SKODA Rapid NH 2013, Rapid NH 2014 Workshop Manual
Service
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Workshop Manual
Rapid NH 2013 ➤
Rapid NH 2014 ➤
Brake systems
Edition 07.2017
Service Department. Technical Information
List of Workshop Manual Repair Groups
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Re pa ir G ro up
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
Service
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
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Rapid NH 2013 ➤ , Rapid NH 2014 ➤
Brake systems - Edition 07.2017
00 - Technical data
1 Safety instructions
1.1 Safety precautions when working on vehicles with start-stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions during road tests in which testing and measuring equipment is used . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 PR number assignment – brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Brake inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
45 - Anti-lock brake system
1 General points
1.1 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Installation location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Installation location overview - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Installation location overview - ABS/ESC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Exploded view – control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 . . . . . . . . . . . . . . 25
3.3 Disconnecting the control unit from the hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 Fitting the control unit to the hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.1 Removing and installing front speed sensors G45 / G47 . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Removing and installing the rear speed sensors G44 / G46 . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
46 - Brakes - mechanism
1 Front brakes
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.2 Removing and installing brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.2 Removing and installing brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Resetting brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.5 Removing and installing brake anchor plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.6 Removing and installing wheel-brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.7 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1 Assembly overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.2 Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.3 Removing and installing the rear handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.2 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.3 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.4 Clipping the brake pedal onto the brake servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.5 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
47 - Brakes - hydraulics
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
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Brake systems - Edition 07.2017
1 Front brake calipers
1.1 Summary of components - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2 Rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Summary of components - rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Brake servo unit and master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.1 Summary of components - brake servo unit and master brake cylinder . . . . . . . . . . . . . . 101
3.2 Check the operation of the brake servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.3 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.4 Checking the master brake cylinder for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.5 Removing and installing master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.6 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.1 Exploded view – vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.2 Checking the non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.3 Checking the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.4 Connecting vacuum gauge for brake servo VAS 6721 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.5 Checking vacuum generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.6 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.7 Vacuum generation with manual vacuum pump VAS 6213 . . . . . . . . . . . . . . . . . . . . . . . . 143
4.8 Removing and installing the pressure sensor for the brake servo unit . . . . . . . . . . . . . . . . 144
4.9 Removing and installing vacuum sensor G608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.10 Removing and installing electric vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.1 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.2 Prebleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.3 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 153
6.4 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
6.5 Testing leak-tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
ii Contents
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00 – Technical data
1 Safety instructions
(SRL001107; Edition 07.2017)
⇒ “1.1 Safety precautions when working on vehicles with startstop system”, page 1
⇒ “1.2 Safety precautions during road tests in which testing and
measuring equipment is used”, page 1
1.1 Safety precautions when working on ve‐
hicles with start-stop system
When working on vehicles with start/stop system, please observe
the following instructions:
CAUTION
Risk of injury as a result of automatic engine start in vehicles
with start/stop system.
♦ In vehicles with the start/stop system activated (identifiable
by
an indication in the dash panel insert) the engine can start
automatically if required.
♦ Make sure that the start-stop system is deactivated when
carrying out work on the vehicle (switch ignition off, if nec‐
essary switch ignition on again).
Brake systems - Edition 07.2017
1.2 Safety precautions during road tests in
which
testing and measuring equipment
is used
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
There is a risk of accident from deflection and insufficient se‐
curing of testers and measuring instruments.
♦ Using testers and measuring instruments during driving op‐
eration causes distraction.
♦ There is an increased risk of injury from unsecured testers
and measuring instruments.
♦ Always attach the testing and measurement equipment to
the rear seat.
♦ Always have the testing and measurement equipment op‐
erated by a 2nd person.
♦ Always operate the testing and measurement equipment
from the rear seat.
♦ Do not operate the testing and measurement equipment
from the front passenger seat.
♦ Persons can be injured by the release of the passenger air‐
bag in the event of an accident.
1. Safety instructions 1
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Brake systems - Edition 07.2017
2 Identification
⇒ “2.1 PR number assignment – brake”, page 2
2.1 PR number assignment – brake
The brake type installed in the vehicle is indicated by PR num‐
bers.
The PR numbers are indication on the vehicle data sticker in the
luggage compartment floor as well as in the Service Schedule.
Information about the installed brakes can be found in the ELSA
Pro vehicle data system.
Assignment is dependent on the engine type ⇒ Electronic Cata‐
logue of Original Parts .
