Audi A3 (8P, 8P1,8PA) - Brake System

Service |_| Workshop Manual Audi A3 2004 > Audi A3 Cabriolet 2008 > Audi A3 Sportback 2005 > Edition 11.2018 Service Department. Technical InformationGe Service List of Workshop Manual Repair Groups Repair Group 00 - Technical data 45 - Anti-lock brake system 46 - Brakes - mechanism 47 - Brakes - hydraulics Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2018 Audi AG, Ingolstadt 40050305920‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 Contents 00 - Technical data 1 1 Technical data for brakes 1 1.4. Production code (PR No.) allocation: brakes 1 1.2 Technical data for brakes 1 2 Brake test 5 24 Generalnotes ...... : ce ceeees 5 22 Vehicles with front-wheel drive... . . : : 5 23 Vehicles with four-wheel drive. 5 24 Brake test on a single-axle brake dynamometer 6 45 - Anti-lock brake system ..............06 7 1 General notes 7 2 Connecting VAS 5051 x or VAS 5052 and selecting functions 8 3 ABSIESP ITT Mark 60/ ITT Mark 70 ......00.eeeeee ceeteeees wt 3.1 Exploded view " 4 gREFoging)ané Tistaliine\parts of ABS/ESP system cece serene 16 4.1 (( Removing ant ifstalling brake light switch on brake pedal 16 4.2 \Rembving tind installing/brake light switch on brake master cylinder 7 43 Removing and'installing ESP sensor unit G419 18 4.4 Removing and installing steering angle sender G85 20 45 Removing and indtaling brake pressure sender't G201 24 4.6 .-Removing|and installing brake servo vacuum sender G483.--vehicles with optimised hydraulic brake assistance/vacuum sender (OHBV) only 24 5" ABSIESP ITT Mark 60 control unit and hydraulic unit 23 5.1 Exploded view 23 5.2 Removing and installing control unit and hydraulic unit (Mark 60) : ers 5.3. Basic setting of inlet valves and separating valves (Mark 60EC) veceeeeeeees 36 6 ABS. ITT Mark 70 control unit and hydraulic unit eee. eeeeeeeeseeeeeeeeees 37 64 Exploded view ..... : : 37 8.2 Removing and installing control unt and hydraulic unit (Mark 70) : er) 7 ABS control unit -J104- and ABS hydraulic unit -NSS- - TFSI engine sevens 49 7.4 Removing and installing control unit and hydraulic unit-TFSlengine .........ess.... 48 8 ABS control unit -J104- and ABS hydraulic unit -NSS- - 2.0 tt. TDI engine - 58 8.1 Removing and installing control unit and hydraulic unit - 2.0 itr. TDlengine ............ 58 8 ABS control unit -J104- and ABS hydraulic unit N5S--RS3 ..... 2. cece eeeee 68 24 Exploded view .... 68 9.2 Removing and installing ABS control unit ~J104- end ABS hydraulic unit-NSS- 69 10 Control unit and hydraulic unit - vehicles with diesel particulate fiter 74 10.1 Removing and instaling contol unit and hycrauic unit- vehicles wth iesel particulate filter 11 ABSIESP system components on front axle coven eee ce 88 414 Exploded view ..... cece cee : : 85 11.2. Removing and installing speed sensor : 86 12 _ABSIESP system components on rear axle - front-wheel drive vehicles =... -.-..... 87 12.4 Exploded view ..... cose cee : . 87 122 Removing and installing speed sensor : 88 13 ABSIESP system components on rear axle - four-wheel crive vehicles 89 13.1. Exploded view cence cee : . 89 132 Removing and installing speed sensor 80 46 - Brakes - mechanism : weet eee e eee e ee 91 contanis i‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 47- 1 14 12 13 2 24 22 23 3 34 32 4 44 5 54 52 53 54 6 64 7 7A 72 73 74 75 78 77 8 a4 82 83 84 9 O41 92 93 94 95 96 1 14 2 24 22 23 24 3 34 32 33 4 Brakes - hydraulics... 0.0.2.2. eee Servicing front brakes FS Ill (12F) Exploded view - front brakes (FS Ill) Removing and installing brake pads - front brakes Removing and installing brake caliper - front brakes Front brakes (FN-3, 1LJ/1ZA/1ZC/1ZD/1ZENZM/1ZP) Exploded Vig. sy sy Removing(and ig@taling\brak® pads Removing and installing brakelealiper - front brakes. Front brakeS(ENRG-57, 4LK/IZK) Servicing front brakes Removing-and installing brake pads... Brake caliper with vibration damper Removing and installing vibration dampers Servicing front brakes (LG) - RS 3 Removing and installing front brake pads - RS 3 Removing and installing front brake caliper - RS 3 Renewing front brake caliper - RS 3 Removing and installing front brake disc (RS3) Vibration dampers on front brake calipers - RS 3 (new version) Removing and installing vibration dampers - RS 3 Servicing rear brakes oe Exploded view - rear brake for front-wheel dive vehicles. Exploded view - rear brake, four-wheel crive vehicles : Detaching and attaching handbrake cable fromto brake caliper. Pressing back piston in rear brake caliper ve Removing and installing brake pads Removing and installing brake caliper Remove brake disc Hendbrake Exploded view - handbrake Removing and installing handbrake cable Adjusting handbrake Removing and installing handbrake warning switch Brake pedal Exploded view - brake pedal, left-hand drive vehicles Exploded view - brake pedal, left-hand drive vehicles with automatic gearbox Exploded view - brake pedal, right-hand drive vehicles Removing and installing brake pedal ‘Separating and connecting brake pedal and brake servo ‘Separating and connecting brake pedal and brake servo High-pressure and low-pressure tects Tests cee Servicing front brake calipers... - Exploded view - brake caliper FS II Removing and installing piston for brake caliper FS II] Exploded view - brake caliper FN3 Removing and installing piston for front brake caliper FN3 Brake caliper FNRG-57 Servicing brake calipers Removing and installing piston for front brake caliper Brake caliper - RS 3 Servicing rear brake calipers ot eo 94 96 98 98 - 104 - 108 108 - 108 sel 116 M7 118 120 123 125 127 - 130 134 2. 132 - 132 - 135 138 139 140 142 144 147 147 148 150 151 152 152 154 156 158 . 159 - 160 = 162 . 162 . 162 . 164 164 164 166 167 71 171 172 174 175 Contents‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 41 Exploded view 175 42 Removing and installing piston for rear brake caliper 176 5 Bleeding brake system 179 5.4 Brake fluid 179 5.2 Bleeding brake system using brake filing and bleeding equipment ...... 180 5.3 Bleeding brake system without brake filing and bleeding equipment... . . 181 5.4 Bleeding using ABS hydraulic unit NSS pump . ce eeee es 182 6 Brake servolbrake master cylinder - left-hand drive vehicles cece ee eeeeeeeeeeees 183 61 Exploded view . . coe - cee 183 62 Removing and installing brake master cylinder ce ce -.. 185 63 Removing and installing brake servo . . -. 187 64 Removing and installing brake servo - vehicles with 7-speed dual clutch gearbox 190 65 — Removing and installing brake master cylinder - TFSI engine 193 6.6 — Removing and installing brake servo - TFSI engine 196 6.7 Removing and installing brake servo - RS 3 199 7 Electric vacuum pumps for brake servo 203 7.1 Vacuum pump for brakes V192 (ald generation) 203 7.2 Removing and installing vacuum pump for brakes V192_ : : =. 203 7.3 Electric vacuum pump for brakes V192 (new generation)... . seve 208 8 Mechanical vacuum pumps for brake servo. . ce eete tees cette neces -. 208 8.1 Removing and installing vacuum pump - TDI engine 208 8.2 Removing and installing vacuum pump - TFSI engine 212 8.3 Removing and installing vacuum pump - RS 3 213, 8 Checking brake servo vacuum system 216 8.1 Connecting vacuum gauge for brake servo VAS 6721 216 9.2 Checking vacuum generation 217 9.3 Checking for leaks . cee cee eveeeeeees 218 2.4 — Generating vacuum with hand vacuum pump VAS 6213 ...... . 219 10 Brake lines and brake hoses - left-hand drive vehicles 220 10.1 Removing and installing brake lines and brake hoses 220 consents Hii‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 IV contants‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 wy) Technical data 1 Technical data for brakes (ARL006186; Edition 11.2018) 14 Production code (PR No.) allocation: brakes. Which brakes are fitted on the vehicle can be determined from the corresponcing production code (PR No.) on the vehicle data wauzzz8P x3A000151 8P1 ATC is7s019 Arrow 2 - rear brakes ASS! 20 © Arrow 3 - front brakes 4_10KW mss oa2 LY7W/LY7W_N7A/ MB EOA 7A2 4UE 6XE The vehicle data sticker can be found in the spare wheel well and in the Service Schedule. ‘The production code indicate the correct brake caiper brake | a! dee orks pod coninaton, = Etocroncpatecauoquetet- | ZOMG GLARE 9. wr —S es Bsc et ae th 4—TSB 3NZ 8JG UIA XOX 1N3 22G 803 9a2 BZ5 7Q0 CRs 7KO 4X1 GAZ 313 36 SDI 18A 066 ach yas Ha atta 1.2 Technicaldatafonbrakes Brake system Diagonal dual-circult brakesystenarittlotk brake system (ABS) with electronic brake pressure distribution] (EBPD). Certain equipment versions or model production detes additionally feature electronic differential lock (EDL), traction control system (ASR) and electronic stabilisation program (ESP) Brake master cylinder & mm 222 Brake servo ininches Leftchand drive vehicles: 10 Right-hand drive-vehicles: 7/8 tandem Funetion| Pneumatic [Frontbrekes Brakes (PR Za | Zo! | 120) 12e/ | 1ZF | 1ZK) No.) ‘zm | ity | 12° ALK Front brake FN3/FN3|FN3| FNS [FSI] ENR caliper G57 Front brake ~~] 342 | 280 | 312 | 268 | 260] 345, isc mm| Brake disc mm] 25 | 22 | 25 | 25 | 22 | 30 thickness (ventilated) Brake dise mm] 22 | 19 | 22 | 22 | 19 | 27 wear limit Pad thick- mm] 148] 14 | 14 | 44 | 14 [148 ness (new, without backplate) 1. Techical data tor brakes 1‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 Front brakes Padwear mm) 2] 212) 2124) 2 limit (without backplate) (a) Note 4% Maximum lateral run-out of stee! brake disc: 0.06 mm Perform measurement with brake alsc installed. 