Volkswagen ID.3: ABS, ADR, TCS, EDL, ESP. Control unit and hydraulic unit

• Assembly overview – control unit and hydraulic unit, left-hand drive vehicles
• Assembly overview – control unit and hydraulic unit, right-hand drive
• Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], left-hand drive vehicles
• Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], right-hand drive vehicles
• Separating control unit from and connecting to hydraulic unit
• Connecting brake lines to hydraulic unit, left-hand drive vehicles
• Connecting brake lines to hydraulic unit, right-hand drive vehicles

Assembly overview – control unit and hydraulic unit, left-hand drive vehicles

Assembly overview – control unit and hydraulic unit, left-hand drive vehicles

1 - ABS control unit -J104-

❏ → Rep. gr.45; Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55]

2 - Brake line to rear right wheel brake cylinder

❏ 5.25 mm in diameter and union screw with short M12 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

3 - Brake line to brake caliper, front left

❏ 5.25 mm in diameter and union screw with M10 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

4 - Brake line to brake caliper, front right

❏ 5.25 mm in diameter and union screw with short M12 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

5 - Brake line to rear left wheel brake cylinder

❏ 5.25 mm in diameter and union screw with M10 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

6 - ABS hydraulic unit -N55-

❏ → Rep. gr.45; Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55]

7 - Torx bolt

❏ Qty. 4

❏ Renew after removing

❏ → Fig.

8 - Brake line to secondary piston circuit of brake master cylinder

❏ 6 mm in diameter and union screw with M12 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

9 - Brake line to primary piston circuit of brake master cylinder

❏ 6 mm in diameter and union screw with M12 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

10 - Rubber mounting

11 - Bracket

12 - Brake servo -NX6-

❏ → Rep. gr.47; Assembly overview – brake servo/brake master cylinder

❏ → Rep. gr.47; Removing and installing brake servo

13 - Bolt

❏ Qty. 3

❏ 20 Nm

14 - Bracket

15 - Bolt

❏ Qty. 2

❏ 8 Nm

Installing ABS control unit -J104- - specified torque and tightening sequence

StageBoltSpecified torque/turning further angle1-1- to -4-1.25 Nm2-1- to -4-3.5 Nm

Assembly overview – control unit and hydraulic unit, right-hand drive

Assembly overview – control unit and hydraulic unit, right-hand drive

1 - Brake line to rear right wheel brake cylinder

❏ 5.25 mm in diameter and union screw with short M12 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

2 - Brake line to brake caliper, front left

❏ 5.25 mm in diameter and union screw with M10 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

3 - Brake line to brake caliper, front right

❏ 5.25 mm in diameter and union screw with short M12 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

4 - Brake line to rear left wheel brake cylinder

❏ 5.25 mm in diameter and union screw with M10 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

5 - Brake line to secondary piston circuit of brake master cylinder

❏ 6 mm in diameter and union screw with M12 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

6 - Brake line to primary piston circuit of brake master cylinder

❏ 6 mm in diameter and union screw with M12 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

7 - Torx bolt

❏ Thread-forming

❏ Qty. 4

❏ Renew after removing

❏ → Fig.

8 - ABS hydraulic unit -N55-

❏ → Rep. gr.45; Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55]

9 - Bracket

10 - Bolt

❏ Qty. 2

❏ 20 Nm

11 - Bolt

❏ 20 Nm

12 - Rubber mounting

❏ Qty. 3

13 - Mounting bracket

14 - Bolt

❏ Qty. 2

❏ 8 Nm

15 - ABS control unit -J104-

❏ → Rep. gr.45; Separating control unit from and connecting to hydraulic unit

16 - Brake line from secondary piston circuit to hydraulic unit

❏ 6 mm in diameter and union screw with M12 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

17 - Brake line from primary piston circuit to hydraulic unit

❏ 6 mm in diameter and union screw with M12 × 1 thread

❏ With commercially available standard tool: 14 Nm

❏ With special tools VAS 6854, VAG 1410/7 and VAG 1410/6: 12 Nm

18 - Brake servo -NX6-

❏ → Rep. gr.47; Assembly overview – brake servo/brake master cylinder

❏ → Rep. gr.47; Removing and installing brake servo

Installing ABS control unit -J104- - specified torque and tightening sequence

StageBoltSpecified torque/turning further angle1-1- to -4-1.25 Nm2-1- to -4-3.5 Nm

Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], left-hand drive vehicles

Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], left-hand drive vehicles

Special tools and workshop equipment required

♦ Engine bung set -VAS 6122-

♦ Open ring spanner insert, AF 11mm -V.A.G 1410/6-

♦ Torque wrench -VAS 6854-

♦ Universal joint -V.A.G 1410/7-

♦ assembly tool -V.A.G 1410/8-

♦ brake pedal actuator -V.A.G 1869/2-

For sealing plugs (assembly parts), see electronic parts catalogue (ETKA)

1 - Plugs M10

2 - Plugs M12

Removing

ABS control unit -J104- -1- is referred to hereafter as control unit.

ABS hydraulic unit -N55- -2- is referred to hereafter as hydraulic unit.

– Remove air intake unit of heater and air conditioning unit → Heating, air conditioning system; Rep. gr.87; Front heater and air conditioning unit; Removing and installing air intake unit of heater and air conditioning unit.

– Disconnect battery → Electrical system; Rep. gr.27; Battery; Disconnecting and connecting battery.

– Push locking mechanism in direction of -arrow A-.

– Release electrical connector -1- in direction of -arrow B-.

– Disconnect electrical connector -1-.

– Fit brake pedal actuator -V.A.G 1869/2-.

– Connect bleeder hose of first bleeder bottle to bleeder valve of front left brake caliper -1-.

– Open bleeder valve.

– Connect bleeder hose of second bleeder bottle to bleeder screw of rear left wheel brake cylinder -1-.

– Open bleeder valve.

– Depress brake pedal at least 60 mm using brake pedal actuator -V.A.G 1869/2-.

– Close front left and rear left bleeder valves.

– Do not remove brake pedal actuator -V.A.G 1869/2-.

NOTICE

Risk of damage to brake lines when bending.

– Do not adjust curve of brake lines in area of hydraulic unit.

– Unclip brake lines at bulkhead.

NOTICE

Risk of damage due to corrosion.

– Make sure that no brake fluid gets onto electrical contacts.

– Place sufficient lint-free cleaning cloths in area of electrical connectors.

– Mark brake lines -5- and -6- and unscrew from hydraulic unit.

– Seal threaded holes with plugs.

– Mark brake lines (brake calipers/wheel brake cylinders) -1- to -4-, unscrew them, and seal threaded holes.

– Seal brake lines with engine bung set -VAS 6122-.

Note

As an alternative, fit dust caps of bleeder valves onto brake lines.

– Pull out hydraulic unit and control unit -1- together with bracket -3- and rubber mountings -4- in direction of -arrow-.

Installing

Install in reverse order of removal, observing the following:

♦ The hydraulic unit is pre-filled. Do not remove sealing plugs on the hydraulic unit until the corresponding brake line is installed to ensure a sufficient fill level and venting.

Important

● When installing hydraulic unit, rubber bushes must not pressed out of bracket.

– Use assembly tool -V.A.G 1410/8- to fit brake lines in the sequence -1- to -6-.

– Tighten break lines in the sequence -1- to -6-.

– Remove brake pedal actuator -V.A.G 1869/2-.

– → Rep. gr.47; Bleed hydraulic system.

If the ABS control unit -J104- has been renewed, perform the test plan for renewal of the control unit:

– Carry out function “Renew control unit” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Continued

Tightening torques

Assembling special tools for tightening brake lines

1 - Torque wrench -VAS 6854-

2 - Universal joint -V.A.G 1410/7-

3 - Open ring spanner insert AF 11 -V.A.G 1410/6-

♦ → Rep. gr.45; Assembly overview – control unit and hydraulic unit

♦ → Rep. gr.46; Assembly overview – front brake

♦ → Rep. gr.46; Assembly overview – brake shoes

♦ → Electrical system; Rep. gr.27; Battery; Assembly overview – battery

Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], right-hand drive vehicles

Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55], right-hand drive vehicles

Special tools and workshop equipment required

♦ Engine bung set -VAS 6122-

♦ Open ring spanner insert, AF 11mm -V.A.G 1410/6-

♦ Torque wrench -VAS 6854-

♦ Universal joint -V.A.G 1410/7-

♦ assembly tool -V.A.G 1410/8-

♦ brake pedal actuator -V.A.G 1869/2-

For sealing plugs (assembly parts), see electronic parts catalogue (ETKA)

1 - Plugs M10

2 - Plugs M12

Removing

ABS control unit -J104- is called control unit in this manual.