2 Rep. gr.00 - Technical data
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3 Technical data
⇒ “3.1 Technical data for brakes”, page 3
3.1 Technical data for brakes
⇒ “3.1.1 Master brake cylinder and brake servo”, page 3
⇒ “3.1.2 Front brakes”, page 3
⇒ “3.1.3 Rear brake”, page 4
⇒ “3.1.4 Brake fluid”, page 4
3.1.1 Master brake cylinder and brake servo
Assignment is dependent on the engine type ⇒ Electronic Cata‐
logue of Original Parts .
Brake systems - Edition 07.2017
Master brake cyl‐
inder - ∅
Brake servo unit
- ∅
mm 20.64
InchLeft-hand drive: 10
Right-hand drive: 7"/8"
3.1.2 Front brakes
Assignment is dependent on the engine type ⇒ Electronic Cata‐
logue of Original Parts .
Explanations concerning PR Numbers
⇒ “2.1 PR number assignment – brake”, page 2 .
Front brake FS-III
Front brake caliper (type denomination) FS-III
PR number
Front brake caliper, piston - ∅ m
Front brake disc – ∅ m
Brake disc, thickness m
Brake disc, minimum thickness m
Pad thickness with supporting plate m
Minimum pad thickness without sup‐
porting plate
m
m
m
m
m
m
m
1ZG
54.0
256.0
22.0
19.0
19.6
2.0
Front brake FN3
Front brake caliper (type denomination) FN3
PR number
Front brake caliper, piston - ∅ m
Front brake disc – ∅ m
Brake disc, thickness m
Brake disc, minimum thickness m
m
m
m
m
1ZC
54.0
288.0
25.0
22.0
3. Technical data 3
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Brake systems - Edition 07.2017
Front brake caliper (type denomination) FN3
PR number
Pad thickness with supporting plate m
Minimum pad thickness without sup‐
porting plate
m
m
m
1ZC
20.6
2.0
3.1.3 Rear brake
Assignment is dependent on the engine type ⇒ Electronic Cata‐
logue of Original Parts .
Explanations concerning PR Numbers
⇒ “2.1 PR number assignment – brake”, page 2 .
Rear disc brake C 38
Rear brake caliper (type denomination) C 38
PR number
Rear brake caliper, piston - ∅ m
Rear brake disc – ∅ m
Brake disc, thickness m
Brake disc, minimum thickness m
Pad thickness with supporting plate m
Minimum pad thickness without sup‐
porting plate
m
m
m
m
m
m
m
1KT
38
230
9
7
16.9
2.0
Rear drum brake
Rear drum brake
PR number
Brake drum - diameter ∅ m
Wheel-brake cylinder - ∅ m
Brake pad, width m
Pad thickness without supporting shoe m
Minimum pad thickness without sup‐
porting shoe
3.1.4 Brake fluid
m
m
m
m
m
m
1KL
228
19.05
4.4
1.0
32
4 Rep. gr.00 - Technical data
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Brake systems - Edition 07.2017
Classification Only use new original brake fluid N.052.766.Z0 as per US standard FMVSS 571.116, DOT 4 and VW standard 501 14
Top-up ⇒ Maintenance ; Booklet Rapid NH
5
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Brake systems - Edition 07.2017
4 Brake inspection
⇒ “4.1 General points”, page 6
⇒ “4.2 Checking vehicles with front-wheel drive”, page 6
4.1 General points
♦ The test stand is used as drive.
♦ During the testing, the idling speed must be set on vehicles
with manual gearbox and the driving position »N« must be
engaged on vehicles with automatic gearbox.
♦ When conducting the test, observe the specifications provided
by the manufacturer of the test rig.
Note
The brake regulation systems do not function when ignition is off.
4.2 Checking vehicles with front-wheel drive
The brake test must be performed on a single-axle roller dyna‐
mometer.
The test speed must not exceed 6 km/h.
The test stands approved by Škoda comply with these conditions.
6
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45 – Anti-lock brake system
1 General points
⇒ “1.1 Repair instructions for repair work on ABS”, page 7
1.1 Repair instructions for repair work on ABS
The following configurations are possible on vehicles with ABS
from TRW:
♦ ABS
♦ ABS/ESC
The ABS brake system is split diagonally. Brake servo assistance
is provided pneumatically by the vacuum brake servo.
Vehicles fitted with ABS do not have a mechanical brake pressure
regulator.
J104- regulates the brake pressure distribution on the rear axle.
Specifically matched software in the ABS control unit -
Brake systems - Edition 07.2017
Note
♦
If the ABS hydraulic unit - N55- is damaged, the ABS control
unit - J104- must be fully replaced with the ABS hydraulic unit
- N55- .
♦
The ABS control unit - J104- can be separated from the ABS
hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”,
page 32 .
♦
The hydraulic pump and the ABS hydraulic unit - N55- must
not be separated from each other.