4% Use dial gauge bracket VAS 6079/1 and dial gauge VAS 6079. % Remove any dirt and rust from brake disc. Perform measurement 10 mm from outer edge of brake disc. =-3 Front brakes (FNRG-57, 1LK/1ZK)" page 108 ="1 Servicing front brakes FS Ill (1ZF)", page 91 ="2 Front brakes (FN-3, 1LJ/MZA/1ZC/ZDMZEMZM/ZPY’ page 98 Front brakes (RS 3) Brakes (PR Ne) 1LG Front brakecaliper: Brembo (Ma) Piston @ 40144 mm Front brake disc @ 3701mim Brake disc thickness (ventilated) 32mm Brake disc, wear limit 30mm Pad wear limit (without backplate) 2mm (F) mae Maximum lateral run-out of ste! brake disc: 0.06 mm Perform measurement with brake alse installed. Use dial gauge bracket VAS 6079/1 and dial gauge VAS 6078. & Remove any dirt and rust from brake disc. + Perform measurement 10 mm from outer edge of brake disc. =" Servicing front brakes (1LG) - RS 3°, page 118 Rear brakes Brakes (PR aKD | 1ke/ | 1KQ J 1KU | 1Kz No.) aKF 1K Rear brake 38 | ci [cae | cn | cu caliper ATHR 38HR| 38HR| Rear brake 2] 253 | 256 | 253 | 282 | 282 ise mm| Brake disc mm] 10 | 12 | 10 | 12 | 12 thickness: Brake disc “mm 8 10 | 8 | to | 10 wear limit 2 Rep. 07: 00- Technical data‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 Rear brakes: Padthick- mm] 12 | 12 | 12 | 12 | 12 ness (new. ‘without backplate) Pad wearlimit mm] 2 2 2 [2/2 (waithout backplate) (a) Note Maximum lateral run-out of steel brake disc: 0.06 mm © Perform measurement with brake disc installed. ¢ Use dial gauge bracket VAS 6079/1 and dial gauge VAS 6079. . + Remove any dirt and rust from brake disc. Perform measurement 10 mm from outer edge of brake disc. ="T Servicing rear brakes”, page 132 Rear brakes, four-wheel drive Brake caliper (PR No.) 1KE 1K 4KU. 1KW. 2EA Rear brake caliper ON4IHR | CN4iHR | CI4tHR | CIl4tHR | CI4tHR Piston Zmm|__ 44 a a4 a4 4 Rear brake disc Zmm| 256 282 282 310 310 Brake disc thickness mm| 12 12 12 22 22 (non-ventilated) Brake dise wear limit mam| 9 2 8 18 19 Pad thickness (new, mm| 12 12 2 12 12 ‘without backplate) Pad wear limit (without mm! 2 2 2 2 2 backplate) Maximum lateral run-out of steel brake disc: 0.06 mm ¢ Perform measurement with brake disc installed. © Use dial gauge bracket VAS 6079/1 and dial gauge VAS 6079 © Remove any dirt and rust from brake dise. © Perform measurement 10 mm from outer edge of brake disc. ar brake Brake caliper (PR No.) 1KS. Piston 2mm| 38 Rear bee dis Bmm| 272, Brake dist thickness (non-ven- mm| 10 fitateay Brake disc wear limit mm] Pad thickness (new! without rnin] 4 packplate). 1. Technical data tor brakes, 3‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 Rear brakes: Pad wear limit (withoutibacke mm] 2 plate) (a) Note 4% Maximum*tateral run-out of steel brake disc:\0.06 mm Perform measurement with brake alse installed, + Use dial gailge bracket VAS 6079/1 and dial gauge VAS6079. + ’ Remove any dirt and rust from brake disc. Perform measurement 10 mm trom outer edge of brake aise, Rear brakes (RS 3) Rear brake caliper ci4t HR Piston mm 44 Rear brake disc mm 310 Brake disc thickness (ventilated mm| 22 brake disc) Brake disc, mm] 19 wear limit Pad wear limit (without back- mm| 2 plate) i Note 4% Maximum lateral run-out of steel brake disc: 0.06 mm Perform measurement with brake disc installed. Use dial gauge bracket VAS 6079/1 and dial gauge VAS 6079, Remove any dirt and rust from brake disc. Perform measurement 10 mm trom outer edge of brake aise. woes 4 Rp. 07:00- Technical data‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > 2 Brake test General notes = “2.1 General notes”, page 5 Vehicles with front-wheel drive ="2.2 Vehicles with front-wheel drive”, page 5 Vehicles with four-wheel drive 2 f Brake test on a single-axle brake dynamometer ='2.4 Brake test on a single-axle brake dynamometer" page 6 21 General notes ‘The wheels are driven by the test rollers. During the test the gearbox must be in neutral on manual gearboxes or in position Won aufomatie Gearboxes, Follow the instructions provided bythe manufacturer of the brake test equipment whenperforming the test. 2.2 Vehicles with front-wheel drive General notes = “2.4 Genital ote. Bae 5 Vehicles with four-wheel drive’ = "2.3 Vehicles with four-wheel drive’ page 5, Brake test on a single-axle brake dynamometer ="2.4 Brake test on a single-axle brake dynamometer” page 6 Perform brake test on a single-axle brake dynamometer. Test speed must not exceed 6 kmih, Otherwise the EDL control can activate the brakes ifthe rollers start at different points in time. All brake test equipment approved by Audi meets these require- ments. 2.3 Vehicles with four-wheel drive General notes = "2.1 General notes", page 5 Brake test on a single-axle brake dynamometer > "2.4 Brake test on a single-axle brake dynamometer page 6 Testing on a single-axle brake dynamometer [F) Note ¢ Brakes on front and rear axles must only be checked with engine switched off In order to prevent power transmission from one axie to the other, always switch off the engine during brake tests on single-axle roller dynamometers. ‘© Only start the engine in order to create the necessary brake pressure for the brake test © Then switch the engine off again. Test sequence’ ¢ The wheels are driven by the brake test rollers. @ On vehicles with manual gearbox, the engine must be idling Brake eystem - Edition 11.2018 2.Brakotest 5‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 # On vehicles with automatic gearbox or dual clutch gearbox, shift gearbox into position "N”. # The rollers drive the wheels of one axle in opposite directions to avoid transmitting torque to the other axle. # The test speed must not exceed 6 km/h, Otherwise the EDL control can activate the brakes if the rollers start at different points in time. + All bake te8t equipment epprOyed by Audi meets these re- quirements, 24 Brake test ora’ single-axle brake dynamometer We recommend use of a brake test dynamometer with controlled roller speed ahd'a maximum test speed of 5 kmih fsiure teu eau reiting intérvénion by the EDL aye" fem. In this case the engine and the ignition should be switched off for the test. If necessary, run the engine briefly to ensure that enough vacuum is built up for the brake test. 6 op. o:00- Technical data‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 Anti-lock brake syste! 1 General notes Dy werune The anti-lock brake system is basically maintenance-free. Testing, removing, instaling and repair work may only be per. formed by qualified personnel. Failure to observe the information described in this Workshop ‘Manual may result in damage to the system and could make the vehicle unsafe. The vehicle is equipped with a diagonally split ABS brake system ‘The servo-assistance is pneumatic, supplied by the vacuum brake servo unit, \Vehicles equipped with the ABS Mark 60 do net have a mechanical brake pressure regulator. A specially matched software in the control unit controls the reer axle brake pressure regulation Malfunctions in the ABS system do not influence the brake system and servo action, The.conventional braking system remains func- tional evep withdlt ABS, However. the vehicle's braking behav- jour can change, After the ABS warning lamp comes on, the rear wheels ca lock erly when brekingl © Before carrying out repair work on the anti-lock brake system, determine the cause of the problem using self-diagnosis. ‘© Always switch off ignition before unplugging the connector at hydraoliercontrol anit ¢ Ifa new hydrauté control unit has beén fitted, it must be én: coded. Vehicle diagnostic, testing and information system - VAS 5051 x- or -VAS 5052- Bleed brake system after performing work involving opening of brake system: ABS/ESP Mark 60/ ABS Mark 70 = page 179 . To do £0, use for example the brake filing and ibleeding equipment- V.A.G 1869- or brake filing and bleeding equipment - VAS 5234- © Observe the relevant safety precautions and information when handling brake fluid ‘© Absolute cleanliness is required when working on the anti-lock brake system; avoid any products that contain mineral oil such as oil, grease, etc. ‘@ Ensure that no brake fluid enters electrical connectors. ‘@ Thoroughly clean all connections and the adjacent areas before loosening, but do not use aggressive cleaning agents such as brake cleaner, petrol, thinners or similar After removal, place parts on a clean surface and cover them. ¢ Carefully cover or seal open components if repairs cannot be carried out immediately. Use plugs from repair kit; Part No. = ETKA ‘@ When the system is open, do not work with compressed air and do not move the vehicle. © Do not use fluffy cloths. ¢ Only use genuine spare parts from original packaging, 1.Gonoral notes 7‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 4 Only remove replacement parts from packaging immediately prior to installation, # During the final road test, ensure that at least one ABS.controlled braking operation is performed (pulsations must be felt at the brake pedal). # During painting operations, the electronic control unit can be ‘exposed to a maximum temperature of 95 °C for only a short Btlod, endo « maximum of 85°C foronger periods (epprox ours) 4 Before carrying out welding work with an electric welding unit, refer to > General notes; Body repairs; Safety notes 8 Rep. o745- Antiock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 2 Connecting -VAS 5051 x- or - VAS 5052- and selecting functions Special tools and workshop equipment required Vehicle diagnostic, testing and information system -VAS 5051 x- or -VAS 5052- VAS 5051 A wane % Testers and measuring equipment must always be secured on the rear seat during a road test. During the road test, the equipment may only be operated by the passenger. — Attach the diagnosis cable connector VAS 5051/Sa to the diagnosis connection. 2. Connecting VAS 5051 x or VAS 5052 and selecting tinctons 9‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 = Switch on the tester -arrow. The tester is ready as soon as a picture of a car appears in the display. = Switch on ignition ~ Press the Guided Fault Finding button on the display screen. = Select the following Make Type Model year Version eeeee Engine code = Confirm the entered information, Wait until the tester Has interrogated all the contfof units‘ the vehicle, — Press the [Sauz_] button and!select the option *Function/com! ponent selectio Now follow the instructions on the screen to start the desired functions, (F) no ifthe ABS control unit - J104. (with ESP) is renewed, the following senders must be calibrated: Bleeding brakes at workshop, channel 1 Steering angle sender - G85-, channe! 