Volkswagen Golf / Golf GTI / Jetta. Manual — part 419

45-60

- Separate hydraulic unit with

hydraulic pump from control
module by carefully lifting off joint
-1-.

When pulling off control module,

make sure that the hydraulic unit
valve dome does not contact the
control module solenoid valves.

Cover control module magnetic coils
with a lint-free cloth.

After separating control module and
hydraulic unit use transportation
protection for valve dome.

The contact pin -2- which is supplied
as a replacement part along with the
control module can only be clipped
in once and then it cannot be
removed.

Hydraulic unit, brake booster/brake master cylinder Mark 60, assembly overview

45-61

Installing

Note:

Only remove sealing plugs on new hydraulic

unit when the corresponding brake line is going
to be installed.

If the sealing plugs are removed too early,

brake fluid can escape, it can no longer be
guaranteed that the module is sufficiently filled
or adequately bled.

When assembling the control module and

hydraulic unit, be sure that the hydraulic unit
valve dome does not come in contact with the
control module solenoid valves.

- Using new bolts, install control module to

hydraulic unit. Do not tighten more than a max. 4
Nm (35 in. lb).

- Bolt ABS module to bracket.

Do not tighten bolts completely. Attaching the

individual brake lines is made easier.

- After tightening brake lines, tighten hydraulic

unit.

- Further installation is carried out in the reverse

sequence.

Hydraulic unit, brake booster/brake master cylinder Mark 60, assembly overview

45-62

- Remove brake pedal depressor VAG 1869/2.

- Bleed brake system

Page 47-38

- Enter radio code.

- Code ABS control module (w/EDL) -J104-.

- Basic settings must be performed when

replacing ABS control module (w/EDL) -J104-.

- Connecting VAS 5051 and selecting functions

Page 45-38

Tightening Torques:

Control module to hydraulic unit

max.

4 Nm (35 in.

lb)

Hydraulic unit to bracket

8 Nm (70 in.

lb)

Nut for brake master cylinder to
brake booster

20 Nm (15 ft.

lb)

Brake lines at ABS module:

Thread M 10 x 1

14 Nm (10 ft.

lb)

Thread M 12 x 1

14 Nm (10 ft.

lb)

Cap nut to body

20 Nm (15 ft.

lb)

Hydraulic unit, brake booster/brake master cylinder Mark 60, assembly overview

45-63

DTCs displayed by
(ABS) Mark 60 warning
lights -K32-, -K47-, -
K118-, and -K155-

Warning lamps

Note:

The ASR/ESP control lamp -K155-
for stabilization program ASR/ESP is
used by ABS/EDL/ASR and
ABS/EDL/ASR/ESP brake systems.

Pos.

Component

1

Brake pad wear indicator
light -K32-

2

ABS warning light -K47-

3

Warning light for brake
system -K118-

4

ASR/ESP Control Lamp -
K155-

DTCs displayed by (ABS) Mark 60 warning lights -K32-, -K47-, -K118-, and -K155-