♦
Faults in the ABS do not influence the brake system and servo
assistance. The conventional braking system remains fully
functional even without ABS. There will be a change in braking
behaviour. After the ABS warning lamp comes on, the rear
wheels may lock prematurely during braking.
ABS arrangement, left-hand drive to CW 21/2015
1 - ABS hydraulic unit - N55- with ABS control unit - J1042 - Brake servo
1. General points 7
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Brake systems - Edition 07.2017
ABS arrangement, left-hand drive to CW 22/2015
1 - Brake servo
2 - ABS hydraulic unit - N55- with ABS control unit - J104-
Arrangement of the ABS, right-hand drive vehicle
1 - Brake servo
2 - ABS hydraulic unit - N55- with ABS control unit - J104Vehicles with ABS
The ABS control unit - J104- -1-
-2- form a single unit and cannot be separated. The hydraulic
pump -3- must not be separated from the ABS hydraulic unit N55- -2-.
Vehicles with ABS / ESC to 04/2015
The ABS control unit - J104- -1-
-2- form a single unit and cannot be separated. The hydraulic
pump -3- must not be separated from the ABS hydraulic unit N55- -2-.
Vehicles with ABS / ESC from 05/2015
and the ABS hydraulic unit - N55-
and the ABS hydraulic unit - N55-
8 Rep. gr.45 - Anti-lock brake system
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Brake systems - Edition 07.2017
The ABS control unit - J104- -1-
-2- form a single unit. They can only be separated after the
complete unit is removed. The ABS control unit - J104- can be
separated from the ABS hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page
32
. The hydraulic pump -3- must not be separated from the ABS
hydraulic unit - N55- -2-.
New control units supplied by the spare parts area are not coded.
They must be coded after installation ⇒ Vehicle diagnostic tester.
Continued for all vehicles
♦ Before starting work on anti-lock brake systems, query the
event memory to check for complaints and conduct guided
fault finding ⇒ Vehicle diagnostic tester.
♦ Do not separate plug connections unless the ignition is switch‐
ed off.
♦ Before working on anti-lock braking systems, switch off the
ignition and disconnect the ground strap from the battery ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnect and con‐
nect battery .
♦ If the battery earth strap is disconnected and connected, carry
out additional operations ⇒ Electrical System; Rep. gr. 27 ;
Battery .
♦ Welding work using electric welding equipment may affect the
ABS system.
♦ Do the following before commencing welding work using elec‐
trical welding tool:
– Disconnect the earth strap from the negative terminal of the
battery and cover the negative terminal.
– Connect the earth connection of the electric welding tool di‐
rectly to the part to be welded. There must not be any electri‐
cally insulated parts between the earth connection and the
welding point.
– Electronic control units and electrical wiring must not touch the
earth connection or the welding electrode.
♦ During painting operations, the ABS control unit - J104- may
be exposed to a maximum temperature of 95 °C for only a
short period, and to a maximum of 85 °C for longer periods
(approx. 2 hours).
♦ Do not drive the vehicle if the connector is unplugged from the
ABS control unit - J104- .
♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean connection points and the surrounding area
before disconnecting, but do not use any aggressive cleaning
agents, such as brake cleaner, petroleum, thinner or similar.
♦ Place removed parts on a clean surface and cover.
♦ Carefully cover or close opened components if the repair is not
completed immediately (use plugs from the repair kit - 1H0 698
311 A- ).
♦ Only use lint-free cloths.
♦ Do not remove spare parts from their wrappings until immedi‐
ately before installation.
♦ Use only genuine wrapped parts.
and the ABS hydraulic unit - N55-
1. General points 9
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Brake systems - Edition 07.2017
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ The valve coils in the ABS control unit - J104- must not be
calibrated.
♦ The valve coils in the ABS control unit - J104- cannot be re‐
placed.
♦ The pressure sensor must not be modified or damaged.
♦ The pressure sensor cannot be replaced.
♦ The sensor housing must not be subjected to mechanical load.
♦ No measurements must be carried out at the contact points of
the ABS control unit - J104- .
♦ No measurements must be carried out at the contact points of
the ABS hydraulic unit - N55- .
♦ The valve domes of the ABS hydraulic unit - N55- must not be
damaged or bent.
♦ The contacts on the ABS control unit - J104- and the ABS hy‐
draulic unit - N55- cannot be replaced.
♦ Do not use contact spray.
♦ No contamination or foreign object may located between ABS
control unit - J104- and ABS hydraulic unit - N55- .
♦ Ensure that no brake fluid enters connectors.
♦ Observe the relevant instructions when handling brake fluid.
♦ After completing work which involved opening the brake sys‐
tem,
bleed the brake system with the brake filling and bleeding
device , e. g. -VAS 5234- ,
⇒ “6.3 Bleeding hydraulic system following standard proce‐
dure”, page 153 .
