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Home >> Volkswagen >> 2001 >> Jetta GL Sedan (9M2) L4-1.9L DSL Turbo (ALH) >> Repair and Diagnosis >> Brakes and Traction Control >> Antilock Brakes / Traction Control Systems >> Technical Service Bulletins >> Recalls >> Recall - Check/Replace ABS Control Unit >> Work Sequence >> Section C

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





- 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 UNIT.
- MAKE SURE NO BRAKE FLUID GETS ONTO CONTROL UNIT CONTACTS





- 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 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 at least 2 more vehicles. 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

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