1996 VOLKSWAGEN PASSAT vacuum

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ABS hydraulic unit and ABS control
module (Teves 20 GI), removing and
installing
Carefully read and follow all cautions and
warnings Page 45-7 before beginning work.
Location
The ABS control module is bolted to the ABS
hydraulic unit, located on the left-side of the
engine compartment.

CAUTION!
Do not bend brake lines at or near the ABS
hydraulic unit.
Switch ignition OFF when disconnecting and
reconnecting the ABS control module
connector.
Part numbers are listed here for reference
only. Always check with your Parts
department for the latest information. Sealing plug kit Part No. 1H0 698 311 A:
1 - Valve dome transportation protection (plastic
foam)
2 - Sealing plugs -M10- 3 - Sealing plugs -M12- Page 3 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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After separating ABS control module from ABS
hydraulic unit, always install valve dome
transportation protection on hydraulic unit.
Warranty claims for ABS hydraulic units on which
the valve dome transportation protection was not
used will not be accepted.

Removing

CAUTION!

Determine correct radio anti-theft coding
before disconnecting the battery.

- Disconnect battery Ground (GND) strap.
- Remove coolant expansion tank and swing to
one side. Page 4 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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- Release retainer and disconnect ABS control
module connector (arrows).
- Connect bleeder hose and bleeder bottle to left-
front brake caliper bleeder screw, and open
bleeder screw.
- Depress brake pedal at least 60 mm (2-3/8 in.). - Install brake pedal loading device from special tool
VAG 1238B.
- Close left-front bleeder screw. - Remove heat shield from brake master cylinder. - Disconnect brake lines from brake master cylinder
and ABS hydraulic unit.
- Seal lines and threaded holes with plugs from
repair kit Page 45-11 . Page 5 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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-
Remove Torx socket-head bolts (T25) from
ABS hydraulic unit bracket.
- Remove ABS hydraulic unit/ABS control module
assembly.

- Disconnect ABS hydraulic pump connector from
ABS control module. CAUTION! - Remove ABS control module mounting bolts
(arrows) and pull off ABS control module. Pull control module straight off. Do not tilt. Cover control unit magnetic coils with a lint-
free cloth. After separating the ABS hydraulic unit and
ABS control module, always use the plastic
foam valve dome transportation protection
Page 45-11 . Page 6 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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Installing

Note:
Remove the sealing plugs from a new ABS
hydraulic unit one at a time, and only when the
corresponding brake line is to be connected.
If the plugs are removed too soon, brake fluid
can escape and it can no longer be certain that
the unit is sufficiently filled or adequately bled.

- Mount ABS control module to hydraulic unit
using new bolts.

Tightening torque: 4 Nm (35 in lb)
- Reconnect ABS hydraulic pump connector. The remainder of the installation procedure is the
reverse of removal, with the following additions:

- Bleed brake system Page 47-29 . Page 7 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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Note:
For vehicles equipped with ABS/EDL, on which
the brake fluid reservoir has been completely
empty (e.g. leaks in brake system), it is
necessary to initiate the "Basic Setting" function
of the On Board Diagnostic (OBD) program:
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Otherwise the standard brake bleeding
procedures apply.

- Code ABS control module: Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01
Tightening torques

ABS control unit to ABS
hydraulic unit 4 Nm (35 in.
lb)
ABS hydraulic unit to bracket
(Torx T25 socket-head bolts) 8 Nm (71 in.
lb)
Brake master cylinder to
vacuum booster 25
Nm (18 ft
lb)
Heat shield to brake master
cylinder 8 Nm (71 in.
lb)
Brake lines to ABS hydraulic
unit
M10 x 1 15
Nm (11 ft
lb)
M12 x 1 15
Nm (11 ft
lb) Page 8 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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Brake hydraulic system, bleeding and
filling

Vehicles with ABS/EDL
For vehicles with ABS/EDL, when the brake fluid
reservoir has been completely emptied (e.g. due
to leaks in the brake system) it is necessary to
initiate the "Basic Setting" function of the On
Board Diagnostic (OBD) program.
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Otherwise the standard brake bleeding
procedures apply Page 47-29 . Page 9 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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Removing

- Release brake servo vacuum by operating the
brake pedal several times.

- Remove connector from expansion tank.
- Swing coolant expansion tank to side.
- Pull connector off sensor. - Expand circlip with a small screwdriver in a
clockwise direction and pull sensor (arrow) out of
brake servo. Page 9 of 10Assembly overview - hydraulic unit, brake servo/brake master cylinder12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.4