Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 775
Special Tool Assembly for Tightening the Brake Lines
♦ Refer to
⇒ “3.1 Overview - Control Module and Hydraulic Unit”,
♦ Battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Bat‐
tery; Overview - Battery .
♦ Noise insulation bolts. Refer to ⇒ Body Exterior; Rep. Gr. 66 ;
Noise Insulation; Overview - Noise Insulation .
♦ Front exhaust pipe. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/
Mufflers; Front Exhaust Pipe, Removing and Installing .
♦ Pendulum support. Refer to ⇒ Engine Mechanical, Fuel In‐
jection and Ignition; Rep. Gr. 10 ; Subframe Mount; Overview
- Subframe Mount .
♦ Driveshaft. Refer to ⇒ Suspension, Wheels, Steering; Rep.
Gr. 40 ; Drive Axle; Overview - Drive Axle .
♦ Lower control arm. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 40 ; Lower Control Arm and Ball Joint; Overview -
Lower Control Arm and Ball Joint .
♦ Front bleeder valve. Refer to
⇒ “1.1 Overview - Front Brake Caliper”, page 97
♦ Rear bleeder valves. Refer to
⇒ “2.1 Overview - Rear Brake Caliper”, page 100
3.3
Control Module, Separating from Hy‐
draulic Unit
Special tools and workshop equipment required
♦ ESD Work Surface - VAS6613-
♦ TORX
®
Insert T25
♦ If the ABS Control Module - J104- is faulty, then the control
module is to be separated from the ABS Hydraulic Unit - N55-
and only the control module replaced.
♦ If the ABS Hydraulic Unit - N55- is faulty, then replace the ABS
Hydraulic Unit - N55- together with the ABS Control Module -
J104- .
♦ To separate the ABS Control Module - J104- and the ABS Hy‐
draulic Unit - N55- the unit must be removed.
WARNING
♦ The return flow pump may also not be separated from the
ABS Hydraulic Unit - N55- .
♦ The circuit board is exposed when the ABS Control Mod‐
ule - J104- is removed.
♦ Protect the ABS Control Module - J104- from moisture and
dirt particles from getting inside.
♦ Avoid build-up of static electricity!
This build-up of static electricity can lead to malfunctions when
contacting electrical components.
– Touch a grounded object, before working on electrical equip‐
ment ESD Work Surface - VAS6613- . Do not touch directly
on the connector terminals or the electrical components.
– Place the ABS Hydraulic Unit - N55- with the ABS Control
Module - J104- on the ESD Work Surface - VAS6613- .
– Remove the three TORX
®
bolts from the ABS Control Module
- J104- and set aside immediately (risk of confusing them with
the new TORX
®
bolts).
– Place the ABS Hydraulic Unit - N55- with the ABS Control
Module - J104- upward on the ESD Work Surface - VAS6613- .
– Remove the ABS Control Module - J104- from the ABS Hy‐
draulic Unit - N55- without tilting it.
– Cover ABS Control Module - J104- solenoid coils with a lint-
free cloth.
– Clean the ABS Hydraulic Unit - N55- sealing surface using
mineral spirits and a lint-free cloth.
The ABS Hydraulic Unit - N55- sealing surface must not be
worked with a file, metal scraper, sand paper or similar.
If the ABS Hydraulic Unit - N55- sealing surface is damaged (for
example through grooves or scrapes) the ABS Hydraulic Unit -
N55- must be replaced with the ABS Control Module - J104- .
The seal on the ABS Control Module - J104- must not be pulled
out or raised up.
The seal on the ABS Control Module - J104- cannot be replaced.
3.4
Control Module, Attaching to Hydraulic
Unit
Special tools and workshop equipment required
♦ Torque Screwdriver - VAG1624-
♦ ESD Work Surface - VAS6613-
♦ TORX
®
insert T25
WARNING
Excessive shaking (for example, dropping, impact) can dam‐
age the ABS Control Module - J104- . Do not use the ABS
Control Module - J104- again if this happens.
• Surface must be cleaned before assembling.
– Place the ABS Control Module - J104- on the ABS Hydraulic
Unit - N55- without tilting it.
– Tighten the ABS Hydraulic Unit - N55- and the ABS Control
Module - J104- with the supplied new TORX
®
bolts in two
steps switching back and forth to the tightening specification.
Note
♦
The ABS Hydraulic Unit - N55- threads cannot be re-cut to
secure the ABS Control Module - J104- .
♦
If the threads are damaged, the ABS Hydraulic Unit - N55-
must be replaced.
♦
If the bolts are difficult to remove by hand or cannot be tight‐
ened to the tightening specification then the threads are dam‐
aged.
Tightening Specification
♦ Refer to
⇒ “3.1 Overview - Control Module and Hydraulic Unit”,
Note
♦
A new ABS Control Module - J104- can be installed on an old
ABS Hydraulic Unit - N55- three times, maximum. This as‐
sures the elastic seal will not leak.
♦
A used ABS Control Module - J104- may not be installed a
second time.
3.5
Brake Lines, Attaching to Hydraulic Unit
On Tandem Master Brake Cylinder:
A - Master Brake Cylinder Primary Piston Circuit to the ABS Hy‐
draulic Unit - N55- .
- Identification: 6 mm diameter and tube fitting with a M12 x 1
thread
B - Master Brake Cylinder Secondary Piston Circuit to the ABS
Hydraulic Unit - N55- .
- Identification: 6 mm diameter and tube fitting with a M12 x 1
thread
1 - ABS Hydraulic Unit - N55- to the Left Front Brake Caliper
3 - ABS Hydraulic Unit - N55- to the Left Rear Brake Caliper
4 - ABS Hydraulic Unit - N55- to the Right Rear Brake Caliper
Tightening Sequence:
1 - ABS Hydraulic Unit - N55- to the Right Rear Brake Caliper
- Identification: 5.25 mm diameter and tube fitting with a M12 x 1
short thread
2 - ABS Hydraulic Unit - N55- to the Left Front Brake Caliper
- Identification: 5.25 mm diameter and tube fitting with a M10 x 1
thread
3 - ABS Hydraulic Unit - N55- to the Right Front Brake Caliper
- Identification: 5.25 mm diameter and tube fitting with a M12 x 1
short thread
4 - ABS Hydraulic Unit - N55- to the Left Rear Brake Caliper
- Identification: 5.25 mm diameter and tube fitting with a M10 x 1
thread
5 - ABS Hydraulic Unit - N55- to the Master Brake Cylinder Sec‐
ondary Piston Circuit
- Identification: 6 mm diameter and tube fitting with a M12 x 1
thread
6 - ABS Hydraulic Unit - N55- to the Master Brake Cylinder Pri‐
mary Piston Circuit
- Identification: 6 mm diameter and tube fitting with a M12 x 1
thread
Tightening Specification
♦ Refer to
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