Hydraulic unit with ABS return flow pump
The hydraulic unit and ABS return flow pump form one unit
and must always be replaced together if malfunction exists.
2 - Hydraulic pump for traction control with brake pressure

sensor.
The hydraulic pump for traction control and the brake

pressure sensor form one unit and must always be
replaced together if malfunction exists.
Warning!

unit!
Removing

necessary.
- Release hydraulic unit connector - arrow 1 - and pull off

- arrow 2 - .

V.A.G 1869/2 .

- Place sufficient lint-free cloths under hydraulic unit.
Make sure no brake fluid gets onto contacts.
These procedures are only for removing the hydraulic

unit.

from repair kit Part No. 1H0 698 311 A.
- Remove nuts on hydraulic unit bracket - arrows - .
These procedures are for removing the hydraulic unit

and the hydraulic pump for traction control
- Remove power steering fluid reservoir - 1 - and set aside

with hoses connected.
- Remove coolant reservoir - 2 - and set aside with

coolant hoses connected.
- Remove brake lines to the hydraulic unit and hydraulic

pump for traction control.
- Disconnect connector from hydraulic pump for traction

control.
- Remove brake fluid supply hose from hydraulic pump for

traction control.

- Remove bolts on hydraulic unit bracket
- Remove hydraulic unit with traction control hydraulic

pump upward.
Installing
Note:

the corresponding brake line is going to be
connected.
To bleed the brake system, it is first necessary to activate

the hydraulic pump for traction control V156 .
- Perform the activation of the hydraulic pump for traction

control in the base setting display group number 2.
Perform base setting in Vehicle diagnostic, test and
information system in Guided Fault Finding.
For this, use the Go to button in the

"Functions/Component selection" .
- Enter radio code.
- Code control module Coding the control module with

the Vehicle diagnostic, test and information system in
Guided Fault Finding.
Tightening torques:
Brake lines to ABS assembly and hydraulic pump for traction control:
Nut for ABS hydraulic unit N55 to bracket Item - 14 - .
Nut for Hydraulic pump for traction control V156 to bracket

Item - 14 - .
Bracket hex bolt to body Item - 10 - .
ABS/EDL/ASR/ESP Bosch 5.3, assembly overview, from

model year 2000 - Vehicles from VIN 3B Y 000 001

As of model year 2001,

vehicles with a gasoline
with a brake vacuum pump
47-6, Brake system
vacuum pump V192 .

pump is equipped.
Functional check:


becomes effective).
completely.

(vehicles as of model year
2000)

with "HL"

with "HR"
Brake line
Brake master

with "HZ2"
Brake line
Hydraulic unit to hydraulic


with "VLP"

control "HE"
Brake line

with "VL"
Hex nut, 12 Nm
Threaded stud
Rubber bushing
ABS hydraulic unit
Brake line

with "VR"
Bracket
Hex head bolt, 9 Nm
Rubber bushing
Hydraulic pump for traction

control
Brake line
Brake master
to hydraulic pump for traction
control
control "HZ"
Hex nut, 9 Nm
Rubber bushing
Connection for traction control

hydraulic pump
Connection for brake fluid from

brake fluid reservoir
control "BA"
Brake pressure sensor
Always replace together with

the hydraulic pump for
traction control.
Bracket
Application Parts
Catalog
Rubber bushing
Hex head bolt

replace completely.

47-7, Brake master cylinder,
(Vehicles as of model year
2000)

Nm
Sealing plug

reservoir
Seal ring
Cap
Vacuum hose

Seal ring
Connection of brake lines from tandem master cylinder and

the hydraulic pump for traction control to the hydraulic unit
for ABS/EDL/ASR and ESP
A - Hydraulic unit to hydraulic pump for traction control

- Marked on hydraulic unit with VLP ,
- Identification on the hydraulic pump for traction control
HE
circuit
ABS Hydraulic Unit N55 with Hydraulic pump for traction

control V156 , removing and installing

The ABS hydraulic unit N55 and hydraulic pump for

traction control V156 are located in the left side of engine
compartment.
1 - Hydraulic unit with ABS return flow pump
The hydraulic unit and ABS return flow pump form one unit
and must always be replaced together if malfunction exists.
2 - Hydraulic pump for traction control with brake pressure

sensor.
The hydraulic pump for traction control and the brake

pressure sensor form one unit and must always be
replaced together if malfunction exists.
Warning!

unit!
Removing

necessary.
- Release hydraulic unit connector - arrow 1 - and pull off

- arrow 2 - .

V.A.G 1869/2 .