60 Lateral acceleration sender - G200-, channel 63 Brake pressure sender 1 - G201-, channel 66 Longituatinal acceleration sender - G251-, channe/ 69 (fitted ur-wheel drive vehicles only) From model year 2009 onwards, steering angle and brake pressure aré also measured by the ABS contro! unit - J104- (with ESP); these values must then be calibrated. ESP road test and system test must then be carried out. teeee 10 ep. o-:45- anttock brake system3 3.1 1- ABS control unit (with ESP) J404- (F) re ooooo oo8g ‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 ABS/ESP ITT Mark 60/ ITT Mark 70 Exploded view 3 ¢ From model year 20pS onwa ESP). A, + Fiom mode! year 20po nua. ABS control unto ESP) mustbe rons int Galo faceted + ‘From model year 20 ABS controlunit - J ESP) must be cali has been renewed. calibrated. Fitting location: on hydraulic unit on right-side of engine compartment Do not unplug connector before completing seif-diagnosis. Switch off ignition before unplugging connector. ABS/ESP system ITT Mark 60 = page 23 Removing and installing (Mark 60) = page 27, ABS system ITT Mark 70 = pede 37 Removing and installing (Mark 70) = page 40 Removing and installing (TFSI engine) > page 49 Removing and installing (RS 3) = page 68 Removing and instaling (2.0 tr. TD| engine) = page 58 Removing and installing (vehicles with diesel particulate filter) > page 74 fa Note Ifthe ABS control unit - J104- (with ESP) is renewed, the following senders must be calibrated ¢ Bleeding brakes at workshop, channel 1 8 ABSIESP ITT Mark 60) TT Mark 70.141‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 % Steering angle sender - G85-, ‘channel 60 © Lateral acceleration sender - G200-, channel 63 Brake pressure sender 1 - G20'-, channel 66 Longitudinal acceleration sender - G251-, channel 69 (fitted on Four-wheel drive vehicles only) % From model year 2009 onwards, steering angle and brake pressure are also measured by the ‘ABS control unit - J104- (with ESP); these values must then be calibrated. + ESP road test and system test must then be carried out. 2- ABS hydraulic unit - N55- Fitting location: on hydraulic unit on right-side of engine compartment The ABS hydraulic pump - V64. , the ABS hydraulic unit - N5B- and the ABS control unit -J404- (with ESP) together make up the hydraulic control unit, With integrated brake pressure sender 1 - G201- Removing and installing (Mark 60) = page 27 ABSIESP system ITT Mark 60 > page 23 ABS system ITT Mark 70 = page 37 Removing and installing (Mark 70) = page 40 Removing and installing (TFSI engine) > page 49 Removing and installing (RS 3) = page 68 Removing and installing (2.0 ttr. TDI engine) = page 58 Removing and installing (vehicles with diesel particulate fiter) = page 74 For correct version refer to = ETKA (F) re . Wf the ABS control unit - J104- (with ESP) is renewed, the following senders must be caliorated’ gr Blecdino brakes at Workshop, channel f ooocoocooce oo ‘a steering angle sender G85-, enannar 6 Lateral acceleration sender - G20") channer'63 "Brake pressure Beridlet 1 G201-, channel 66 % Longitudinal acceleration sender - G251-, channel 69 (fitted on four-whéel drive vehicles only) From model year 2009 onwards, steering angle and brake pressure are also measured by the ABS control unit - J104- (with ESP); these values must then be calibrated. 12. Rep. o-45- Anttock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 © ESP road test and system test must then be carried out. 3 - Button for TCS/ESP -E258- 2 Fitting location: in centre console 4- ESP sensor unit -G419- (F) re © Onright-hand and left-hand drive vehicles up to model year 2008, sensor unit -G419- 8 always installed underneath right- hand seat. ¢ From model year 2008 onwards, sensor unit -G4 19. is installed in ABS control unit - J104- (with ESP). © From model year 2009 onwards, ABS control unit -J104- (with ESP) must be renewed if sensor Unit -G419. is defective. ¢ From model year 2009 onwards, ABS control unit - J104- (with ESP) must be caliorated after it fas been renewed. 8, ABSIESP ITT Mark 60) TT Mark 70 13;‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 From model year 2009 onwards, steering angle and brake pressure are also measured by the ‘ABS control unit - J104- (with ESP); these values must then be calibrated. ‘Combined in one housing ‘Combined lateral acceleration sender - G200- and yaw rate sender - G202- Longitudinal acceleration sender - G251- (only four-wheel drive vehicles) Removing and installing ESP sensor unit = page 18 20Nm 5 - Stabilising program (TCS/ESP) warning lamp - K155- G2 Fitting location: In instrument cluster 6 - Brake pad warning lamp - K32- Brake pad worn Q Fitting location: In instrument cluster 7 - Brake system warning lamp - K118- Fitting location: In instrument cluster Brake malfunction, handbrake applied Check brake fluid level if flashing 8 - ABS waming lamp - K47- O Fitting location: In instrument cluster 9- Handbrake warning switch - F9- Fitting location: on handbrake lever 410 - Rear rightirear left speed sensor -G44- / -G46- Removing and installing > page 88 11 - Wheel bearing/hub unit The sensor ringirotor for ABS is installed in wheel bearing 412 - Wheel bearing housing 1 Removing anG'instaling’ Rep. gr. 42 13 - Steering angle Sender - GB5- Fitting fecationoreturmsrifg with slip ring on steering column switch Removing and installing = page 20 14 - Diagndstic'connisction 1 pFitting location: cover in-driver's footivell 15 - Brake light switch Fe @® Note The brake light switeh is not fitted on all models ooooo Removing and installing = page 16 Removing and installing brake light switch on brake master cylinder = page 17 Bolt on brake light switch: 5 Nm 416 - Front lefufront right speed sensor -G45-/ .G47- Removing and installing = page 86 17 - Brake master cylinder Removing and installing = page 185 With brake light switch attached 14 ep. o-:45- anttock brake system‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 (F) re The brake light switch is not fitted on all models Removing and installing brake light switch on brake master cylinder = page 17 Bolt on brake light switch: 5 Nm 18 - Wheel bearing/hub unit 2 The sensor ring/rotor for ABS i installed in wheel bearing 19 - Wheel bearing housing Removing and installing + Rep. gr. 40 20 - Brake fluid level warning contact - F34- > Maintenance ; Booklet 808 fa Note © Clean bolts and nuts before reusing. ¢ Always renew self-locking bolts/nuts. ¢ Always renew damaged bolts/nuts. 8, ABSIESP ITT Mark 60) TT Mak 70 15)‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 4 Removing and installing parts of ABS/ESP system CF noe The ESP drive test is designed to check the plausibility of the following signals: brake pressure sender 1 - G201-. lateral acceleration sender - G200-, yaw rate sender - G202- and longitu. dinal acceleration sender - G251-. Removing ancjnstaling brakeight switch on brake pedal = page I Removing and installing brake light switch on brake master cylinder = pavest7" Removing and installing ESP sensor unit - G419- => page 18 Removing ahd insta steering angle sender - 685: > page 2 Removing-and installing brake-pressure sendent > G201+ > page 21 Removing and installing brake servo vacuum sender - G483- = page 21 44 Removing and installing brake light switch on brake pedal CF) ne Depending on the model, the brake light switch is located on the brake master cylinder. = page 17 (F no To ensure a secure fit, the switch may only be fitted once. Removing — Remove driver's storage compartment > Rep. gr. 68 — Unplug electrical connector. = Tum brake light switch anti-clockwise through 48° and remove. Installing Install in reverse sequence, paying attention to the following 16 ep. o-45- Anttock brake system‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 = Pull out plunger of brake light switch as far as it will go -arrow-. (F) note On some types of brake light switch it is not necessary to pull out the plunger. = Insert retaining tabs -1- and -2- of ewitch in recesses provided in mounting hole and secure by tuning clockwise through 45° = Attach plug for brake light switch CB When installing, brake pedal must not be pressed. © The plunger adjusts itself automatically when the brake light ‘switch is inserted. — Check operation of brake lights both with brake pedal pressed and at rest. 4.2 ‘REMovingandinstalling brake light Switch on brake master cylinder Removing The brake light switch is located on the brake master evlinder, © The brake light switch is not adjustable. = Unplug electrical connector -1- — Remove securing bolt for brake light switch -2- from brake master cylinder. = Pull brake light switch at bottom out of brake master cylinder and lift switch out of retaining tab at top. Installing (w= Clean bolts and nuts before reusing. © Always renew selt-locking botts/nuts, @ Always renew damaged bolts/nuts. Installation is carried out in reverse sequence. Ensure proper seating of switch in retaining tab at top. = Secure brake light switch with specified torque: 5 Nm. 4, Removing and insaling parts of ABSIESP systom 17‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 43 Removing and installing ESP sensor unit ~G419- ies % On right-hand and left-hand drive vehicles up to model year 2006; sensor unit -G479-t8aMuays instelfed undemeet Heft: and sea + From model year 2009 onwards, sensor unit -G419-/s instal, ed in ABS control unit -J404- (with ESP). 4% From model year 2009 onwards, ABS control unit- J104- (with ESP) must be renewed if sensor unit -G418- is defective, 4% From model year 2009 onwards, ABS control unit- J104- (with ESP) must be calibrated after it has been renewed, + From model year 2009 onwards, steering angle and brake pressure aré also measured by the ABS control unit - J104- (with ESP); these values must then be calibrated. fw Note # Control unit for ABS - J104- (with ESP), Mark 60 = page 23 © Control unit for ABS - J104- (with ESP), Mark 70 Removing (E ne The ESP sensor contains the following senders: lateral acceler ation sender - G200-, yaw rate sender - G202- and fongitudinal acceleration sender - G251- (only four-wheel arive vehicles). ~ Remove seat (right-side) = Rep. gr. 72 - Remove sill panel trim (on passenger side) and lif up carpet > Rep. gr. 72 Unplug electrical connector -2-. 18 ep. o-45- Anttock brake system‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 = Unscrew bolts -4. — Remove ESP sensor unit -1- upwards, — Item -3- seat cross member ‘Arrow in illustration faces direction of travel (Note ¢ The ESP sensor unit is sensitive to impact. ¢ If the ESP sensor unit has been dropped, it may not work properiy. The sensor unit is then no /onger to be used. Installing fa) Note © Clean bolts and nuts before reusing. © Always renew self-locking bolts/nuts. © Always renew damaged bolts/nuts. Install in reverse sequence, paying attention to the following: — Calibrate lateral acceleration sender - G200- , channel 63, — Calibrate longitudinal acceleration sender - G251- , channel 69 (four-wheel drive vehicles only) To,do.g0,use the vehicles dlagnosti, testing and information system - VAS 5051 x- or -VAS 5052- = See: Running gear Brake system (Repair group 01; 45) = 01- Self-diagnosis compatible systems — 03- Brake electronics ABS/ESP Mark 60 — Calibrate lateral acceleration sender - G200- = Calibrate longitudinal acceleration sender - G251- (four-wheel drive vehicles only), or — Carry out ESP road test and system test. ‘To do so, use the vehicle diagnostic, testing and information system - VAS 5051 x- or -VAS 5052- = See: Running gear = Brake system (Repair group 01; 45) — 01 - Self-diagnosis compatible systems ~ 03- Brake electronics ABS/ESP Mark 60 = J104 - Control unit for ABS/TCS/ESP, Functions Tightening torque [Component Nm TESP sensor unit to bracket 20 4, Removing and insaling parts of ABSIESP systom_ 19)‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 44 Remoyifigyafthinstallif steering angle sender - G85- i Note The return ring with silo ring and the housing for steering angle sender - G85- are installed on the steering Column electronics control unit = J827- Removing — Remove airbag unit and steering wheel > Rep. gr. 48 — Tum wheels to straight ahead position. Item -1-: Return ring with slip ring - Clipped to switch for turn signal indicator, main beam, dipped beam and headlight flasher lem -1-: Steering angle sender - G85- = Clipped to return ring with slip ring Ay waren The return ring with slip ring must not be rotated following removal. - Remove driver's storage compartment > Rep. or. 68 = Remove steering column switch module = Rep. gr. 94 Installing (B) me + Clean bolts and nuts before reusing. 