8.1 Details of installation of the control unit and hydromodulator ESP "Mark 60EC"
1 block "J104 " ESP control, with built-in ESP sensor assembly "G419"
2 Hydromodulator "N55" ESP
3 Brake pipe, from the primary circuit of the GHC to the hydraulic modulator, diameter 6.5 mm, long nut M12x1
4 Brake pipe, from the GTZ secondary circuit to the hydraulic modulator, diameter 6.5 mm, long nut M12x1
5 Brake pipe, to the front left caliper, diameter 5.25 Nm, union nut M10x1
6 Brake pipe, to the front right caliper, diameter 5.25 Nm, union nut M12x1
7 Brake pipe, to the rear left caliper, diameter 5.25 Nm, union nut M12x1
8 Brake pipe, to the rear right caliper, diameter 5.25 Nm, union nut M10x1
9 Bolt, 5.5 Nm
10 Bracket
11, 12 Bolts, 8 Nm
13 Vacuum booster gasket
14 Vacuum booster
15 Vacuum booster O-ring
16 GTZ
17 Assembly D/V "F" brake lights and sensor "F47" brake pedal position
18 Bolt, 5 Nm
19 Heat shield
20 Nut, replaceable, 25 Nm
21 Seals
22 Brake fluid reservoir
23 Tank cover 22
24 Hose seal 25
25 Vacuum hose
26 Vacuum sensor "G608", built into the vacuum hose (on some models)
2. Using a scan tool, read and record the present control unit code.
3. Disconnect the negative cable from the battery.
4. Remove the engine top cover (in the presence of).
5. On 1.8L engines, remove the top charge air hose.
6. On diesel engines, remove the charge air hose to the side.
7. On models with a particulate filter, remove the particulate filter together with the intake exhaust pipe.
8. Unlock the connector in the direction of the arrow (1 per resist. illustrations) and disconnect the connector in the direction of the arrow (2).
8.8 Disconnecting the connector
9. Lock the depressed brake pedal with VAG1869/2 or ask an assistant to depress and hold the brake pedal.
10. Connect hoses to unions of prorolling of forward left and back left support; lower the other ends of the hoses into a container to collect brake fluid. Open the fittings and with the help of an assistant or the VAG1869/2 tool, depress the brake pedal by at least 60 mm. Close fittings. Do not release the brake pedal.
11. Lay a lint-free cloth to absorb brake fluid under the ESP control unit and hydraulic modulator assembly.
12. Mark the brake pipes coming from the GTZ, disconnect them from the hydraulic modulator and plug the pipes and holes in the hydraulic modulator.
13. Mark the brake pipes going to the calipers, disconnect them from the hydraulic modulator and plug the pipes and holes in the hydraulic modulator.
14. Pull the control unit and hydraulic modulator assembly out of the rubber dampers in an upward direction.
15. Installation is carried out in the reverse order. Tighten the assembly fastening bolts on the bracket with a force of 8 Nm. Tighten the nuts of the brake lines on the hydraulic modulator with a force of 14 Nm.
16. Finally, bleed the hydraulic brakes (see chapter 1) and encode the ESP block "J104" using a diagnostic tool. To do this, apply the basic settings for the sensor "G85" steering wheel angle sensor "G200" lateral acceleration, sensor No. 1 "G201" brake pressure and sensor "G251" longitudinal acceleration.