♦ During the subsequent road test, ensure that at least one con‐
trolled
brake application is performed (pulsing must be felt on
the brake pedal).
10 Rep. gr.45 - Anti-lock brake system
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Brake systems - Edition 07.2017
2 Installation location overview
⇒ “2.1 Installation location overview - ABS”, page 11
⇒ “2.2 Installation location overview - ABS/ESC”, page 13
2.1 Installation location overview - ABS
Note
The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.
1 - ABS control unit - J104-
❑ Fitting location: on the
ABS hydraulic unit N55- in engine compart‐
ment
⇒ “1.1 Repair instruc‐
tions for repair work on
ABS”, page 7
do not disconnect the
❑
plug connection before
the self-diagnosis is
complete; switch off the
ignition before discon‐
necting the plug con‐
nection
The following components are
integrated in the ABS control
unit - J104- :
♦ Lateral acceleration sender
- G200♦ Yaw rate sender - G202♦ Longitudinal acceleration
sender - G251- (depending
on equipment fitted)
♦ the components cannot be
changed individually
❑ Check ⇒ Vehicle diag‐
nostic tester
❑ Removing and installing
the ABS control unit J104- with the ABS hy‐
draulic unit - N55-
⇒ “3.2 Removing and
installing ABS control
unit J104 / ABS hydraul‐
ic unit N55 ”, page 25
2 - ABS hydraulic unit - N55The ABS hydraulic unit - N55- consists of these components:
ABS return flow pump - V39-
♦
♦ Valve block (contains inlet and outlet valves).
❑ The ABS return flow pump - V39- and the valve block must not be separated from each other
❑ Removing and installing
⇒ “3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 ”, page 25
3 - ABS warning light - K47-
Fitting location: in the dash panel insert
❑
2. Installation location overview 11
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4 - Dual circuit and hand brake system warning light - K7 -
❑
Fitting location: in the dash panel insert
5 - Diagnostic connection
❑ Fitting location: behind bottom part of dash panel, driver side
6 - Brake light switch - F-
❑ Including brake pedal switch - F47❑ Removing and installing
7 - Front right and left wheel speed sensors - G45- / -G47-
❑
Check ⇒ Vehicle diagnostic tester
❑ Removing and installing
8 - Wheel hub with wheel bearing
❑
Sensor ring for ABS is built into the wheel hub
9 - Rear right and left wheel speed sensors - G44- / -G46-
❑ Check ⇒ Vehicle diagnostic tester
❑ Removing and installing
⇒ “4.2 Removing and installing the rear speed sensors G44 / G46 ”, page 36
10 - Wheel hub with wheel bearing
❑
Sensor ring for ABS is built into the wheel hub
⇒ “3.3 Removing and installing brake light switch”, page 105
⇒ “4.1 Removing and installing front speed sensors G45 / G47 ”, page 36
12 Rep. gr.45 - Anti-lock brake system
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Brake systems - Edition 07.2017
2.2 Installation location overview - ABS/ESC
Note
♦
If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the
ABS hydraulic unit - N55- .
♦
On vehicles manufactured from 05/2015 (⇒ Electronic Catalogue of Original Parts ), you can disconnect
the ABS control unit - J104- from the ABS hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32 .
♦
The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.
1 - ABS control unit - J104-
❑ Fitting location: on the
ABS hydraulic unit -
N55- in engine compart‐
ment
❑ do not disconnect the
plug connection before
the self-diagnosis is
complete; switch off the
ignition before discon‐
necting the plug con‐
nection
The following components are
integrated in the ABS control
unit - J104- :
♦ Lateral acceleration sender
- G200♦ Yaw rate sender - G202♦ Longitudinal acceleration
sender - G251- (depending
on equipment fitted)
♦ the components cannot be
changed individually
❑ Check ⇒ Vehicle diag‐
nostic tester
❑ Removing and installing
the ABS control unit J104- with the ABS hy‐
draulic unit - N55-
⇒ “3.2 Removing and
installing ABS control
unit J104 / ABS hydraul‐
ic unit N55 ”, page 25
Vehicles as of 05/2015
❑ Disconnecting the con‐
trol unit from the hy‐
draulic unit ⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32
❑ Fitting the control unit to the hydraulic unit
⇒ “3.4 Fitting the control unit to the hydraulic unit”, page 34
2 - ABS hydraulic unit - N55The ABS hydraulic unit - N55- consists of these components:
❑ ABS return flow pump - V39❑ Brake pressure sender 1 - G201-
Valve block (contains inlet and outlet valves).