4% Always renew self-locking bolts/nuts, 4 Alvays renew damaged bolts/nuts. Install in reverse sequence, paying attention to the following — Install airbag unit and steering wheel = Rep. gr. 48. = Start calibration for steering angle sender - G85- , channel 60. — Carry out ESP road test and system test. = See: Running geer = Brake system (Repair group 01; 45) ~ 01- Self-diagnosis compatible systems = 03. Brake electronics ABSIESP Mark 60 = J104- Control unit for ABS/TCSIESP, Functions G85 - Calibrate steering angle sensor = Vehicle diagnostic, testing and information system - VAS 5051 x oder VAS 5052- = Connect vehicle diagnosis, testing and information system - VAS 5051 x- or -VAS 5052- and select function. 20 op. or45- Antilock brake system‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 45 Removing and installing brake pressure sender 1 - G201- Special fools and workshop equipment required Brake fling and bieeding equipment - VAS 5234- VAs 6234 + Or © Upgrade kit and extraction unit - V.A.G 1869/4- Removing (F) ne The brake pressure sender 1 - G201- is integrated in the ABS Aydraulic unit - N5- — Remove and install ABS hydraulic unit - N5S- Installing Install in reverse sequence, paying attention to the following: — Bleed brake system, Bleed clutch hydraulics: > Rep. gr. 30 = Start calibration for brake pressure sender 1 - G201--1-, channel 66. = Carry out ESP road test and aystem test. ‘To do so, use the vehicle diagnostic, testing and information system - VAS 5051 x- or -VAS 5052- = Copnect yehicle diagnosis, testing and information system - WAS'505T xx0r "VAS 5052- and select function. —|\See:\Running gear =" Brake Systerm(REpair group 01; 45) = 01 - Self-diagnosis compatible systems = "03" Brake electronids ABSIESP Mark 60 ~Si04 = Control unit for ABS/TCS/ESP, Functions — Calibrate brake pressure sender 1 - G201- 46 Removing and installing brake servo vacuum sender - G483- - vehicles with optimised hydraulic brake assistance/ vacuum sender (OHBV) only Special tools and workshop equipment required 4 Removing and insaling parts of ABSIESP systam 21‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 # Vehicle diagnostic, testing and information system - VAS 5051 x= or -VAS 5052- fw Note © Brake servo vacuyfh sender "CESS 2Mbes Ret have to be call. brated after renewal. ¢ The "Guided Fault Finding”cantains@ description of the electrical check. Removing Remove battery 3°Rep!'gt:'27 = Remove battery ttay'-strowe.. = Unplug electrical connector -1-. = Pull outretaining clip -1- and pull sender 6483 -2- out of brake servo. Installing CF re Clean bolts and nuts before reusing. + Always renew self locking bolts/nuts. + Always renew damaged bolts/nuts. Installation is carried out in reverse sequence. 22 op. or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 5 ABS/ESP ITT Mark 60 control unit and hydraulic unit On vehicles with Mark 60EC system (8) ote ¢ From model year 2009 onwards, sensor unit -G419. is instal- fed in ABS control unit -J104- (with ESP). © From model year 2009 onwards, ABS contro! unit -J104-(with ESP) must be renewed if sensor unit -G419- is defective. ¢ From model year 2009 onwards, ABS control unit -J104- (with ESP) must be calibrated after it has been renewed. ¢ From model year 2009 onwards, steering angle and brake pressure aré also measured by the ABS control unit - J104= (with ESP), these values must then be calibrated. Steering angle sender - G85-, channel 60 Lateral acceleration sender - G200-, channel 63 Brake pressure sender 1 - G201-, channel 66 Longitudinal acceleration sender - G251- , channel 69 (fitted ‘on four-wheel drive vehicles only) eeee © From model year 2009 onwards, steering angle and brake pressure aré also measured by the ABS control unit - J104- (with ESP); these values must then be calibrated. (© ESP road test and system test must then be carried out. If the ABS control unit -J104- is renewed on vehicles with Mark 60EC system, an additional basic setting must be performed for the inlet valves and separating valves. > page 36 Todo so, use the vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- . 5.1 Exploded view A WARNING Interchanging brake line connections will result in ESP system ‘malfunction. = Perform final control diagnosis after attaching brake lines to hydraulic unit. Vehicle diagnostic, testing and information eystem - VAS 5051 x - or -VAS 5052- (i) we Final control diagnosis can be used to establish whether line connections have been interchanged. 5. ABSIESP ITT Mark 60 contol unit and hydraulic unt 23‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 1 - Brake line O Hydraulic unitto rear left 11 12 13 14 15 brake caliper 2- Bolt O 4Nm 3 - Brake line Hydraulic unit to rear ‘ightbrakeccaliper. 4-Boit 2 _4Nm 5 - ABS hydraulic unit - N55- G. Fitting location: engine ‘compartment (right- side) B., .Removing and installing, Removing and installing (TFSI engine) =page 49 Removing and installing (20 ltr. TDI engine) = page 58 1D Removing and installing (vehicles with diesel particulate filter) 2 On vehicles with OHBV (optimised hydraulic brake assistance/vacuum sender), do not separate control unit from hydraulic unit. Re- new complete unit (con- \ Ca] tral unit with hydraulic — 24 op or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > unit) For correét version réfet tof \ETKA, ESP contral unit and hydraulic unit, must be removed before removing bracket a 7-Bolt Q 8Nm 8 - Rubber buffer 9 - Mounting bracket 10- Bolt 2 20Nm 14 - ABS control unit (with ESP) - J404- (Fy) nee ¢ From model year 2008 onwards, ‘sensor unit -G419-is installed in ABS control unit - J104- (with ESP), ¢ From model year 2009 onwards, ABS control unit - J104- (with ESP) must be renewed if sensor unit -G419. is defective. ¢ From model year 2009 onwards, ABS control unit - J104- (with ESP) must be calibrated after it has been renewed. ¢ From model year 2009 onwards, ‘steering angle and brake pressure are also measured by the ABS control unit - J104- (with ESP); these values must then be calibrated. Control unit is bolted to hydraulic unit Removing and installing = page 27 o cocoouuN For correct version refer to> ETKA (B) nee © Ifthe ABS control unit - J104- (with ESP) is renewed, the following senders must be calibrated: Fitting location: engine compartment (right-side) Removing and installing (TFSI engine) = page 49 Removing and installing (2.0 ltr. TDI engine) = page 58 Removing and installing (vehicles with diesel particulate fiter) = page 74 (On vehicles with OHBY (optimised hydraulic brake assistance/vacuum sender), do not separate control unit from hydraulic unit. Renew complete unit (control unit with hydraulic unit) Brake eystem - Edition 11.2018 5. ABSIESP ITT Mark 60 contol unit and hydrautic unt 25‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 % Bleeding brakes at workshop, channel 1 ssicering able serder - G85. Sanne’ 60 + Lateralaccelefation sender - ‘E2002, channe? 63 4% Brake pressure sender 1 - 20%, channel 66 4 | Longitueimaracecleration serider +1,G251-..channe! 69 (fitted on Four-wheel drive vehicles only) © From model year 2009 onwards, steering angle and brake pressure are also measured by the ‘ABS control unit - J104- (with ESP); these values must then be calibrated. + ESP road test and system test must then be carried out. (On vehicles with Mark 60EC system If the ABS control unit -J104- is renewed on vehicles with Mark 60EC system, an additional basic setting must be performed for the iniet valves and separating valves. = page 36 12- Brake line Hydraulic unit to front left brake caliper 13- Brake line Brake master cylinderiprimary piston circuit to hydraulic unit 14 Brake line Hydraulic unit to front right brake caliper 15 Brake line Brake master cylinderisecondary piston circuit to hydraulic unit (F ne # Clean bolts and nuts before reusing. + Always renew self-locking bolis/nuts. + Always renew damaged bolts/nuts. 26 op. or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 5.2 Removing and installing control unit and hydraulic unit (Mark 60) fa) Note ¢ From model year 2009 onwards, sensor unit -G419- is instal- fed in ABS control unit - J104- (with ESP). © From model year 2009 onwards, ABS control unit -J104-(with ESP) must be renewed if sensor unit -G419- is defective. ¢ From model year 2009 onwards, ABS control unit -J104- (with ESP) must be calibrated after it has been renewed. ¢ From model year 2009 onwards, steering angle and brake pressure aré also measured by the ABS control unit - J104- (with ESP), these values must then be calibrated. (B) re The right air duct must be disconnected on vehicles with TFSI engine. On vehicles with Mark 60EC system Ifthe ABS control unit -J104- is renewed on vehicles with Mark 60EC system, an additional basic setting must be performed for the inlet valves and separating valves. = page 36 5. ABSIESP ITT Mark 60 contol unit and hydraulic unt 27‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 Special tools and workshop equipment required VAG 1931 VAG 1810 VAG 19892 # Torque wrench - VAG 1331- # Torque wrench -V.AG 1410- # Brake pedal actuator - V.A.G 1869/2- 28 op. or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 Sealing plug repair kit, Part no. 1H0 698 311 A. After separating the control unit from the hydraulic unit, you must fit the transport protection for contact pins onto the hydraulic unit. No warranty can be assumed for hydraulic units without transport, protection 1+ Transport protection for contact pins (foam) 2» Sealing plugs M10 for brake lines and tapped holes 3 - Sealing plugs M12 for brake lines and tapped holes Removing (a) Note The right air duct must be disconnected on vehicles with TFSI engine. ~ If fitted, remove covers in engine compartment (rear right) = Rep. gr. 20 Insert brake pedal actuator - V.A.G 1869/2- between brake pedal and drivers seat. Depress the brake pedal atleast — Connect hose of bleeder bottle to bleeder screws of front left and rear left brake calipers and open bleeder screws. (B) rue This will release the pressure in the hydraulic unit. = Close front left and rear left bleeder screws. = Do net remove brake pedal actuator - V.A.G 1869/2- — Release connector at control unit -arrow 1- and unplug arrow 2- (F) ree ¢ Make sure brake fluid does not get into connector housing of control unit. This can result in corrosion of the contacts and failure of the system. © Use compreSsedhalr 10 eG reRIMY clean connector housing if necessary, 5. ABSIESP ITT Mark 60 control unit and hydrautc unt 2Q‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 = As protection against escaping brake fluid, place a sufficient number of lint-free cloths in area beneath control unit and hydraulie unit, = Mark brake lines, ~ Unscrew brake lines fromhydraulic unit -1- to brake master cylinder and tier place: = Disconnect remaining brake lines -2- on hydraulic unit. AQ wasn Do not bend the brake lines in the vicinity of the hydraulic unit. =. Seal brake lines and tapped holes with sealing plugs from repair kit, =. Prise hydraulic unit with control unit off upwards -arrows-. = Unscrew all bolts on bracket for hydraulic unit -1- (tightening torque 8 Nm), ‘Some models have an additional M6 bolt for control unit on bracket = Place hydraulic unit on a clean flat surface with control unit facing downwards, Removing control unit from hydraulic unit 30 Rop. o:45- Antttock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 — Unscrew Torx socket head bolts -arrows- from hydraulic pump. LX [wasntine “Hyaraiiic Pip MUSE not be separated from hydraulic unit. = The hydraulic pump must therefore be secured on the hydraulic unit with the retainer -1- from the repair kit and two sealing plugs -2- — Carefully it hydraulic unit with hydraulic pump off control unit at seam-t-. 