- Place sufficient lint-free cloths under hydraulic unit.
These procedures are only for removing the hydraulic

unit.

- Remove hex nuts on bracket for hydraulic unit - arrows -

.
These procedures are for removing the ABS hydraulic

unit N55 and the hydraulic pump for traction control
V156
- Remove power steering fluid reservoir - 1 - and set aside

with hoses connected.
- Remove coolant reservoir - 2 - and set aside with

Vehicles with electrical vacuum pump
- Remove electrical vacuum pump 47-6, Brake system

vacuum pump V192 , removing and installing .
Continued for all vehicles
- Remove brake lines to the hydraulic unit and hydraulic

pump for traction control.

- Disconnect connector from hydraulic pump for traction

control.
- Pull off brake fluid supply hose from the hydraulic pump
for traction control.
- Unfasten bolts on bracket for hydraulic unit.
- Remove the hydraulic unit with hydraulic pump for

traction control upward.
Installing

- Further installation is in the reverse sequence of

removal.
To bleed the brake system, it is first necessary to activate

the hydraulic pump for traction control V156 .
- Perform the activation of the hydraulic pump for traction

control in the base setting display group number 2
Perform base setting in "Guided Fault Finding" with Vehicle
diagnostic, test and information system VAS 5051 .
For this, use the Sprung button in the

"Functions/Component selection" .
- Enter radio code.

system in . Guided Fault Finding
Tightening torques:
Brake lines to ABS assembly and hydraulic pump for traction control:
Nut for ABS hydraulic unit N55 to bracket Item - 7 - .
Nut for Hydraulic pump for traction control V156 to bracket

Item - 17 - .
Bracket hex bolt to body Item - 13 - .

ABS/EDL/ASR/ESP Bosch 5.7, assembly overview, as of

model year 2002

Vehicles with a gasoline

with a vacuum pump for
brakes 47-6, Brake
system vacuum pump V192

pump is equipped.
Functional check:



becomes effective).
completely.
With adhesive seal

47-9, Brake master cylinder
with brake booster
Brake line
Brake master
to hydraulic unit

with "HZ1"
Brake line
Brake master

with "HZ2"
Brake line

with "VL"
Brake line

with "VR"
Brake line

with "HR"
Brake line

with "HL"
Brake Pressure Sensor 1 G201

45-5, Brake Pressure Sensor
1 G201 , removing and
installing
ABS hydraulic unit
ABS control module
Locking clip
Buffer
Bracket
Application Parts
Catalog
Hex head bolt, 9 Nm
Seal ring

replace completely.

together with brake booster
47-9, Brake master
cylinder with brake booster
Self-locking hex nut, 49 Nm

T45 torx socket head bolt, 25

Nm
Cap
Sealing plug

reservoir
Dowel bolt, 10 Nm
Vacuum hose
Connecting brake lines from tandem master cylinder to

hydraulic unit
A - Hydraulic unit to master cylinder primary piston circuit

circuit

ABS Control Module J104 and ABS Hydraulic Unit N55 ,

If the hydraulic unit is faulty the whole assembly must be

replaced. If the control module is faulty it can be replaced
separately from the hydraulic unit.
Location:

located in the engine compartment on the left side.
Warning!

unit!
Removing

necessary.
Note:
The hydraulic control unit - 1 - for the W8 is rotated

180 .
- Remove coolant expansion tank - 2 - and set aside with

- Release and remove connector from control module in

the direction of - arrow - .
- Disconnect connector from brake pressure sensor.

V.A.G 1869/2 .

- Place lint-free cloths under the control module and

hydraulic unit.
- Disconnect brake lines from the hydraulic unit.

- Release locking clips - 1 - from below and remove in

direction of - arrow - .
Installing
Note:


that the unit is sufficiently filled or adequately bled.
- Bleeding brake system 47-4, Braking system,

bleeding .
- Enter radio code.

system in . Guided Fault Finding
Tightening torques:
Thread M 12 x 1, SW11 14 Nm
Thread M 12 x 1, SW12 24 Nm
Brake Pressure Sensor 1 G201 , removing and installing
The Brake Pressure Sensor 1 G201 is located on the

hydraulic control unit - 1 - .
Note:
The hydraulic control unit - 1 - for the W8 is rotated

180 .
Removing
This work procedure does not apply to the W8:
- Unfasten coolant expansion tank - 2 - and set aside with

This work procedure applies only to the W8:
- Unfasten power steering fluid reservoir - 3 - and set

aside with hoses connected.
Continued for all vehicles

- Disconnect connector - 1 - from brake pressure sensor -

2- .
- Place lint-free cloths under control module and hydraulic

unit.
- Remove brake pressure sensor.
Installing
Tightening torque:
Brake Pressure Sensor 1 G201 20 Nm

