45 - 5 Hydraulic unit, brake booster/brake master cylinder, assembly overview ABS Bosch 5.3 up to model year 1999 - Vehicles up to VIN 3B X 600 000 With the following versions: ABS; ABS/EDL and ABS/EDL/ASR Brake booster On gasoline engines the vacuum required is taken from the intake manifold. To produce vacuum with diesel engines, a vacuum pump is equipped. Functional check: Page 1 / 49 Volkswagen Passat B5 - Hydraulic unit, brake booster/brake master cylinder
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45 - 5
Hydraulic unit, brake booster/brake master cylinder, assembly overview
ABS Bosch 5.3 up to model year 1999 - Vehicles up to VIN 3B X 600 000
With the following versions: ABS; ABS/EDL and ABS/EDL/ASR
Brake booster
On gasoline engines the vacuum required is taken from the intake manifold.
To produce vacuum with diesel engines, a vacuum pump is equipped.
Removing and installing 47-8, Brake booster, removing and installing (Vehicles up to model year 1999)
Spring
Self-locking nut, 9 Nm
Threaded stud
Rubber bushing
Control module
Removing and installing separately 45-5, ABS Control Module, removing and installing separately
Remove and install together with hydraulic unit 45-5, Control module and hydraulic unit, removing and installing
T 20 torx socket head bolt, 8 Nm
ABS hydraulic unit
Note different versions:
ABS Front Wheel Drive (FWD)
ABS/EDL front and All
- With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
- Depress brake pedal with average foot pressure, hold and start engine. If the booster unit is working properly, the pedal will be felt to give slightly under foot (booster assist becomes effective).
Wheel Drive (AWD) 45-5, Connecting tandem brake master cylinder to hydraulic unit for ABS/EDL front and all wheel drive, as well as ABS/EDL/ASR front wheel drive
ABS/EDL/ASR Front Wheel Drive (FWD) 45-5, Connecting tandem brake master cylinder to hydraulic unit for ABS/EDL front and all wheel drive, as well as ABS/EDL/ASR front wheel drive
Removing and installing 45-5, Control module and hydraulic unit, removing and installing
Brake line connection
Hydraulic unit to right front brake caliper
Brake line connection
Hydraulic unit to left front brake caliper
Brake line
Brake master cylinder/secondary piston circuit to hydraulic unit
Brake line
Brake master cylinder/primary piston circuit to hydraulic unit
- Carefully slide control module - 1 - onto hydraulic unit - 2 - . Make sure valves do not cant.
- Control module housing edge must glide over offset on hydraulic unit.
Note:
Use new bolts.
A new control module may be assembled on an already used hydraulic unit a maximum of two times in order to guarantee the seal of the elastic gaskets.
A control module which was once in driving operation must not be installed a second time.
- Press control module onto hydraulic unit and install new bolts - 1 and 2 - evenly (do not tighten) until control module makes contact evenly on hydraulic unit.
- Install bolts - 1 to 6 - until making contact, do not tighten.
- Now tighten bolts in the specified sequence to tightening torque of 2.5 Nm.
- If control module is codeable, code control module Coding control module using Vehicle Diagnosis, Testing and Information System VAS 5051 , via "Guided Fault Finding" .
Tightening torque: Control module to hydraulic unit 2.5 Nm
Control module and hydraulic unit, removing and installing
Special tools, testers and auxiliary items required
To produce vacuum with diesel engines, a vacuum pump is equipped.
Functional check:
Removing and installing 47-8, Brake booster, removing and installing (vehicles as of model year 2000)
Brake line connection
To left rear brake caliper
Marked on hydraulic unit with "HL"
Brake line connection
To right rear brake caliper
Marked on hydraulic unit with "HR"
Brake line
Brake master cylinder/secondary piston circuit to hydraulic unit
Brake line
- With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
- Depress brake pedal with average foot pressure, hold and start engine. If the booster unit is working properly, the pedal will be felt to give slightly under foot (booster assist becomes effective).
Removing and installing 47-7, Brake master cylinder, removing and installing (Vehicles as of model year 2000)
T 45 torx socket head bolt, 25 Nm
Self-locking nut, 49 Nm
Sealing plug
Moisten with brake fluid and press into brake fluid reservoir
Brake fluid reservoir
Sealing ring
Cap
Vacuum hose
Insert into brake booster unit
Seal ring
Connecting tandem master cylinder brake lines to hydraulic unit for ABS/EDL front and all wheel drive (AWD), as well as ABS/EDL/ASR front wheel drive (FWD)
A new control module may be assembled on an already used hydraulic unit a maximum of two times in order to guarantee the seal of the elastic gaskets.
A control module which was once in driving operation must not be installed a second time.
- Press control module onto hydraulic unit and install new bolts - 1 and 2 - evenly (do not tighten) until control module makes contact evenly on hydraulic unit.
- Install bolts - 1 to 6 - until making contact, do not tighten.
- Now tighten bolts in the specified sequence to tightening torque of 2.5 Nm.
- If control module is codeable, code control module Coding control module using Vehicle Diagnosis, Testing and Information System VAS 5051 , via "Guided Fault Finding" .
Tightening torque: Control module to hydraulic unit 2.5 Nm
Control module and hydraulic unit, removing and installing
Special tools, testers and auxiliary items required
Torque wrench V.A.G 1331
Brake pedal loading device V.A.G 1869/2
If the hydraulic unit is faulty the whole assembly must be replaced. If the control module is faulty it can be replaced separately from the hydraulic unit.
Location:
The control module is bolted to the hydraulic unit and is located in the engine compartment, on the left side.