5. ABSIESP ITT Mak 60 contol unit and hydraulic unt O41‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 When pulling off tye contfo! unit, ensiite thatthe hydraulic unit contact pins are riot carted against the contfol unit solenoids. Item -2-: Adapter fSkpumpmator. — Cover control unit solenoids with a lint-free cloth. After disconnecting control Unit and hydrate unit ff transporta> tion protection for-contact pins: Installing new control unit (a) Note 4% Clean bolts and nuts before reusing. + Alnays renew selt-locking bolts/nuts. + Alays renew damaged bolts/nuts. A\ warn ‘Severe shocks orjolts can damage the control unit. The contro! unit must not be re-installed ifit has been damaged in any way. 4 First clip in the adapter for pump motor until it engages with a click before installing the new control unit. Make sure not to damage the adapter guide. # The adapter (supplied as replacement partfor control unit) can only be clipped in once and then no longer detached. 4 The white paste on the bottom of the control unit serves as sealant and must not be removed. # To ensure that the components are kept clean and to prevent damage, do not touch any contact surfaces on the adapter, pressure sensor or control unit, or the silicone gel and sealing ‘components by hand or with tools, ete. = Clip adapter into adapter guide until it engages with a click. = Place control unit on hydraulic unit (make sure net to cant control unit. = Bolt control unit to hycraulic unit with the new Torx socket head bolts supplied: (F ne # To avoid any risk of leakage at the flexible seal, a new control unit must not be fitted more than twice onto an “ola” hydraulic unit that is being re-installed. # Acontro! unit which has been in operation while the vehicle is ‘being driven must not be fitted a second time. 32 Rop.o-45- Antbtock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 oz, | \Y LY NY 5. ABSIESP ITT Mark 60 contol unit and hydraulic unt 3B‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 Unscrew hexagon nut -1- (tightening torque 20 Nm) Installing Install in reverse sequence, paying attention to the following: w Note Clean bolts and nuts before reusing. + Alnays renew seftlocking bolts/nuts. © Alnays renew damaged botts/nuts. (E] re # Donotremove sealing plugs from new hydraulic unit until cor responding brake line is ready to be fitted. 4 /fsealing plugs are removed from hydraulic unit sooner, brake fluid may escape and it may no longer be possible to fill and bleed the unit properiy. = When assembling control unit and hydraulic unit, make sure contact pins of hydraulic unit do not cant on control unit solenoids. = Connect lines in accordance with markings > page 23 . = Secure ABS unit to bracket f® Note Do not tighten bolts completely. This will make it easier to attach the individual brake lines to the hydraulic unit. = Tighten all brake line connections. — After tightening brake lines, tighten hydraulic unt ~ Perform final control diagnosis after attaching brake lines to hydraulic unit. Vehicle diagnostic. testing and information system - VAS 5051 x - or -VAS 5052- i) Note Final control diagnosis can be used to establish whether line connections have been interchanged. Tordo,a0,uge the vehicle ciagnostic, testing and information ys- tem - VAS 5051 x- or -VAS 5052- =. Select function tests via unction/cofmponent selection” = page 9 = "Running gear = "Brake system’ = "01 Seif-diagniosis compatibie systems? — “104 - Cohtral unit for ABS/TCS/ESP Mark’ 60” — W104 - Control unit for ABS/TGS/ESP, Functions" 34 op. 45 Antttock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 On vehicles with Mark 60EC system If the ABS control unit -J104- is renewed on vehicles with Mark 80EC system, an additional basic setting must be performed for the inlet valves and separating valves. > page 36 To do.so,use the vehicle diagnostic, testing and information sys- temeVASI505 10x - or VAS 5052- Tightening forques (B) Note The right air duct must be connected on vehicles with, TFSI engine. ~ Bleed brake system > page 179 = Ifa new control unit has been fitted, it must be encoded. To do so, use the vehicle diagnostic, testing and information system - VAS 5051 x - or VAS 5052- ~ Connect vehicle diagnos, testing and information system and select “Function/component’ for function test = pace 9 Then “Running gear” ~ ‘Brake system’ ~ ‘01 Selt-iagnosis compatible systems” — “W104 - Control unit for ABS/TCS/ESP Mark 60° — "W104 - Control unit for ABS/TCS/ESP, Functions’ = “W104 - Encoding control unit” (CF) nee If the ABS control unit - J104- (with ESP) is renewed, the following senders must be calibrated: Bleeding brakes at workshop, channel 1 Steering angle sender - G85. , channel 60 Lateral acceleration sender - G200-, channel 63 Brake pressure sender 1 - G201-, channel 66 Longitudinal acceleration sender - G251- , channel 69 (fitted irewheel drive vehicles only) ¢ From model year 2009 onwards, steering angle and brake pressure aré also measured by the ABS control unit - J104= (with ESP), these values must then be calibrated. ¢ ESP road test and system test must then be carried out ee eee To do so, use the vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- Select function tests via “Function/component selection’ = page 9 “Running gear’ Brake system “01 - Self-diagnosis compatible systems’ 5. ABSIESP ITT Mark 60 contol unit and hydraulic unt 3‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 = "104 - Control unit for ABS/TCS/ESP Mark 60" — “W104 - Control unit for ABS/TCS/ESP, Functions” (On vehicles with Mark 60EC system If the ABS control unit -J104- is renewed on vehicles with Mark 60EC system, an additional basic setting must be performed for the inlet valves and separating valves. = page 36 To do 50, use the vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- Tightening torques [Component Nm |Control unit to hydraulic unit 4 Hydraulic unit to bracket 8 Brake lines to hydraulic unit 14 53 Basic setting of inlet valves and separating valves (Mark 60EC) The basic setting of the inlet valves should only be performed if the ABS control unit -J104- has been renewed. To do $0, use vehicle diagnostic, testing and information eystem - VAS 5051 x-- or -VAS 5052- (E) re If the basic setting of the inlet valves has to be performed, you must then perfogmthe baste setting OF the separating valves. = Connect vehicle diagnosis, testing and information system - VAS 5051 x - orsVASS052= Running gear Brake system 01 - Self-diagndsis compatible systems 03 ABS control unit J104 MK60EC 03 Functions ABS MK60EC J104 Basic setting of inlet valves ese eeee Basic setting of separating valves Please follow the instructions on the display exactly. 36 op. o-45- Antttock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 6 ABS- ITT Mark 70 control unit and hydraulic unit age 37 1 Exploded vie Exploded view @| Note ¢ From mode! year 2009 onwards, sensor unit -G419- is insta fed in ABS control unit - J104- (with ESP). ‘© From model year 2009 onwards, ABS control unit -J104- (with ESP) must be renewed if sensor unit -G4 19. is defective. ¢ From model year 2009 onwards, ABS control unit -J104- (with ESP) must be calibrated after it has been renewed. © From model year 2009 onwards, steering angle and brake pressure aré also measured by the ABS control unit - J104- (with ESP); these values must then be calibrated. A WARNING interchanging brake line connections wil result in ESP system ‘malfunction. - Perform final control diagnosis after attaching brake lines to hydraulic unit. Vehicle diagnostic, testing and information eystem - VAS 5051 x - or -VAS 5052- (F) Note Final control diagnosis can be used to establish whether line connections have been interchanged. 6. ABS- ITT Mark 70 contral unt and hydraulic unt O7‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 1 - Brake line Hydraulic yntfto Reeir ety 10 1112 13 14 brake caliger ) 2- Brake line Q Hydraulic unit to rear right brake caliper 3 ABS hydraulic unit - NSS- Fitting location: éngine Compartment (right- side) 2 Removing and installing = page 40 Removing and installing (TFSI engine) = page 43 Removing and instaling (2.0ltr. TBI engine) = page 58 Removing and installing (ehicles with diesel Particulate fiter) > page 74 Control unit for ABS - J104- with ESP (RS 3) = page 68 6 - Rubber buffer 7 - Mounting bracket 8 - Bolt, 20Nm 9 - Hexagon bolt, 5.5 Nm 10 - ABS control unit (with ESP) - J104- fw Note % From model year 2009 onwards, ‘sensor unit -G419. is installed in ABS control unit - J104- (with ESP), + From model year 2008 onwards, ABS control unit - J104- (with ESP) must be renewed if sensor unit -G419-is defective. # From model year 2009 onwards, ABS control unit -J104- (with ESP) must be calibrated after it has been renewed. 