Hydraulic unit, brake booster/brake master cylinder, …doc.vwclub.org.ua/brake/b5/b5_45-05.pdf · - Bleeding brake system 47-4, Braking system, bleeding . - Enter radio code. - If

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

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).

- If faulty, replace completely.

Page 2 / 49Hydraulic unit, brake booster/brake master cylinder, assembly overview

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


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


Hydraulic unit to left rear brake caliper



Hydraulic unit to right rear brake caliper

Bracket

Hex head bolt, 9 Nm

Bracket


Self-locking hex nut, 49 Nm

Tandem brake master cylinder

With seal

Cap

Brake fluid reservoir

Connecting brake lines from tandem master cylinder to ABS hydraulic unit

A - Secondary piston circuit

B - Primary piston circuit

1 - Hydraulic unit to left rear brake caliper

2 - Hydraulic unit to right rear brake caliper

3 - Hydraulic unit to right front brake caliper

4 - Hydraulic unit to left front brake caliper


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 Control Module, removing and installing separately

Special tools, testers and auxiliary items required

Torque Wrench (5-60 Nm) VAG1783

- For vehicles equipped with coded anti-theft radio, note radio code, obtain if necessary.

- Disconnect battery.

- Remove left front wheel.


- Remove left front wheel housing liner

.

Repair Manual, Body Exterior, Repair Group 66, Wheel housing liner

- Loosen power steering fluid reservoir.

- Remove tank for windshield washer system

.

Repair Manual, Electrical Equipment, Repair Group 92, Windshield washer system

- Thoroughly clean control module, hydraulic unit and surrounding area.

- Vacuum clean control module, hydraulic unit and surrounding area in order to prevent dirt and moisture from entering the unit.

- Disengage connector - arrow 1 - and disconnect - arrow 2 - from control module.


- Disengage and disconnect harness connector - 1 - .

- Remove bolts - 1 - and pull control module - 2 - off hydraulic unit without canting.

- Clean sealing surface - 2 - using plastic scraper - 1 - enclosed.

- Check valves - 3 - for damage.

Note:

Do not use aggressive cleaning agents (use cleaning agent enclosed).

Check sealing surface for damage (visual check).

Caution!

No moisture or particles of dirt must penetrate in interior of control module.

If sealing surface or contact tags are damaged, hydraulic unit must be replaced.

Excessive shaking (e.g. dropping, impact) may destroy the control module. Control module must then no longer be used.


- 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.


- Install harness connector - 1 - .

- Code radio.

- 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


Torque wrench V.A.G 1331


Brake pedal loading device V.A.G 1869/2

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!

Removing

- Note or request radio code on vehicles with coded radio if necessary.


- Release control module connector - arrow 1 - and pull off - arrow 2 - .

- Connect bleeder bottle hose to left front brake caliper bleeder screw and open bleeder screw.

- Install brake pedal loading device V.A.G 1869/2 .

- Depress brake pedal with brake pedal loading device V.A.G 1869/2 .


- Close left front bleeder screw.

- Place sufficient lint-free cloths under control module and hydraulic unit.

- Disconnect brake lines from the hydraulic unit.

- Plug brake lines and threaded holes with sealing plugs from the repair kit Part No. 1H0 698 311 A.

- Remove nuts on hydraulic unit bracket - arrows - .

- Remove hydraulic unit with control module.

Installing

Note:

Remove sealing plugs on new hydraulic unit when the corresponding brake line is going to be connected.

If the sealing plugs are removed too early, brake fluid can escape, and can no longer be guaranteed that the unit is filled or adequately bled.

- Installation is in reverse order of removal.

- Bleeding brake system 47-4, Braking system, bleeding .

- Enter radio code.

- If control module can be coded, then code control module 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 10 x 1 14 Nm


Thread M 12 x 1 14 Nm

Hydraulic unit hex to bracket Item - 3 -

ABS Bosch 5.3 from model year 2000 - Vehicles from VIN 3B Y 000 001

With the following versions: ABS; ABS/EDL and ABS/EDL/ASR

Tandem brake booster


As of model year 2001, vehicles with a gasoline engine and automatic transmission are equipped with a brake vacuum pump

47-6, Brake system vacuum pump V192 .