2. Installation location overview 13
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❑ The ABS return flow pump - V39- and the valve block must not be separated from each other
❑
Removing and installing
⇒ “3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 ”, page 25
3 - Warning light 2 for ESC and TCS - K216-
❑
Fitting location: in the dash panel insert
4 - ABS warning light - K47-
❑ Fitting location: in the dash panel insert
5 - Warning light for ESC and TCS - K155-
❑ Fitting location: in the dash panel insert
6 - Dual circuit and hand brake system warning light - K7 -
❑ Fitting location: in the dash panel insert
7 - Warning light for tyre pressure display - K220-
❑ Fitting location: in the dash panel insert
8 - Brake light switch - F-
❑ Including brake pedal switch - F47❑ Removing and installing
9 - TCS and ESP button - E256-
❑
Fitting location: in the dash panel
10 - Diagnostic connection
❑ Fitting location: behind bottom part of dash panel, driver side
11 - Steering angle sender - G85-
❑ Fitting location: on the steering column between the steering wheel and the steering column switch
❑ Removing and installing ⇒ Electrical System; Rep. gr. 94
12 - Front right and left wheel speed sensors - G45- / -G47-
❑ Check ⇒ Vehicle diagnostic tester
❑ Removing and installing
13 - Wheel hub with wheel bearing
❑
Sensor ring for ABS is built into the wheel hub
14 - Rear right and left wheel speed sensors - G44- / -G46-
❑ Check ⇒ Vehicle diagnostic tester
❑ Removing and installing
⇒ “4.2 Removing and installing the rear speed sensors G44 / G46 ”, page 36
15 - Wheel hub with wheel bearing
❑
Sensor ring for ABS is built into the wheel hub
⇒ “3.3 Removing and installing brake light switch”, page 105
⇒ “4.1 Removing and installing front speed sensors G45 / G47 ”, page 36
14 Rep. gr.45 - Anti-lock brake system
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3 Control unit and hydraulic unit
⇒ “3.1 Exploded view – control unit and hydraulic unit”,
page 15
⇒ “3.2 Removing and installing ABS control unit J104 / ABS hy‐
draulic unit N55 ”, page 25
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page
32
⇒ “3.4 Fitting the control unit to the hydraulic unit”, page 34
3.1 Exploded view – control unit and hy‐
draulic unit
⇒ “3.1.1 Summary of components - control unit and hydraulic unit
for ABS, left-hand drive vehicles”, page 15
⇒ “3.1.2 Summary of components - control unit and hydraulic unit
for ABS, right-hand drive vehicles”, page 17
⇒ “3.1.3 Summary of components - control unit and hydraulic unit
for ABS/ESC, left-hand drive vehicles up to 21/2015”, page 19
⇒ “3.1.4 Summary of components - control unit and hydraulic unit
for ABS/ESC, right-hand drive vehicles from 22/2015”,
page 21
⇒ “3.1.5 Summary of components - control unit and hydraulic unit
for ABS/ESC, right-hand drive vehicles”, page 23
Brake systems - Edition 07.2017
3.1.1 Summary of components - control unit and hydraulic unit for ABS, left-hand
drive vehicles
Note
♦
If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the
ABS hydraulic unit - N55- .
♦
The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.
3. Control unit and hydraulic unit 15
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1 - ABS control unit - J104-
❑ with
❑ Removing and installing
2 - Brake line
❑
❑ Marking on the ABS hy‐
❑ With thread M10 x 1
❑ 14 Nm
3 - Brake line
❑ to rear left brake caliper/
❑ Marking on the ABS hy‐
❑ With thread M12 x 1
❑ 14 Nm
4 - Brake line
❑ to rear right brake cali‐
❑ Marking on the ABS hy‐
❑ With thread M10 x 1
❑ 14 Nm
5 - Brake line
❑ to front left brake caliper
❑ Marking on the ABS hydraulic unit - N55- -Front left (VL)❑ With thread M12 x 1
❑ 14 Nm
6 - Brake line
❑ from master brake cylinder (push rod piston circuit) to ABS hydraulic unit - N55❑ Marking on the ABS hydraulic unit - N55- -Hydraulic cylinder 2 (HZ2)❑ With thread M12 x 1
❑ 14 Nm
7 - Brake line
❑ from master brake cylinder (floating piston circuit) to ABS hydraulic unit - N55❑ Marking on the ABS hydraulic unit - N55- -Hydraulic cylinder 1 (HZ1)❑ With thread M12 x 1
❑ 14 Nm
8 - Brake servo
❑ Removing and installing
9 - Nut
❑
ABS hydraulic unit -
N55-
⇒ “3.2 Removing and in‐
stalling ABS control unit
J104 / ABS hydraulic
unit N55 ”, page 25
to front right brake cali‐
per
draulic unit - N55-
-Front right (VR)-
wheel-brake cylinder
draulic unit - N55-
-Rear left (HL)-
per/wheel-brake cylin‐
der
draulic unit - N55-
-Rear right (HR)-
⇒ “3.6 Removing and installing brake servo”, page 114
self-locking
16 Rep. gr.45 - Anti-lock brake system
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Brake systems - Edition 07.2017
❑ 20 Nm
10 - Mounting bracket
11 - Screw
❑
8 Nm
12 - Mounting bracket
❑ Moisten the bolt of the support with lubricant, e.g. -D 007 000 A2- , before inserting into the rubber
bearings
❑ after installing, check for firm seating
3.1.2 Summary
of components - control unit and hydraulic unit for ABS, right-hand
drive vehicles
Note
♦
If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the
ABS hydraulic unit - N55- .