ABS hydraulic unit -N55- is called hydraulic unit in this manual.

– Remove battery tray → Electrical system; Rep. gr.27; Battery; Removing and installing battery tray.

– Push locking mechanism in direction of -arrow A-.

– Release electrical connector -1- in direction of -arrow B-.

– Disconnect electrical connector -1-.

– Fit brake pedal actuator -V.A.G 1869/2-.

– Connect bleeder hose of first bleeder bottle to bleeder valve of front left brake caliper -1-.

– Open bleeder valve.

– Connect bleeder hose of second bleeder bottle to bleeder screw of rear left wheel brake cylinder -1-.

– Open bleeder valve.

– Depress brake pedal at least 60 mm using brake pedal actuator -V.A.G 1869/2-.

– Close front left and rear left bleeder valves.

– Do not remove brake pedal actuator -V.A.G 1869/2-.

NOTICE

Risk of damage to brake lines when bending.

– Do not adjust curve of brake lines in area of hydraulic unit.

– Unclip brake lines at bulkhead.

NOTICE

Risk of damage due to corrosion.

– Ensure that no brake fluid gets onto electrical contacts.

– Place sufficient lint-free cleaning cloths in area of electrical connectors.

– Mark brake lines -5- and -6- and unscrew from hydraulic unit.

– Seal threaded holes with plugs.

– Mark brake lines (brake calipers/wheel brake cylinders) -1- to -4-, unscrew them, and seal threaded holes.

– Seal brake lines with engine bung set -VAS 6122-.

Note

Alternatively, fit dust caps of bleeder valves onto brake lines.

– Pull out hydraulic unit and control unit -1- together with bracket -3- and rubber mountings -4- in direction of -arrow-.

Installing

Install in reverse order of removal, observing the following:

♦ The hydraulic unit is pre-filled. Do not remove sealing plugs on the hydraulic unit until the corresponding brake line is installed to ensure a sufficient fill level and venting.

Important

● When installing hydraulic unit, rubber bushes must not pressed out of bracket.

– Use assembly tool -V.A.G 1410/8- to fit brake lines in the sequence -1- to -6-.

– Tighten break lines in the sequence -1- to -6-.

– Remove brake pedal actuator -V.A.G 1869/2-.

– → Rep. gr.47; Bleed hydraulic system.

If the control unit has been renewed, carry out the test plan for renewal of control unit:

– Carry out function “Renew control unit” using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Continued

Tightening torques

Assembling special tools for tightening brake lines

1 - Torque wrench -VAS 6854-

2 - Universal joint -V.A.G 1410/7-

3 - Open ring spanner insert AF 11 -V.A.G 1410/6-

♦ → Rep. gr.45; Assembly overview – control unit and hydraulic unit

♦ → Rep. gr.46; Assembly overview – front brake

♦ → Rep. gr.46; Assembly overview – brake shoes

♦ → Electrical system; Rep. gr.27; Battery; Assembly overview – battery

Separating control unit from and connecting to hydraulic unit

Separating control unit from and connecting to hydraulic unit

Special tools and workshop equipment required

♦ ESD workplace VAS 6613 International -VAS 6613-

ABS control unit -J104- is called control unit in this manual.

ABS hydraulic unit -N55- is called hydraulic unit in this manual.

Important

● If the control unit is defective, the control unit must be disconnected from the hydraulic unit and only the control unit renewed.

● If the hydraulic unit is defective, the hydraulic unit must be renewed together with the control unit.

● The seal of the control unit may not be pulled out or raised.

NOTICE

Risk of damage to hydraulic unit caused by removal of the ABS return flow pump.

Malfunction of hydraulic unit.

– Never detach the return flow pump from the hydraulic unit.

– Remove control unit and hydraulic unit → Rep. gr.45; Removing and installing ABS control unit [J104]/ABS hydraulic unit [N55].

NOTICE

Risk of damage to electrical components.