Functional check:

Removing and installing 47-8, Brake booster, removing and installing (vehicles as of model year 2000)


To left rear brake caliper

Marked on hydraulic unit with "HL"


To right rear brake caliper

Marked on hydraulic unit with "HR"

Brake line


Brake line






Brake line

To left front brake caliper

Marked on hydraulic unit with "VL"

Hex nut, 12 Nm

Threaded stud

Rubber bushing

Control module and hydraulic unit

Control Module, removing and installing separately 45-5, ABS Control Module, removing and installing separately

Control module and hydraulic unit, removing and installing 45-5, Control module and hydraulic unit, removing and installing

Brake line

To right front brake caliper

Marked on hydraulic unit with "VR"

Bracket

Hex head bolt, 9 Nm

Bracket

Application Parts Catalog

Rubber bushing

Hex head bolt


Tandem master cylinder

Cannot be repaired. If faulty, replace.

Removing and installing 47-7, Brake master cylinder, removing and installing (Vehicles as of model year 2000)



Sealing plug

Moisten with brake fluid and press into 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)








ABS Control Module, removing and installing separately



- For vehicles equipped with coded anti-theft radio, note radio code, obtain if necessary.


- Remove left front wheel.

- Remove left front wheel housing liner

.

Repair Manual, Body Exterior, Repair Group 66, Wheel housing liner

- Loosen power steering fluid reservoir.

- Remove tank for windshield washer system

Repair Manual, Electrical Equipment, Repair Group 92, Windshield washer system


.

- Thoroughly clean control module, hydraulic unit and surrounding area.

- Vacuum clean control module, hydraulic unit and surrounding area in order to prevent dirt and moisture from entering the unit.

- Disengage connector - arrow 1 - and disconnect - arrow 2 - from control module.

- Disengage and disconnect harness connector - 1 - .

- Remove bolts - 1 - and pull control module - 2 - off hydraulic unit without canting.


- Clean sealing surface - 2 - using plastic scraper - 1 - enclosed.

- Check valves - 3 - for damage.

Note:

Do not use aggressive cleaning agents (use cleaning agent enclosed).

Check sealing surface for damage (visual check).

Caution!

No moisture or particles of dirt must penetrate in interior of control module.

If sealing surface or contact tags are damaged, hydraulic unit must be replaced.

Excessive shaking (e.g. dropping, impact) may destroy the control module. Control module must then no longer be used.

- 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.

- Install harness connector - 1 - .

- Code radio.


- 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




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!



Removing



- Release control module connector - arrow 1 - and pull off - arrow 2 - .





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

- Detach brake lines from the hydraulic unit.



- Unfasten nuts on hydraulic unit bracket - arrows - .


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 filled or adequately bled.

- Further Installation is in reverse order of removal.

- 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 module: Thread M 10 x 1 14 NmThread M 12 x 1 14 Nm

Hydraulic unit nut to bracket Item - 7 -

ABS/EDL/ASR/ESP Bosch 5.3, assembly overview, up to model year 1999 - Vehicles up to VIN 3B X 600 000



With seal


Cap


Brake line

Brake master cylinder/primary piston circuit to hydraulic pump for traction control

Identification on the hydraulic pump for traction control "HZ"


Brake booster



Functional check:

Removing and installing 47-8, Brake booster, removing and installing (Vehicles up to model year 1999)







Rubber bushing

Hex head bolt, 9 Nm





Brake line


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 hydraulic pump for traction control "HE"

Brake line



Hex nut

8 mm with 12 Nm

6 mm with 9 Nm

Threaded stud

Brake line



ABS hydraulic unit

Bracket

Bracket

Hydraulic pump for traction control


Brake pressure sensor

Always replace together with the hydraulic pump for traction control.

