Section C

Section C - ABS Control Module Removal and Installation

^ Obtain radio code and record radio preset stations

^ Turn Ignition Switch to "OFF" position

^ Open hood and place fender cover in position

^ Disconnect the ground cable (GDN) from the negative (-) battery terminal





<-- Disconnect electrical connector -1- from mass air flow sensor -2-

<-- Remove vacuum line -7- attached to lower corner of air box (TDI vehicles only)

<-- Remove clamp -3- and disconnect intake air hose from mass air flow sensor

<-- If applicable, remove secondary air hose -4- from air filter box -5-

<-- Remove screws -6- securing air filter box and remove air filter box

^ If applicable, remove and move aside secondary air relay box and harness from supporting clip

^ If applicable, disconnect electrical connector on brake fluid reservoir





<-- Release ABS control module electrical connector by pulling latch upward -arrow 1-

<-- Pull electrical connector off ABS control module -arrow 2-

^ Raise vehicle and connect brake bleeder bottle to left front brake caliper and left rear caliper bleed screw and open bleed screws

^ Lower vehicle

^ Obtain brake pedal depressor device VAG 1869/2 and place in position in vehicle

^ Slowly depress and hold the brake pedal at least 60 mm (2.36 in.) with brake pedal depressor

^ Raise vehicle

^ Close left front and left rear caliper bleed screws when brake fluid stops flowing

^ Lower vehicle

^ Do not remove brake pedal depressor from brake pedal at this time

Note:
By holding the brake pedal in a down position, the master cylinder central valves are closed and brake fluid does not leak out of system

^ Place sufficient lint-free cloths under the ABS control module and hydraulic unit





<-- Remove brake lines -3- on the side of hydraulic unit

CAUTION!
DO NOT BEND BRAKE LINES IN THE AREA OF THE HYDRAULIC

CAUTION!
MAKE SURE NO BRAKE FLUID





<-- From the repair kit provided (1J0 998 375) place red plastic bracket -1- on hydraulic unit and secure in position with yellow plugs -2-

IMPORTANT:
If parts from repair kit are being reused, make certain the parts are free of debris and contaminates

Note:
The red bracket locks the pump motor to the hydraulic unit for later removal of ABS control module

CAUTION!
DO NOT REMOVE THE PUMP FROM THE HYDRAULIC UNIT





<-- Remove brake fluid lines -1- and -2- and install plugs from kit into hydraulic unit

Note:
The black colored plug is a smaller diameter and used for the brake line inserted into the smaller hole





<-- Remove 2 bolts with 10 mm hex heads -arrows- securing hydraulic unit/control module to bracket

^ Remove hydraulic unit with control module from bracket and place on a clean level work bench

^ Remove the new ABS control module (1C0 907 379 J) from package





<-- Insert new adaptor -3- from kit into new ABS control module

<-- Push adaptor down until clips -4- snap into position

CAUTION!
THE ADAPTER CAN ONLY BE PRESSED BE REMOVED AGAIN WITHOUT PRESSED IN ONCE AND CANNOT BE REMOVED AGAIN WITHOUT BEING DAMAGED





<-- Remove the 2 torx screws -arrows- from the removed pump and hydraulic unit

^ Lift pump and hydraulic unit upward and off the ABS control module and carefully slide it onto the new ABS control module and push down to stop

CAUTION!
DO NOT TILT OR JAM THE VALVE DOMES OF THE HYDRAULIC UNIT AND THE SOLENOIDS OF THE ABS CONTROL MODULE WHEN REMOVING OR INSTALLING THE CONTROL MODULE

<-- Reinstall 2 torx screws -1- and tighten to 4 Nm (35 in. lbs.)

^ Install pump and hydraulic unit with new ABS control module onto bracket in vehicle and hand start previously removed screws

Note
Do not tighten bolts securing hydraulic unit at this time. Leaving hydraulic unit loose will aid in brake line reinstallation

^ Remove four plugs from the top of the hydraulic unit one at a time and insert each brake fluid line and tighten to 14 Nm (10 ft. lbs)

Note
Prior to reinstalling brake fluid lines, make certain ends of lines and hydraulic unit holes are clean

^ Remove yellow plastic plugs and red bracket from hydraulic unit

^ Insert brake fluid lines and tighten to 14 Nm (10 ft. lbs.)

^ Clean all debris and contaminants from all removed plugs and bracket

IMPORTANT:
Save all the plugs and plastic bracket. They can be used on atleast2morevehicles.Only one repair kit will be allocated for every 3 vehicles

^ Tighten bolts for hydraulic unit to bracket to 8 Nm (71 in. lbs.)

^ Remove lint-free clothes from under the ABS control module and hydraulic unit





<-- Place electrical connector -1- into ABS control module and push in direction of -arrow 2-

<-- Lock electrical connector to ABS control module by pushing latch down -arrow 3-

^ If applicable, reinstall secondary air relay box and reinsert harness in support clip

^ If applicable, reconnect electrical connector to brake fluid reservoir





<-- Reinstall air filter box and secure with 2 screws -6- and tighten to 6 Nm (53 in. lbs.)

<-- If applicable reconnect air hose -4- from secondary air pump to air filter box -5-

<-- Reconnect vacuum line -7- to air box (TDI vehicles only)

<-- Reconnect air intake hose to mass air flow sensor and secure with clamp -3-

<-- Reconnect electrical connector -1- to mass air flow sensor -2-

^ Reconnect the ground cable (GDN) from the negative (-) battery terminal

^ In the vehicle, remove brake pedal depressor from the brake pedal

^ Proceed to Section D