38 0p. o-45- Antttock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 ¢ From model year 2008 onwaras, steering angle and brake pressure are also measured by the ‘ABS control unit - J104- (with ESP); these values must then be calibrated. Fitting location: engine compartment (right-side) Control unit is bolted to hydraulic unit Removing and installing = page 40 Removing and installing (TFSI engine) = page 49 Removing and installing (2.0 ltr. TDI engine) = page 58 Removing and installing (vehicles with diesel particulate fiter) = page 74 Control unit for ABS - J104- with ESP (RS 3) = page 68 (F) re «te ABs cont unt 04 (with ESP) is renewed, the fol- eet re ay © Bleeding brakes at workshop, channel 1 ¢ Steering angle sender - G85- channel 60 oooocog Lateral acceleration sender - G200-,, channel 63 ¢ Brake pressure sender 1 - G201-, channel 66 ‘© Longituciinal acceleration sender + G251-, channel 69 (fitted on four-whéel drive vehicles only) ¢ From model year 2009 onwards, ‘steering angle and brake pressure are also measured by the ABS control unit - J104- (with ESP); these values must then be calibrated. ¢ ESP road test and system test must then be carried out. 11 - Brake line Brake master cylinder/primary piston circuit to hydraulic unit 12- Brake line DL Hydraulic unit to front left brake caliper 43. Brake lige 1 ydratulle unitto front right brake caliper 14" Brake line Brake master cylinder/secondary piston circuit to hydraulic unit 6. ABS- ITT Mark 70 contral unt and hydraulic unit BQ‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 fw Note # Clean bolts and nuts before reusing. # Alnays renew seltlocking bolts/nuts. + Alnays renew damaged bolts/nuts. 6.2 Removing and installing control unit and hydraulic unit (Mark 70) (F ro 4 From model year 2009 onwards, sensor unit -G419- fs installed in ABS control unit - J104- (with ESP). From model year 2009 onwards, ABS control unit - J104- (with ESP) must be renewed if sensor unit -G418- is defective. From mode! year 2009 onwards, ABS control unit - J104- (with ESP) must be calibrated after it has been renewed. # From model year 2009 onwards, steering angle and brake pressure aré also measured by the ABS control unit - J104- (with ESP); these values must then be calibrated. 40 0p. 45 Antilock brake system‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 Special tools and workshop equipment required VAG 1991 V.AG 1410 V.AG 1069°2 © Torque wrench - V.AG 1331- # Torque wrench - V.AG 1410- © Brake pedal actuator - V.A.G 1869/2- Sealing plug repair kt, Part no. 1HO 698 311 A After separating the control unit from the hydraulic unit, you must, fit the transport protection for contact pins onto the hydraulic unit. No warranty can be assumed for hydraulic units without transport protection 1 - Transport protection for contact pins (foam) 2.- Sealing plugs M10 for brake lines and tapped holes 3 - Sealing plugs M12 for brake lines and tapped holes Removing = If fitted, remove covers in enging eompaitment (rear right). > Rep. gf. 20 6.ABS- ITT Mark 70 contral unt and hysrautl unit 44‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 — Insert brake pedal a¢tuatot- V.A/G)18d8/2- betiveen brake edal and rivers seal. Depgbss the brakt pegs! at least mm, = Connect hose of bleeder bottle to bleeder screws of front left and rear left brake calipers and open bbleeder sorews. (F no This will release the pressure in the hydraulic unit. = Close front left and rear left bleeder screws. — Do not remove brake pedal actuator - V.A.G 1869/2- = Release connector at control unit -arrow 1 and unplug arrow 2. (F ro» # Make sure brake fluid does not get into connector housing of control unit. This can result in corrosion of the contacts and failure of the system. # Use compressed air to carefully clean connector housing it necessary. = As protection against escaping brake fluid, place a sufficient number of lint-free cloths in area beneath control unit and hy- , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 = Prise hydraulic unit with control unit off upwards -arrows- - Unscrew bolts on bracket for hydraulic unit -1- (tightening torque 8 Nm). Removing contol unit rom hydraulic uit = Place hydraulic unit on ¢ clean flat surface with control unit facing upwards. — Remove Torx socket head bolts -arrows- ee eee for 6.ABS- ITT Mark 70 contral unt and hydraulic unit 43‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 = Detach control unit from hydraulic unit -arrow- (make sure not to cant control unit = Carefully take off all seals from contact pins of hydraulic unit. A wns The printed circuit bosrd is exposed when the control unit is removed. Make sure that no moisture or dirt can enter the control unit. Hydraulic pump mustnotbe separated from hydraulic unit = Cover control unit solenoids with a lint-free cloth. After disconnecting control unit and hydraulic unit, fit transporta- tion protection for contact pins. Installing new control unit (i) Note 4 Clean bolts and nuts before reusing. # Always renew self-locking bolts/nuts. + Alnays renew damaged bolts/nuts. Ay wane Severe shOcks OF /ols CaM aaiage the contro! unit. The control unit must not be re-ipstaliad ifit has been damaged in any way. + Clean surfaces before assembling. ~ Fitall seais “A. slightly dnto cdntact pins. — Place control unit on hydraulic unit, taking care to keep it straight. The seals are thus moved to end position. = Boltcontrol unit to hydraulic unit with the new Torx sockethead bolts supplied. i Note % To avoid any risk of leakage at the flexible seal, g new control me unit must not be fitted more than twice onto an “old” hydraulic unit that is being re-installed. # Acontro! unit which has been in operation while the vehicle is ‘being driven must not be fitted a second time. 44. 0p. or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 oz, | \Y LY NY 6.ABS- ITT Mark 70 contral unt and hydraulic unit 45‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 Unscrew hexagon nut -1- (tightening torque 20 Nm) Installing Install in reverse sequence, paying attention to the following: w Note Clean bolts and nuts before reusing. + Alnays renew seftlocking bolts/nuts. © Alnays renew damaged botts/nuts. (E] re % Donot remove sealing plugs from new hydraulic unit until cor aanencige bee Tbe adh ibe tod 4 /fsealing plugs.are removed from hydraulic unit sooner, brake uid may escapeand iemay acJanger be possible to fill and bleed the unit properly. - When assembling control unit and hydraulic Unit: make sure! contact pins. of hydraulic unit. do not cant.on contro}, unit solenoids. = Connect lines in accordance with markings > page 37. = Bolt ABS unit to bracket, f® Note Do not tighten bolts completely. This will make it easier to attach the individual brake lines to the hydraulic unit. = Tighten all brake line connections. — Perform final control diagnosis after attaching brake lines to hydraulic unit. Vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- (F ne Final control alagnosis can be used to establish whether line connections have been interchanged. To do s0, use the vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- ~ Select function tests via “Function/component selection” = page 9 ~ ‘Running gear” - “Brake system’ = 01 -Self-diagnosis compatible systems” = “J104 - Control unit for ABS/TOS/ESP Mark 60° ~ “104 Control unit for ABS/TCS/ESP, Functions” — After tightening brake lines, tighten hydraulic unit. 6 op. or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 fa Note The right air duct must be reconnected on vehicles with TFS/engine. ~ Bleed brake system = page 178 = fa new control unit has been fitted, it must be encoded. To do so, use the vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- — Connect vehicle diagnostic, testing and information system and select “Function/component’ for function test = page 2 Then Running gear” — gSrake syste” ~\'01 + Self-diagnosis compatible systems" = “y104 SeentrerunitforABS/TCS/ESP Mark 60" = “J104 - Control unit for ABS/TCS/ESP, Functions” ~ “H04~ Encoding contro! unit” Perform final control diagnosis after attaching brake lines to Ihydrablicunit: Vehicle diagnostic, testing and! information sys tem - VAS 5051 x - or -VAS 5052- (F) ne ¢ Ifthe ABS control unit - J104- (with ESP) is renewed, the following senders must be calibrated. Bleeding brakes at workshop, channel 1 Steering angle sender - G85-, channe! 60 Lateral acceleration sender - G200-, channe| 63 Brake pressure sender 1 - G201-, channel 66 Longitudinal acceleration sender - G251-, channel 69 (fitted ‘on four-wheel drive vehicles only) ¢ From model year 2009 onwards, steering angle and brake pressure aré also measured by the ABS control unit - J104= (with ESP), these values must then be calibrated. ¢ ESP road test and system test must then be carried out. eo eee To do so, use the vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- — Connect -VAS 5051 x - or -VAS 5052- and select "function! component’ for function test = page 9 Running gear” Brake system “01 - Self-diagnosis compatible systems’ *J104 - Control unit for ABS/TCS/ESP Mark 60’ = “104 - Control unit for ABS/TCS/ESP, Functions” 6.ABS- ITT Mark 70 contral unt and hydraulic unit 47‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 Tightening torques [Component Nm [Control unit to hydraulic unit 35 Hydraulic unit to bracket 8 [Brake lines to hydraulic unit 14) ) For M10 and M2 connections AB 0p. or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 7 ABS control unit -J104- and ABS hydraulic unit -N55- - TFSI engine ling control unit.and hydraul ur Remoying and lgstalling control unit and hydraulle Unit= TFSI engine (CF) ne ¢ From model year 2009-onwards; sensor unit-G4 19-(9\instal- fed in ABS control unit -J104- (with ESP). ¢ From model year 2009 onwards, ABS control unit -J104- (with ESP) must be renewed if sensor unit -G419- is defective. ¢ From model year 2009 onwards, ABS control unit -J104- (with ESP) must be calibrated after it has been renewed. ¢ From model year 2009 onwards, steering angle and brake pressure aré also measured by the ABS control unit - J104- (with ESP); these values must then be calibrated. fa) Note The right air duct must be disconnected on vehicles with TFS! engine. On vehicles with Mark 60EC system If the ABS control unit -J104- is renewed on vehicles with Mark 8OEC system, an additional basic setting must be performed for the inlet valves and separating valves. = page 36 7. ABS control unit-J104- and ABS hydraulic unt-NSS-- TFSi engine 4Q‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 Special tools and workshop equipment required VAG 1931 VAG 1810 VAG 19892 % Torque wrench -V.AG 1331- % Torque wrench -V.AG 1410- # Brake pedal actuator - V.AG 1869/2- Sealing plug repair kt, Part no. 1H0 698 311A After separating the control unit from the hydraulic unit, you must fit the transport protection for contact pins onto the hydraulic unit. No warranty can be assumed for hydraulic units without transport protection, 1 - Transport protection for contact pins (foam) 2 - Sealing plugs M10 for brake lines and tapped holes 3 Sealing plugs M12 for brake lines and tapped holes Removing 50 