Electrostatic charge may damage electrical components.

– Work on electrical components must always be carried out at an ESD workplace.

– Place control unit with hydraulic unit on ESD workplace -VAS 6613-.

Control unit with 3 bolts

– Unscrew bolts -1- to -3-.

All vehicles (continued)

Control unit with 4 bolts

– Unscrew bolts -1- to -4-.

All vehicles (continued)

– Pull off control unit -1- from hydraulic unit -2- evenly in direction of -arrows-.

– Cover hydraulic unit actuators -2- with a lint-free cleaning cloth.

Connect in reverse order of removal, noting the following:

Important

● If threads of the hydraulic unit are damaged, the hydraulic unit must be renewed.

● If hydraulic unit sealing surface is damaged by scoring or scratches, hydraulic unit must be renewed together with control unit.

● Seal on control unit must not be pulled out or lifted off.

– Clean sealing surfaces between hydraulic unit and control unit using lint-free cleaning cloth.

NOTICE

Risk of damage if installation is not carried out correctly.

Leakage between control unit and hydraulic unit.

– A new control unit must be installed only 3 times.

– Renew control units that have already seen use in a vehicle following removal.

– Place control unit evenly onto hydraulic unit.

Tightening torques

♦ → Rep. gr.45; Assembly overview – control unit and hydraulic unit

Connecting brake lines to hydraulic unit, left-hand drive vehicles

Connecting brake lines to hydraulic unit, left-hand drive vehicles

To hydraulic unit:

1 - Hydraulic unit to rear right wheel brake cylinder

❏ 5.25 mm in diameter and union screw with short M12 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

2 - From hydraulic unit to front left brake caliper

❏ 5.25 mm in diameter and union screw with M10 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

3 - From hydraulic unit to front right brake caliper.

❏ 5.25 mm in diameter and union screw with short M12 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

4 - Hydraulic unit to rear left wheel brake cylinder

❏ 5.25 mm in diameter and union screw with M10 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

5 - From hydraulic unit to secondary piston circuit of brake master cylinder.

❏ 6 mm in diameter and union screw with M12 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

6 - From hydraulic unit to primary piston circuit of brake master cylinder.

❏ 6 mm in diameter and union screw with M12 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

On brake master cylinder:

1 - Brake servo and brake master cylinder

2 - Secondary piston circuit of brake master cylinder to hydraulic unit

❏ Specified torque → Rep. gr.47; Assembly overview – brake servo/brake master cylinder

3 - Primary piston circuit of brake master cylinder to hydraulic unit

❏ Specified torque → Rep. gr.47; Assembly overview – brake servo/brake master cylinder

Connecting brake lines to hydraulic unit, right-hand drive vehicles

Connecting brake lines to hydraulic unit, right-hand drive vehicles

To hydraulic unit:

1 - Hydraulic unit to rear right wheel brake cylinder

❏ 5.25 mm in diameter and union screw with short M12 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

2 - From hydraulic unit to front left brake caliper

❏ 5.25 mm in diameter and union screw with M10 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

3 - From hydraulic unit to front right brake caliper.

❏ 5.25 mm in diameter and union screw with short M12 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

4 - Hydraulic unit to rear left wheel brake cylinder

❏ 5.25 mm in diameter and union screw with M10 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

5 - From hydraulic unit to secondary piston circuit of brake master cylinder.

❏ 6 mm in diameter and union screw with M12 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

6 - From hydraulic unit to primary piston circuit of brake master cylinder.

❏ 6 mm in diameter and union screw with M12 × 1 thread

❏ Specified torque → Rep. gr.45; Assembly overview – control unit and hydraulic unit

7 - Clip

8 - Hydraulic unit

On brake master cylinder:

1 - Brake servo and brake master cylinder

2 - Secondary piston circuit of brake master cylinder to hydraulic unit

❏ Specified torque → Rep. gr.47; Assembly overview – brake servo/brake master cylinder

3 - Primary piston circuit of brake master cylinder to hydraulic unit

❏ Specified torque → Rep. gr.47; Assembly overview – brake servo/brake master cylinder

ABS, ADR, TCS, EDL, ESP. Overview of fitting locationsABS, ADR, TCS, EDL, ESP. Sensors