♦
The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.
1 - Brake line
❑ from master brake cylin‐
der (push rod piston cir‐
cuit) to ABS hydraulic
unit - N55-
❑ Marking on the ABS hy‐
draulic unit - N55-
3. Control unit and hydraulic unit 17
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Brake systems - Edition 07.2017
-Hydraulic cylinder 2 (HZ2)-
❑
With thread M12 x 1
❑ 14 Nm
2 - Brake line
❑ from master brake cylinder (floating piston circuit) to ABS hydraulic unit - N55❑ Marking on the ABS hydraulic unit - N55- -Hydraulic cylinder 1 (HZ1)❑ With thread M12 x 1
❑ 14 Nm
3 - Brake line
❑ to front right brake caliper
❑ Marking on the ABS hydraulic unit - N55- -Front right (VR)❑ With thread M10 x 1
❑ 14 Nm
4 - Brake line
❑ to rear left brake caliper/wheel-brake cylinder
❑ Marking on the ABS hydraulic unit - N55- -Rear left (HL)❑ With thread M12 x 1
❑ 14 Nm
5 - Brake line
❑ to rear right brake caliper/wheel-brake cylinder
❑ Marking on the ABS hydraulic unit - N55- -Rear right (HR)❑ With thread M10 x 1
❑ 14 Nm
6 - Brake line
❑ to front left brake caliper
❑ Marking on the ABS hydraulic unit - N55- -Front left (VL)❑ With thread M12 x 1
❑ 14 Nm
7 - ABS control unit - J104-
❑ with ABS hydraulic unit - N55❑ Removing and installing
⇒ “3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 ”, page 25
8 - Mounting bracket
9 - Screw
❑
8 Nm
10 - Nut
❑ self-locking
❑ 20 Nm
11 - Mounting bracket
❑ Moisten the bolt of the support with lubricant, e.g. -D 007 000 A2- , before inserting into the rubber
bearings
❑ after installing, check for firm seating
12 - Brake servo
❑ Removing and installing
⇒ “3.6 Removing and installing brake servo”, page 114
18 Rep. gr.45 - Anti-lock brake system
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3.1.3 Summary of components - control unit and hydraulic unit for ABS/ESC, left-
hand drive vehicles up to 21/2015
Note
♦
If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the
ABS hydraulic unit - N55- .
♦
On vehicles manufactured from 05/2015 (⇒ Electronic Catalogue of Original Parts ), you can disconnect
the ABS control unit - J104- from the ABS hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32 .
♦
The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.