Rep. o-45- Antttock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 — Insert brake pedal actuator - V.A.G 1869/2- between brake Vv pedal and driver's seat. Depress the brake pedal at least v Le CIN 60 mm. = Connect hose of bleeder bottle to bleeder screws of front left and rear left brake calipers and open bleeder screws. ae This will release the pressure in the hydraulic unit. ~ Close front left and rear left bleeder screws — Do not remove brake pedal actuator - V.A.G 1869/2- Remove engine cover panel = Disconnect air duct. - Release connector at control unit -arrow 1+ and unplug -arrow 2. (B) ere *nitake-surebrake fivid does not get into connector housing of control unit. This can result in corresion of the contacts and failure of the system. ¢ Use compressed air to carefully clean connector housing if wecessary As protection against escaping brake fluid, place a sufficient umber of lint-free cloths in area beneath control unit and hydraulic unit. = Mark brake lines, — Unscrew brake lines from hydraulic unit -1- to brake master cylinder and tie in piace. = Disconnect remaining brake lines -2- on hydraulic unit. A WARNING Do not bend the brake lines in the vicinity of the hydraulic unit. - Seal brake lines and tapped holes with sealing plugs from repair kit. 7. ABS contol unit ~J104- and ABS hydrauic unit-NSS-- TSI engino 541‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 = Prise hydraulic unit with control unit off upwards -arrows-. Unscrew bolts on bracket for hydraulic unit -1- (tightening torque 8 Nm). Removing control unit from hydraulic unit = Place hydraulic unit on a clean flat surface with control unit facing downwards. — Unscrew Torx socket head bolts -arrows- from hydraulic pump. LY warns ‘Hydraulic pump must not be separated from hydraulic unit. = The hydraulic pump must therefore be secured on the hydraulic unit with the red retainer -1- from the repair kit and two sealing plugs -2.. 52 kop. 45 Antbtock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 - Carefully ift hydraulic unit with hydraulic pump off control unit at seam 7. ABS contol unit-J104- and ABS hydraulic unit -NSS-- TFSI engine SS‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 When pulling off the control unit, ensure that the hydraulic unit contact pins are not canted against the control unit solenoids. Item -2-: Adapter for pump motor — Cover control unit solenoids with a lint-free cloth. After disconnecting control unit and hydraulic unit, ft transporta- tion protection for contact pins. Installing new control unit (a) Note 4% Clean bolts and nuts before reusing. + Alnays renew selt-locking bolts/nuts. + Alays renew damaged bolts/nuts. A\ warn ‘Severe shocks orjolts can damage the control unit. The contro! unit must not be re-installed ifit has been damaged in any way. 4 First clip in the adapter for pump motor until it engages with a click before installing the new control unit. Make sure not to damage the adapter guide. # The adapter (supplied as replacement partfor control unit) can only be clipped in once and then no longer detached. 4 The white paste on the bottom of the control unit serves as sealant and must nobbe,emovyed: # To ensure that the components are Kept clean and to prevent damage, do not touch any contact surfaceson the adapter, pressure sensor or Contfolunit, orthe silicone gel and sealing ‘components by hand or with tools, ete. ~ Clip adapter into adapter guide until it engages witha click. = Place control unit,on hyciraulic unit: (make sure notite cant control unit. = Bolt control unit to hydraulic unit with the new Torx socket head bolts supplied: (F ne # To avoid any risk of leakage at the flexible seal, a new control unit must not be fitted more than twice onto an “ola” hydraulic unit that is being re-installed. # Acontro! unit which has been in operation while the vehicle is ‘being driven must not be fitted a second time. 54 kop. oc 45- Antttock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 = Unscrew cross-head bolt -1- = Unelig line -2. 7. ABS contol unit-J104- and ABS hydraulic unit-NSS-- TFSI engine 5S‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 Unscrew hexagon nut -1- (tightening torque 20 Nm) Installing Install in reverse sequence, paying attention to the following: w Note Clean bolts and nuts before reusing. + Alnays renew seftlocking bolts/nuts. © Alnays renew damaged botts/nuts. (E] re # Donotremove sealing plugs from new hydraulic unit until cor responding brake line is ready to be fitted. 4 /fsealing plugs are removed from hydraulic unit sooner, brake fluid may escape and it may no longer be possible to fill and bleed the unit properiy. = When assembling control unit and hydraulic unit, make sure contact pins of hydraulic unit do not cant on control unit solenoids. — Copnectiines in-secordance with markings > page 23 . = Securd ABS brit tolbtecket f Note Do rit tighten'bolts cémpietely” This Wi make iteasiet te attach the individual brake lines to.the hydrautic-unit ~ Tighten ail brake'line connections. — After tightening brake lines, tighten hydraulic unt ~ Perform final control diagnosis after attaching brake lines to hydraulic unit. Vehicle diagnostic. testing and information system - VAS 5051 x - or -VAS 5052- i) Note Final control diagnosis can be used to establish whether line connections have been interchanged. Tordo,a0,uge the vehicle ciagnostic, testing and information ys- tem - VAS 5051 x- or -VAS 5052- = Select function tests via “Function/component selection” = page 9 = "Running gear’ = "Brake system’ = ‘01 - Seifdiagnosis compatible systems” — “104 - Control unit for ABS/TCS/ESP Mark 60” — "104 - Control unit for ABS/TCS/ESP, Functions’ 56 Rep. o-45- Antttockbraka systom‘Alidi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > On vehicles with Mark 60EC system If the ABS contro} Unit -J104"i¢ renewed on vehicles with Mark 80EG eystem, an additional basic setting must be performed for: the inlet valves and separating valves. > page 36 To do so, use the vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- Tightening torques = Connect air duct = Bleed brake system > page 179 — fa new control unit has been fitted, it must be encoded. (B) Note ¢ Ifthe ABS control unit - J104- (with ESP) is renewed, the following senders must be caliorated: Bleeding brakes at workshop, channel 1 Steering angle sender - G85- , channel 60 Lateral acceleration sender - G200-, channel 63 Brake pressure sender 1 - G201-, channel 66 Longitudinal acceleration sender - G251-, channel 69 (fitted irewheel drive vehicles only) © From model year 2009 onwards, steering angle and brake pressure are also measured by the ABS control unit J104- (with ESP); these values must then be calibrated. ¢ ESP road test and system test must then be carried out. wees To do s0, use the vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- . = Connect vehicle diagnostic, testing and information system and select “Function/component” for function test > page 9 Then “Running gear’ Brake system” “01 - Self-diagnosis compatible systems” = “W104 - Control unit for ABS/TCS/ESP Mark 60" = *J104 - Control unit for ABS/TCS/ESP, Functions’ — “J104~ Encoding control unit” [Component Nm [Control unit to hydraulic unit 4 Hyéraulic unit to bracket @ Brake lines to hydraulie unit 14 Brake eystem - Edition 11.2018 7. ABS control unit-J104- and ABS hydraulic unt-NSS-- TFSi engine ST‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 8 ABS control unit -J104- and ABS hydraulic unit -N55- - 2.0 Itr. TDI engine 8.1 Removing and installing control unit and hydra itr. TDI engine”, page 58 8.1 Removing and installing control unit and hydraulic unit - 2.0 Itr. TDI engine Vehicles without diesel particulate filter @ Note From model year 2009 onwards, sensor unit -G419- is instak led in ABS control unit - J104- (with ESP). From model year 2009 onwards, ABS control unit- J104- (with ESP) must be renewed if sensor unit -G4 19. is defective. # From model year 2009 onwards, ABS control unit -J104- (with ESP) must be calibrated after it has been renewed. From model year 2008 onwards, steering angle and brake, pressure are also measured by the ABS control unit - J104- (nth ESP); these values must then be calibrated. (On vehicles with Mark @0EC s¥stera If the ABS control unit -J104- ig renewed om vehicles with Mark G0EC system, an additional:basie-setting mustbe performed for the inlet valves and separating valves. = page 36 To do so, use the vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- 58 Rep. o:45- Antttock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 Special tools and workshop equipment required VAG 1991 V.AG 1410 V.AG 1069°2 © Torque wrench - V.AG 1331- # Torque wrench - V.AG 1410- © Brake pedal actuator - V.A.G 1869/2- Sealing plug repair kt, Part no. 1HO 698 311 A After separating the control unit from the hydraulic unit, you must, fit the transport protection for contact pins onto the hydraulic unit. No warranty can be assumed for hydraulic units without transport protection 1 - Transport protection for contact pins (foam) 2.- Sealing plugs M10 for brake lines and tapped holes 3 - Sealing plugs M12 for brake lines and tapped holes Removing 8. ABS control unit-J104- and ABS hydraulic unit-NSS-- 2.01". TDI engine SQ‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 — Insert brake pedal actuator - V.A.G 1869/2- between brake pedal and driver's seat. Depress the brake pedal at least 60 mm. = Connect hose of bleeder bottle to bleeder screws of front left and rear left brake calipers and open bleeder screws. (F no This will release the pressure in the hydraulic unit. = Close front left and rear left bleeder screws. — Do not remove brake pedal actuator - V.AG 1869/2- = Remove engine cover panel -1 and 2. Unfasten and push aside turbocharger air duct. ~ Release connector at control unit -arrow 1 and unplug -arrow 2- @ Note + Make sure brake fluid does not get into connector housing of control unit. This can result in corrosion of the contacts and failure of the system. # Use compressed air to carefully clean connector housing if necessary. — As protection against escaping brake/fiuid, place a sufficient number of lint-free clottis in ara beneath control unit and hydraulic unit = Mark brake lines, 6 op or45- Antilock brake system‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 Unscrew brake lines from hydraulic unit -1- to brake master cylinder and tie in place, Disconnect remaining brake lines -2- on hydraulic unit. A WARNING Do not bend the brake lines in the vicinity of the hydraulic unit. = Seal brake lines and tapped holes with sealing plugs fram re- Pair kit. Prise hydraulic unit with control unit off upwards -arrows-. Unscrew bolts on bracket for hydraulic unit -1- (tightening