Connection for brake fluid from brake fluid reservoir

Identification on the hydraulic pump for traction control "BA"

Connection for the hydraulic pump for traction control

Torx socket head bolt T45, 25 Nm

Connection of brake lines from tandem master cylinder and the hydraulic pump for traction control to the hydraulic unit for ABS/EDL/ASR and ESP

A - Hydraulic unit to hydraulic pump for traction control

- Marked on hydraulic unit with VLP

- Identification on the hydraulic pump for traction control HE

B - Hydraulic unit to master cylinder secondary piston circuit

- Marked on hydraulic unit with HZ2


- Marked on hydraulic unit with VL



- Marked on hydraulic unit with VR


- Marked on hydraulic unit with HR


- Marked on hydraulic unit with HL

ABS Hydraulic Unit N55 with Hydraulic pump for traction control V156 , removing and installing





The ABS hydraulic unit N55 and the hydraulic pump for traction control V156 are located in left side of engine compartment.

1 - Hydraulic unit with ABS return flow pump

The hydraulic unit and ABS return flow pump form one unit and must always be replaced together if malfunction exists.

2 - Hydraulic pump for traction control with brake pressure sensor.

The hydraulic pump for traction control and the brake pressure sensor form one unit and must always be replaced together if malfunction exists.

Warning!


Removing




- Release hydraulic unit connector - arrow 1 - and pull off - arrow 2 - .





- Place sufficient lint-free cloths under hydraulic unit.

Make sure no brake fluid gets onto contacts.

These procedures are only for removing the hydraulic unit.


- Plug brake lines and threaded holes with sealing plugs from repair kit Part No. 1H0 698 311 A.

- Remove nuts on hydraulic unit bracket - arrows - .


These procedures are for removing the hydraulic unit


and the hydraulic pump for traction control

- 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.


- 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.


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.


For this, use the Go to button in the "Functions/Component selection" .


- Enter radio code.

- Code control module 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 - 14 - .

Nut for Hydraulic pump for traction control V156 to bracket Item - 14 - .

Bracket hex bolt to body Item - 10 - .

ABS/EDL/ASR/ESP Bosch 5.3, assembly overview, from model year 2000 - Vehicles from VIN 3B Y 000 001




As of model year 2001, vehicles with a gasoline engine and automatic transmission are equipped with a brake vacuum pump

47-6, Brake system vacuum pump V192 .


Functional check:

- With engine switched off, depress brake pedal firmly several times (to exhaust


Removing and installing 47-8, Brake booster, removing and installing (vehicles as of model year 2000)







Brake line



Brake line

Hydraulic unit to hydraulic pump for traction control

Marked on hydraulic unit with "VLP"

Identification on the

the vacuum in the unit).




hydraulic pump for traction control "HE"

Brake line



Hex nut, 12 Nm

Threaded stud

Rubber bushing

ABS hydraulic unit

Brake line



Bracket

Hex head bolt, 9 Nm

Rubber bushing

Hydraulic pump for traction control

Brake line

Brake master cylinder/primary piston circuit to hydraulic pump for traction control

Identification on the hydraulic pump for traction control "HZ"

Hex nut, 9 Nm

Rubber bushing

Connection for traction control hydraulic pump

Connection for brake fluid from


brake fluid reservoir

Identification on the hydraulic pump for traction control "BA"

Brake pressure sensor

Always replace together with the hydraulic pump for traction control.

Bracket


Rubber bushing

Hex head bolt


Cannot be repaired. If faulty, replace completely.

Removing and installing 47-7, Brake master cylinder, removing and installing (Vehicles as of model year 2000)



Sealing plug



Seal ring

Cap

Vacuum hose



Seal ring

Connection of brake lines from tandem master cylinder and the hydraulic pump for traction control to the hydraulic unit for ABS/EDL/ASR and ESP

A - Hydraulic unit to hydraulic pump for traction control

- Marked on hydraulic unit with VLP ,

- Identification on the hydraulic pump for traction control HE











ABS Hydraulic Unit N55 with Hydraulic pump for traction control V156 , removing and installing





The ABS hydraulic unit N55 and hydraulic pump for traction control V156 are located in the left side of engine compartment.