1 - ABS control unit - J104-
❑ with ABS hydraulic unit -
N55-
❑ Disconnecting the con‐
trol unit from the hy‐
draulic unit
⇒ “3.3 Disconnecting
the control unit from the
hydraulic unit”,
page 32
❑ Fitting
❑ Removing
2 - Brake line
❑
❑ Marking on the ABS hy‐
❑ With thread M10 x 1
❑ 14 Nm
3 - Brake line
❑ to rear left brake caliper/
❑ Marking on the ABS hy‐
❑ With thread M12 x 1
❑ 14 Nm
4 - Brake line
❑ to rear right brake caliper/wheel-brake cylinder
❑ Marking on the ABS hydraulic unit - N55- -Rear right (HR)-
❑ With thread M10 x 1
❑ 14 Nm
the control unit to
the hydraulic unit
⇒ “3.4 Fitting the control
unit to the hydraulic
unit”, page 34
and installing
⇒ “3.2 Removing and in‐
stalling ABS control unit
J104 / ABS hydraulic
unit N55 ”, page 25
to front right brake cali‐
per
draulic unit - N55-
-Front right (VR)-
wheel-brake cylinder
draulic unit - N55-
-Rear left (HL)-
3. Control unit and hydraulic unit 19
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5 - Brake line
❑
to front left brake caliper
❑ Marking on the ABS hydraulic unit - N55- -Front left (VL)❑ With thread M12 x 1
❑ 14 Nm
6 - Brake line
❑ from master brake cylinder (push rod piston circuit) to ABS hydraulic unit - N55❑ Marking on the ABS hydraulic unit - N55- -Hydraulic cylinder 2 (HZ2)❑ With thread M12 x 1
❑ 14 Nm
7 - Brake line
❑ from master brake cylinder (floating piston circuit) to ABS hydraulic unit - N55❑ Marking on the ABS hydraulic unit - N55- -Hydraulic cylinder 1 (HZ1)❑ With thread M12 x 1
❑ 14 Nm
8 - Brake servo
❑ Removing and installing
9 - Nut
❑
self-locking
❑ 20 Nm
10 - Mounting bracket
11 - Screw
❑ 8 Nm
12 - Mounting bracket
❑ Moisten the bolt of the support with lubricant, e.g. -D 007 000 A2- , before inserting into the rubber
bearings
❑ after installing, check for firm seating
⇒ “3.6 Removing and installing brake servo”, page 114
20 Rep. gr.45 - Anti-lock brake system
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Brake systems - Edition 07.2017
3.1.4 Summary of components - control unit and hydraulic unit for ABS/ESC, right-hand drive vehicles from 22/2015
Note
♦
If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the
ABS hydraulic unit - N55- .
♦
On vehicles manufactured from 05/2015 (⇒ Electronic Catalogue of Original Parts ), you can disconnect
the ABS control unit - J104- from the ABS hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32 .
♦
The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.
1 - Brake servo
❑ Removing and installing
⇒ “3.6 Removing and in‐
stalling brake servo”,
page 114
2 - Brake line
❑ from
❑ Marking on the ABS hy‐
master brake cylin‐
der (push rod piston cir‐
cuit) to ABS hydraulic
unit - N55-
draulic unit - N55-
-Hydraulic cylinder 2 (HZ2)-
❑ With thread M12 x 1
❑ 14 Nm
3 - Brake line
❑ from master brake cylinder (floating piston circuit) to ABS hydraulic unit - N55❑ Marking on the ABS hydraulic unit - N55- -Hydraulic cylinder 1 (HZ1)❑ With thread M12 x 1
3. Control unit and hydraulic unit 21
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Brake systems - Edition 07.2017
❑ 14 Nm
4 - Brake line
❑
to front right brake caliper
❑ Marking on the ABS hydraulic unit - N55- -Front right (VR)❑ With thread M10 x 1
❑ 14 Nm
5 - Brake line
❑ to rear left brake caliper/wheel-brake cylinder
❑ Marking on the ABS hydraulic unit - N55- -Rear left (HL)❑ With thread M12 x 1
❑ 14 Nm
6 - Brake line
❑ to rear right brake caliper/wheel-brake cylinder
❑ Marking on the ABS hydraulic unit - N55- -Rear right (HR)❑ With thread M10 x 1
❑ 14 Nm
7 - Brake line
❑ to front left brake caliper
❑ Marking on the ABS hydraulic unit - N55- -Front left (VL)❑ With thread M12 x 1
❑ 14 Nm
8 - ABS control unit - J104-
❑ with ABS hydraulic unit - N55❑ Disconnecting the control unit from the hydraulic unit
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32
❑
Fitting the control unit to the hydraulic unit
⇒ “3.4 Fitting the control unit to the hydraulic unit”, page 34
❑
Removing and installing
⇒ “3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 ”, page 25
9 - Mounting bracket
❑
with rubber bearings
❑ attached to the ABS hydraulic unit - N55- by 2 bolts
❑ 8 Nm
10 - Mounting bracket
❑ Moisten the bolt of the support with lubricant, e.g. -D 007 000 A2- , before inserting into the rubber
bearings
❑ after installing, check for firm seating
11 - Nut
❑ self-locking
❑ 20 Nm
22 Rep. gr.45 - Anti-lock brake system
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3.1.5 Summary of components - control unit and hydraulic unit for ABS/ESC, right-hand drive vehicles
Note
♦
If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the
ABS hydraulic unit - N55- .
♦
On vehicles manufactured from 05/2015 (⇒ Electronic Catalogue of Original Parts ), you can disconnect
the ABS control unit - J104- from the ABS hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32 .
♦
The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.