torque 8 Nm). Removing control unit from hydraulic unit Place hydraulic unit on a clean flat surface with control unit facing downwards. Unscrew Torx socket heed bolts -arrows- from hydraulic pump. A WARNING ‘Hydraulic pump must not be separated from hydraulic unit. 8, ABS control unit J104- and ABS nysraull unit NSS--2.01N. TDI engine 61‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 ~The hydraulic pump must therefore be secured on the hydraulic unit with the red retainer -1- from the repair kit and two sealing plugs -2-. = Carefully ift hydraulic unit with hydraulic: pump off contral unit at seam -1~ 62. op. or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 ‘When pulling off the contro! unit, ensure that the hydraulic unit contact pins are not canted against the control unit solenoids, Item -2-: Adapter for pump motor — Cover control unit solenoids with a lint-free cloth. ‘After disconnecting control unit and hydraulic unit, fit transporta- tion protection for contact pins. Installing new control unit 4) Note © Clean bots and nuts before reusing. + Always renew seltocking bots /nuts 6 Always renew demaged bottefnuts, A WARNING ‘Severe shocks orjolts can damage the control unit. The control unit must not be re-installed ifit has been damaged in any way. ¢ First clip in the adapter for pump motor until it engages with a click before installing the new control unit, Make sure not to damage the adapter guide, © The adapter (supplied as replacement part for control unit) can only be clipped in once and then no longer detached. ¢ The white paste on the bottom of the control unit serves as, sealant and must not be removed, ‘@ To ensure that the components are kept clean and to prevent damage, do not touch any contact surfaces on the adapter, pressure sensor or control unit, or the silicone gel and sealing components by hand or with tools, etc. - Clip adapter into adapter guide until it engages with a click. ~ Place control unit on hydraulic unit (make sure not to cant control unit. = Bolt control unitto hydraulie unit With the new Torx socket head bolts supplied. (Bre © To.avoid any risk ofleakage at the flexible seal) anew control unit must not be fitted more than twice onto an “old” hydraulic unit that is being re-installed. ¢ control unit which has been in operation while the vehicle is being driven must not be fitted @ second time. 8. ABS control unit -J104- and ABS hydraulic unt-NSS-- 2.01. TDI engine 63‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 = Unscrew crosshead ott -t- w = Unelip tine -2- Dy c> J 64 op. or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 = Unscrew hexagon nut -1- (tightening torque 20 Nm). Installing Install in reverse sequence, paying attention to the following: fa Note Clean bolts and nuts before reusing. + Alnays renew seitlocking bots/nuts. + Alnays renew damaged bolts/nuts. >, (CF) ne © Do not remove sealing plugs from new hydraulic unit until corresponding brake line is ready to be fitted. Ifsealing plugs are removed from hyaraulic unit sooner, brake fluid may escape and it may no longer be possible to fil and! bleed the unit property. — When assembling control unit and hydraulic unit, make sure contact pins of hydraulic unit do not cant on control unit sole- roids. = Connect lines in accordance with markings > page 23 = Secure ABS unit to bracket. [F) Note Do not tighten bolts completely. This wi make it easier to attach the individual brake lines to the hydraulic unit = Tighten all brake line connections. — Perform final control diagnosis after attaching brake lines to hydraulic unit. Vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- (Bre Final control diagnosis can be used to establish whether line connections have been interchanged. T@ do s6, Use ithe vehicle diagnostic, testing and information system - VAS 5051 x - or" VAS/5052- — Select function tests via “Function/component selection” = page 9 ~ “Running gear ~ ‘Brake system” ~ “01 Seit-diagnosis compatible systems = "W104 - Control unit for ABS/TOS/ESP Mark 60° — “W104 - Control unit for ABS/TCS/ESP, Functions" — After tightening brake lines, tighten hydraulic unit. = Insert and bolt on turbocharger air duct. 8. ABS control unit -J104- and ABS hydraulic unt-NSS--2.01r. TDI engine 6S‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 ~_ Install engine cover panel -1 and 2- — Bleed brake system > page 179 — If anew control unit has been fitted, it must be encoded. To do £0, use the vehicle diagnostic, testing and information system - VAS 5051 x- or -VAS 5052- = Connect vehicle diagnostic, testing and information system and select “Functionicomponent for function test = page 9 Then “Running gear’ = "Brake system’ — 01 - Seif-diagnosis compatible systems" = “W104 - Control unit for ABS/TCS/ESP Mark 60” = "104 - Control unit for ABS/TCS/ESP, Functions” — W104 - Encoding control unit" — Perform final control diagnosis after attaching brake lines to hydraulic unit. Vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- (Fy noe 4 ifthe ABS contro! unit - J104- (with ESP) is renewed, the following senders must be caliorated: Bleeding brakes at workshop, channel 1 Steering angle sender - G85-, channel 60 Lateral acceleration sender - G200- , channel 63 Brake pressure sender 1 - G201-, channel 66 Longitudinal acceleration sender - G251-, channel 69 (fitted on four-wheel dive vehicles only) + From mode! year 2009 onwards, steering angle and brake pressure are also measured by the ABS control unit - J104- (nth ESP); these values must then be calibrated. 4 ESP road test and system test must then be carried out. eeeee To do $0, use the vehicle diagnostic, testing and information system - VAS 5051 x- or -VAS 5052- = Connect -VAS 5051 x - or -VAS 5052- and select "Function! component" for function test = page 9 = "Running gear’ = "Brake system’ = °01 - Seifdiagnosis compatible systems” — “104 - Control unit for ABS/TCS/ESP Mark 60” = “W104 - Control unit for ABS/TGS/ESP.Funetions® 66 op. or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 On vehicles with Mark 60EC system If the ABS control unit -J104- is renewed on vehicles with Mark 80EC eystem, an additional basic setting must be performed for the inlet valves and separating valves. > page 36 To do so, use the vehicle diagnostic, testing and information system - VAS 5051 x - or -VAS 5052- Tightening torques [Component Nm [Control unit to hydraulic unit 4 Hydraulic unit to bracket 8 Brake lines to hydraulic unit 14 8. ABS control unit -J104- and ABS hydraulic unit-NSS--2.01r. TDI engine 67‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 9 ABS control unit -J104- and ABS hydraulic unit -N55- - RS 3 Exploded view", page 68 9.1 Exploded view 1 - Hydraulic unit with contro! unit Removing and installing > page 68 2- Bolt Nm 3 Bracket G| Note ESP control unit and hy must be removed befor bracket 4 - Rubber buffer 5 + Mounting bracket 6-Nut 20Nm 7 - Stud on body + Clean ing. + Aina) ts. + Aina; 4 by copyright. Copying for private or commercial purposes, in part or in Co mitted unless authorist DIAG. AUDI AG does not guarantee or accept any liability to the correctness of infor his document. Copyright by AUDI At 6B op. or45- Antilock brake systom‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 9.2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- Ay cw ABS control unit -J104- and ABS hydraulic unit -N5S- must not be separated. Removing hydraulic unit with control unit — Read out control unit version and note down. = Disconnect battery > Electrical system; Rep. gr. 27 (note ra- dio code). Insert brake pedal actuator - V.A.G 1869/2- between brake Pedal and driver's seat (depress brake pedal at least 60 mm). = Connect hose of bleeder bottle to bleeder screws of front left and rear left brake calipers. — Open bleeder screws of rear left and front left brake calipers. to release pressure in hydraulic unit, — Close bleeder screws of front left and rear left brake calipers. = Do net remove brake pedal actuator - V.A.G 1869/2- — Lower vehicle. Using suitable pliers, unfasten clamp at air hose to air duct and detach hose. = Using suitable pliers, unfasten clamps of air duct and detach = Remove eir duct to turbocharger from bracket = Take air duct out of vehicle. = Unclip coolant line to coolant expansion tank from bulkhead ~ JGereflly pes coBlant ine to one side. 9. ABS contro unit J104- and ABS hycrauic unit-NSS--R83 BQ‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake system - Edition 11.2018 = Release connector at control unit -arrow 1- and unplug -arrow 2-. (B) now # Make sure brake fluid does not get into connector housing of control unit. This can result in corrosion of the contacts and failure of the system. Use compressed air to carefuly clean connector housing if necessary. — Unfasten cable tie for electrical wiring to connector and move wiring clear to one side, — To protect against escaping brake fluid, place a sufficient umber of intsTee cloths in ares beneath contol unt and hy- raulic unit, Mark brake lines. LX weans Do not bend or kink brake lines. = Unsete! lic unit -2- to brake master - Disconnect remaining brake lines -3- on hydraulic unit. = Seal Bike Ines and thidlided Moles’ Using Séeting plugs front > repalk Kt. [B] noe woes os : The hydraulle pump must not be separated from the hycrauile uni 70 Rep. or45- Antilock brake system‘Audi A3 2004 > , Audi A3 Cabriolet 2008 > , Audi A3 Sportback 2005 > Brake eystem - Edition 11.2018 ~ Carel pul Bydedtc nit-2 together with contrat unit and brackste4- out of rubber buffers'on mounting bracket -6-. = Take hydraulic unit out of vehicle. — Unscfew-bolts 15: from bracket=4s.and detach bracket = Place hydraulic unit'on a'clean flat stirtace ‘with control unit: facing downwards, LX _ wornine ‘Severe shocks or jolts can damage the control unit. The control unit must not be re-installed ifithas been damaged in any way. ‘Seal threaded holes and brake lines using sealing plugs - 1HO.698.311.A after removing control unit and hydraulic unit. LX _ warnine ‘Hydraulic pump must not be separated from hydraulic unit. Installing Install in reverse sequence, paying attention to the following: (Bre ¢ Clean bolts and nuts before reusing. © Always renew self-locking bolts/nuts. © Always renew damaged bolts/nuts. (F) note © The hydraulic unit supplied as a replacement is filed with brake fluid. ¢ If seating plugs are removed before fitting corresponding brake line, brake fluid will escape. Proper bleeding is then no longer ensured. 9. ABS contro unit J104 and ABS hysrauic unit-NSS--AS3 71

Audi A3 (8P, 8P1,8PA) - Brake System

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Audi A3 (8P, 8P1,8PA) - Brake System

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