On gasoline engines the vacuum required is taken from the intake manifold.
To produce vacuum with diesel engines, a vacuum pump is equipped.
Functional check:
Removing and installing 47-8, Brake booster, removing and installing (Vehicles up to model year 1999)
Brake line connection
To left rear brake caliper
Marked on hydraulic unit with "HL"
Brake line connection
To right rear brake caliper
Marked on hydraulic unit with "HR"
Rubber bushing
Hex head bolt, 9 Nm
- With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
- Depress brake pedal with average foot pressure, hold and start engine. If the booster unit is working properly, the pedal will be felt to give slightly under foot (booster assist becomes effective).
- Remove power steering fluid reservoir - 1 - and set aside with hoses connected.
- Remove coolant reservoir - 2 - and set aside with coolant hoses connected.
- Remove brake lines to the hydraulic unit and hydraulic pump for traction control.
- Disconnect connector from hydraulic pump for traction control.
- Remove brake fluid supply hose from hydraulic pump for traction control.
- Plug brake lines and threaded holes with sealing plugs from repair kit Part No. 1H0 698 311 A.
- Remove bolts on hydraulic unit bracket
- Remove hydraulic unit with traction control hydraulic pump upward.
Installing
Note:
Remove sealing plugs on new hydraulic unit when the corresponding brake line is going to be connected.
- Installation is in reverse order of removal.
To bleed the brake system, it is first necessary to activate the hydraulic pump for traction control V156 .
- Perform the activation of the hydraulic pump for traction control in the base setting display group number 2. Perform base setting in Vehicle diagnostic, test and information system in Guided Fault Finding.
Removing and installing 47-8, Brake booster, removing and installing (vehicles as of model year 2000)
Brake line connection
To left rear brake caliper
Marked on hydraulic unit with "HL"
Brake line connection
To right rear brake caliper
Marked on hydraulic unit with "HR"
Brake line
Brake master cylinder/secondary piston circuit to hydraulic unit
Marked on hydraulic unit with "HZ2"
Brake line
Hydraulic unit to hydraulic pump for traction control
Marked on hydraulic unit with "VLP"
Identification on the
the vacuum in the unit).
- Depress brake pedal with average foot pressure, hold and start engine. If the booster unit is working properly, the pedal will be felt to give slightly under foot (booster assist becomes effective).
- Plug brake lines and threaded holes with sealing plugs from repair kit Part No. 1H0 698 311 A.
- Disconnect connector from hydraulic pump for traction control.
- Pull off brake fluid supply hose from the hydraulic pump for traction control.
- Unfasten bolts on bracket for hydraulic unit.
- Remove the hydraulic unit with hydraulic pump for traction control upward.
Installing
Remove sealing plugs on new hydraulic unit when the corresponding brake line is going to be installed.
- Further installation is in the reverse sequence of removal.
To bleed the brake system, it is first necessary to activate the hydraulic pump for traction control V156 .
- Perform the activation of the hydraulic pump for traction control in the base setting display group number 2 Perform base setting in "Guided Fault Finding" with Vehicle diagnostic, test and information system VAS 5051 .
For this, use the Sprung button in the "Functions/Component selection" .
- Bleed brake system 47-4, Braking system, bleeding .
- Enter radio code.
- Perform control module coding Coding the control module with the Vehicle diagnostic, test and information system in . Guided Fault Finding
Tightening torques: Brake lines to ABS assembly and hydraulic pump for traction control: Thread M 10 x 1 14 NmThread M 12 x 1 14 Nm
Nut for ABS hydraulic unit N55 to bracket Item - 7 - .
Nut for Hydraulic pump for traction control V156 to bracket Item - 17 - .
Removing and installing 47-9, Brake master cylinder with brake booster
Brake line
Brake master cylinder/primary piston circuit to hydraulic unit
Marked on hydraulic unit with "HZ1"
Brake line
Brake master cylinder/secondary piston circuit to hydraulic unit
Marked on hydraulic unit with "HZ2"
Brake line
To left front brake caliper
Marked on hydraulic unit with "VL"
Brake line
To right front brake caliper
Marked on hydraulic unit
depress brake pedal firmly several times (to exhaust the vacuum in the unit).
- Depress brake pedal with average foot pressure, hold and start engine. If the booster unit is working properly, the pedal will be felt to give slightly under foot (booster assist becomes effective).
ABS Control Module J104 and ABS Hydraulic Unit N55 , removing and installing
Special tools, testers and auxiliary items required
Torque wrench V.A.G 1331
Brake pedal loading device V.A.G 1869/2
If the hydraulic unit is faulty the whole assembly must be replaced. If the control module is faulty it can be replaced separately from the hydraulic unit.
Location:
The control module is bolted to the hydraulic unit and is located in the engine compartment on the left side.
Warning!
Do not bend the brake lines in the area of the hydraulic unit!
- Plug brake lines and threaded holes with sealing plugs from the repair kit Part No. 1H0 698 311 A.
- Release locking clips - 1 - from below and remove in direction of - arrow - .
- Remove hydraulic unit with control module.
Installing
Note:
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, and can no longer be guaranteed that the unit is sufficiently filled or adequately bled.
- Installation is in reverse order of removal.
- Bleeding brake system 47-4, Braking system, bleeding .
- Enter radio code.
- Perform control module coding Coding the control module with the Vehicle diagnostic, test and information system in . Guided Fault Finding
Tightening torques: Brake lines to ABS module: Thread M 12 x 1, SW11 14 NmThread M 12 x 1, SW12 24 Nm