Hydraulic Unit, Brake Booster/brake Master Cylinder, Assembly Overview

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Volkswagen Passat B5 - Hydraulic unit, brake booster/brake master cylinder Page 1 / 49

Hydraulic unit, brake booster/brake master cylinder,

With the following versions: ABS; ABS/EDL and

 On gasoline engines the

 To produce vacuum with

- With engine switched off,

- Depress brake pedal with

 Removing and installing

 Removing and installing

 Remove and install together

 T 20 torx socket head bolt, 8 Nm

 ABS hydraulic unit

 Note different versions:

 ABS Front Wheel Drive

 ABS/EDL front and All

Wheel Drive (AWD) 45-5,

 ABS/EDL/ASR Front Wheel

 Removing and installing

 Brake line connection

 Hydraulic unit to right front

 Brake line connection

 Hydraulic unit to left front

 Brake line connection

 Hydraulic unit to left rear

 Brake line connection

 Hydraulic unit to right rear

 Hex head bolt, 9 Nm

 T 45 torx socket head bolt, 25

 Self-locking hex nut, 49 Nm

 Tandem brake master cylinder

 Brake fluid reservoir

Connecting brake lines from tandem master cylinder to ABS

A - Secondary piston circuit

Connecting tandem brake master cylinder to hydraulic unit

A - Secondary piston circuit

ABS Control Module, removing and installing separately

Special tools, testers and auxiliary items required

 Torque Wrench (5-60 Nm) VAG1783

- For vehicles equipped with coded anti-theft radio, note

- Remove left front wheel.

- Remove left front wheel housing liner

Repair Manual, Body Exterior, Repair Group 66, Wheel

- Loosen power steering fluid reservoir.

- Remove tank for windshield washer system

Repair Manual, Electrical Equipment, Repair Group 92,

- Thoroughly clean control module, hydraulic unit and

- Vacuum clean control module, hydraulic unit and

- Disengage connector - arrow 1 - and disconnect -

- Disengage and disconnect harness connector - 1 - .

- Remove bolts - 1 - and pull control module - 2 - off

- Clean sealing surface - 2 - using plastic scraper - 1 -

- Check valves - 3 - for damage.

 Do not use aggressive cleaning agents (use

 Check sealing surface for damage (visual check).

No moisture or particles of dirt must penetrate in

If sealing surface or contact tags are damaged,

Excessive shaking (e.g. dropping, impact) may destroy

- Carefully slide control module - 1 - onto hydraulic unit -

- Control module housing edge must glide over offset on

 Use new bolts.

 A new control module may be assembled on an

 A control module which was once in driving

On gasoline engines the

To produce vacuum with

Removing and installing

Removing and installing

Remove and install together

T 20 torx socket head bolt, 8 Nm

ABS hydraulic unit

Note different versions:

ABS Front Wheel Drive

ABS/EDL front and All

ABS/EDL/ASR Front Wheel

Removing and installing

Brake line connection

Hydraulic unit to right front

Brake line connection

Hydraulic unit to left front

Brake line connection

Hydraulic unit to left rear

Brake line connection

Hydraulic unit to right rear

Hex head bolt, 9 Nm

T 45 torx socket head bolt, 25

Self-locking hex nut, 49 Nm

Tandem brake master cylinder

Brake fluid reservoir

Torque Wrench (5-60 Nm) VAG1783

Do not use aggressive cleaning agents (use

Check sealing surface for damage (visual check).

Use new bolts.

A new control module may be assembled on an

A control module which was once in driving

Torque wrench V.A.G 1331

Brake pedal loading device V.A.G 1869/2

Remove sealing plugs on new hydraulic unit when

If the sealing plugs are removed too early, brake

Tandem brake booster

On gasoline engines the

As of model year 2001,

To produce vacuum with

Removing and installing

Brake line connection

To left rear brake caliper

Marked on hydraulic unit

Brake line connection

To right rear brake caliper

Marked on hydraulic unit

To left front brake caliper

Marked on hydraulic unit

Control module and hydraulic

Control Module, removing

Control module and

To right front brake caliper

Marked on hydraulic unit

Hex head bolt, 9 Nm

Hex head bolt

Tandem master cylinder

Cannot be repaired. If faulty,

Removing and installing

T 45 torx socket head bolt, 25

Moisten with brake fluid and

Brake fluid reservoir

Insert into brake booster unit

Torque wrench V.A.G 1783