1 - Brake line
❑ from master brake cylin‐
der (push rod piston cir‐
cuit) to ABS hydraulic
unit - N55-
❑ Marking on the ABS hy‐
draulic unit - N55-
-Hydraulic cylinder 2 (HZ2)❑ With thread M12 x 1
❑ 14 Nm
2 - Brake line
❑ from master brake cylinder (floating piston circuit) to ABS hydraulic unit - N55❑ Marking on the ABS hydraulic unit - N55- -Hydraulic cylinder 1 (HZ1)❑ With thread M12 x 1
❑ 14 Nm
3. Control unit and hydraulic unit 23
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Brake systems - Edition 07.2017
3 - Brake line
❑
to front right brake caliper
❑ Marking on the ABS hydraulic unit - N55- -Front right (VR)❑ With thread M10 x 1
❑ 14 Nm
4 - Brake line
❑ to rear left brake caliper/wheel-brake cylinder
❑ Marking on the ABS hydraulic unit - N55- -Rear left (HL)❑ With thread M12 x 1
❑ 14 Nm
5 - Brake line
❑ to rear right brake caliper/wheel-brake cylinder
❑ Marking on the ABS hydraulic unit - N55- -Rear right (HR)❑ With thread M10 x 1
❑ 14 Nm
6 - Brake line
❑ to front left brake caliper
❑ Marking on the ABS hydraulic unit - N55- -Front left (VL)❑ With thread M12 x 1
❑ 14 Nm
7 - ABS control unit - J104-
❑ with ABS hydraulic unit - N55❑ Disconnecting the control unit from the hydraulic unit
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 32
❑
Fitting the control unit to the hydraulic unit
⇒ “3.4 Fitting the control unit to the hydraulic unit”, page 34
❑
Removing and installing
⇒ “3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 ”, page 25
8 - Mounting bracket
9 - Screw
❑
8 Nm
10 - Nut
❑ self-locking
❑ 20 Nm
11 - Mounting bracket
❑ Moisten the bolt of the support with lubricant, e.g. -D 007 000 A2- , before inserting into the rubber
bearings
❑ after installing, check for firm seating
12 - Brake servo
❑ Removing and installing
⇒ “3.6 Removing and installing brake servo”, page 114
24 Rep. gr.45 - Anti-lock brake system
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3.2 Removing and installing ABS control unit - J104- / ABS hydraulic unit - N55-
⇒ “3.2.1 Removing and installing ABS control unit J104 / ABS
hydraulic unit N55 , left -hand drive vehicles up to 21/2015”, page
25
⇒ “3.2.2 Removing and installing ABS control unit J104 / ABS
hydraulic unit N55 , left -hand drive vehicles from 22/2015”, page
28
⇒ “3.2.3 Removing and installing ABS control unit J104 / ABS
hydraulic unit N55 , right-hand drive vehicles”, page 30
3.2.1 Removing and installing ABS control unit - J104- / ABS hydraulic unit - N55- , left -hand drive vehicles up to 21/2015
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2♦ Brake filling and bleeding device , e. g. -VAS 5234♦ Repair kit - 1H0 698 311 ARemoving
Fitting location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55-
and is located in the engine compartment on the right side.
Brake systems - Edition 07.2017
Note
Do not bend the brake lines in the area of the hydraulic unit.
– Read out and note the actual control unit coding ⇒ Vehicle
diagnostic tester.
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– If present, remove engine cover ⇒ Engine; Rep. gr. 10 .
Vehicles with engines TDI Common Rail DPF (diesel particle fil‐
ter)
– Remove plenum chamber cover ⇒ Body Work; Rep. gr. 66 .
– If present, open heat shield collar.
– Take
– Remove the connector holder from the bulkhead plenum
– Remove intake hose and air filter ⇒ Engine; Rep. gr. 23 .
– Pull the engine control unit out of the bracket and lay to the
– Remove engine control unit bracket.
– Remove the insulation from the bulkhead plenum chamber.
– Remove bulkhead plenum chamber ⇒ Body Work; Rep. gr.
Continued for all vehicles
plug connections -1- to -4- out of the bracket, disconnect
and expose electric cables.
chamber.
side.
50 .
3. Control unit and hydraulic unit 25
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Brake systems - Edition 07.2017
– Press down the red fuse -arrow-.
– Unlock the plug connection of the control unit -arrow- and pull
out towards the front.
– Attach the bleeder hose of the bleeding bottle onto the vent
valves of the front left and rear left brake caliper and open vent
valves.
– Press down brake pedal with brake pedal load , e.g. -V.A.G
1869/2- , at least 60 mm.
– Close front left and rear left bleeder valves.
– Do not remove brake pedal load , e. g. -V.A.G 1869/2- .
– Place a sufficient non-fluffing cloths under and around the ABS
control unit - J104- and the ABS hydraulic unit - N55- .
NOTICE
Make sure that no brake fluid gets onto the contacts of the ABS
control unit - J104- .
26 Rep. gr.45 - Anti-lock brake system
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