1 - Hydraulic unit with ABS return flow pump

The hydraulic unit and ABS return flow pump form one unit and must always be replaced together if malfunction exists.

2 - Hydraulic pump for traction control with brake pressure sensor.

The hydraulic pump for traction control and the brake pressure sensor form one unit and must always be replaced together if malfunction exists.

Warning!


Removing



- Release hydraulic unit connector - arrow 1 - and pull off - arrow 2 - .





- Place sufficient lint-free cloths under hydraulic unit.


These procedures are only for removing the hydraulic unit.




- Remove hex nuts on bracket for hydraulic unit - arrows - .


These procedures are for removing the ABS hydraulic unit N55 and the hydraulic pump for traction control V156

- Remove power steering fluid reservoir - 1 - and set aside with hoses connected.

- Remove coolant reservoir - 2 - and set aside with coolant hoses connected.

Vehicles with electrical vacuum pump

- Remove electrical vacuum pump 47-6, Brake system vacuum pump V192 , removing and installing .

Continued for all vehicles

- Remove brake lines to the hydraulic unit and hydraulic pump for traction control.



- 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


- 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" .


- 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 - .

Bracket hex bolt to body Item - 13 - .


ABS/EDL/ASR/ESP Bosch 5.7, assembly overview, as of model year 2002



Vehicles with a gasoline engine and automatic transmission are equipped with a vacuum pump for brakes 47-6, Brake system vacuum pump V192


Functional check:

- With engine switched off,


With adhesive seal

Removing and installing 47-9, Brake master cylinder with brake booster

Brake line



Brake line



Brake line



Brake line


Marked on hydraulic unit

depress brake pedal firmly several times (to exhaust the vacuum in the unit).




with "VR"

Brake line



Brake line



Brake Pressure Sensor 1 G201

Removing and installing 45-5, Brake Pressure Sensor 1 G201 , removing and installing

ABS hydraulic unit

ABS control module

Locking clip

Buffer

Bracket


Hex head bolt, 9 Nm

Seal ring


Cannot be repaired. If faulty, replace completely.

Removing and installing together with brake booster

47-9, Brake master cylinder with brake booster

Self-locking hex nut, 49 Nm


T45 torx socket head bolt, 25 Nm


Cap

Sealing plug


Dowel bolt, 10 Nm

Vacuum hose


Connecting brake lines from tandem master cylinder to hydraulic unit

A - Hydraulic unit to master cylinder primary piston circuit













ABS Control Module J104 and ABS Hydraulic Unit N55 , removing and installing




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!


Removing




Note:

The hydraulic control unit - 1 - for the W8 is rotated 180 .

- Remove coolant expansion tank - 2 - and set aside with coolant hoses connected.

- Release and remove connector from control module in the direction of - arrow - .

- Disconnect connector from brake pressure sensor.





- Place lint-free cloths under the control module and


hydraulic unit.


- Disconnect brake lines from the hydraulic unit.


- Release locking clips - 1 - from below and remove in direction of - arrow - .


Installing

Note:


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.


- 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


Brake Pressure Sensor 1 G201 , removing and installing

The Brake Pressure Sensor 1 G201 is located on the hydraulic control unit - 1 - .

Note:

The hydraulic control unit - 1 - for the W8 is rotated 180 .

Removing

This work procedure does not apply to the W8:

- Unfasten coolant expansion tank - 2 - and set aside with coolant hoses connected.

This work procedure applies only to the W8:

- Unfasten power steering fluid reservoir - 3 - and set aside with hoses connected.

Continued for all vehicles


- Disconnect connector - 1 - from brake pressure sensor - 2 - .

- Place lint-free cloths under control module and hydraulic unit.

- Remove brake pressure sensor.

Installing


Tightening torque: Brake Pressure Sensor 1 G201 20 Nm



Documents

Hydraulic unit, brake booster/brake master cylinder, …doc.vwclub.org.ua/brake/b5/b5_45-05.pdf · - Bleeding brake system 47-4, Braking system, bleeding . - Enter radio code. - If