Volkswagen Passat B5 - Components of ESP system, removing and installing Page 1 / 17
45 - 7
Components of ESP system, removing and
installing
A description of the construction and function of the ESP is
found in Self-study programme No. 204.
ABS control module J104 (Bosch 5.3) vehicles with ESP,
removing and installing
Removing
The control module is located beneath the right floor
covering on the passenger side.
- Slide right front seat completely rearward.
- Remove passenger side storage tray
Repair Manual, Body Interior, Repair Group 70,
Instrument panel; Instrument panel, removing and installing
- Remove trim from A-pillar in right footwell
Repair Manual, Body Interior, Repair Group 70,
Instrument panel; Instrument panel, removing and installing
- Remove right door sill strip from rocker panel
Repair Manual, Body Interior, Repair Group 70, Door sill
Components of ESP system, removing and installing Page 2 / 17
strips; Door sill strips, removing and installing
- Pull back right front floor covering so far that the control
module for ABS/ESP are accessible in the area of the
bulkhead.
- Remove two securing nuts - arrows - .
- Remove control module with protective housing.
- Remove bolts for protective housing.
- Remove control module.
- To release connector, press release in direction of -
arrow - .
Installing
- Installation is in reverse order of removal.
- Torque specification for nuts that secure the control
module with protective housing to the bulkhead is 9 Nm.
ABS Control Module J104 (Bosch 5.3) vehicles without
ESP, removing and installing
Components of ESP system, removing and installing Page 3 / 17
Removing
Caution!
Control module must only be removed from ABS
hydraulic unit after hydraulic unit is removed from
vehicle.
Note:
The following procedure outlines control module
replacement only. A removed control module that
has been in operation must always be replaced.
Thoroughly clean the hydraulic unit prior to removal
from vehicle.
Prior to removing control module, check DTC
memory.
Place hydraulic unit on a clean, level surface after
removal.
- Remove ABS hydraulic unit 45-5, Hydraulic unit, brake
booster/brake master cylinder, assembly overview .
- Release and disconnect electrical connection - 1 -
- - Remove screws - 1 -
Components of ESP system, removing and installing Page 4 / 17
- - Without twisting, separate control module - 2 - from
hydraulic unit/valves.
- - Thoroughly clean sealing surface - 2 - using plastic
scraper - 1 - . Check valves - 3 - for damage.
Note:
Do not use aggressive cleaning materials or
solvents. Where applicable, use cleaning materials
supplied with replacement control module.
Check sealing surface for damage.
Installing
Caution!
Ensure internal areas of the control module are free
from contaminates and remains dry at all times.
Should the sealing surface or contacts be damaged,
the hydraulic unit must be replaced.
Impacts of any kind (i.e.: by dropping or collision
damage) can damage the hydraulic unit. Do not use a
hydraulic unit that has experienced impact damage.
Components of ESP system, removing and installing Page 5 / 17
- Without twisting, carefully insert control module - 1 - onto
hydraulic unit/valves - 2 - in direction of - arrow - .
- Edge of control module must slide over corresponding
recess in hydraulic unit.
Note:
Always use new screws.
In order to ensure proper sealing of the gasket
material, a new control module must not be removed
and installed more than two times on the same
hydraulic unit.
A removed control module that has been in
operation must always be replaced.
In the event a new hydraulic unit is also installed,
leave brake circuit protective caps in place until just
prior to installing brake lines.
Should the brake circuit protective caps be removed
prior to brake line installation, any brake fluid loss
will adversely affect the system capacity and
subsequent bleeding operation.
Components of ESP system, removing and installing Page 6 / 17
- Ensure control module is centered on hydraulic unit and
then install new screws - 1 - and - 2 - evenly (do not
tighten) so the gap between control module and hydraulic
unit is equal on all sides.
- Install remaining screws - 3 - to - 6 - evenly (do not
tighten).
- Torque screws - 1 - to - 6 - in numbered sequence to
2.5 Nm.
- Reconnect and secure electrical connection - 1 - .
- Reinstall hydraulic 45-5, Hydraulic unit, brake
booster/brake master cylinder, assembly overview .
Components of ESP system, removing and installing Page 7 / 17
- Bleed brakes 47-4, Braking system, bleeding .
- Connect and use VAS 5051 / 5052 in operating mode
"Guided Fault Finding" and perform On Board Diagnostic
(OBD) program "Code ABS Control Module" .
ABS Control Module J104 (Bosch 5.7) vehicles without
ESP, removing and installing
Removing
Caution!
Control module must only be removed from ABS
hydraulic unit after hydraulic unit is removed from
vehicle.
Note:
The following procedure outlines control module
replacement only. A removed control module that
has been in operation must always be replaced.
Thoroughly clean the hydraulic unit prior to removal
from vehicle.
Prior to removing control module, check DTC
memory.
Place hydraulic unit on a clean, level surface after
removal.
- Remove ABS hydraulic unit 45-5, Hydraulic unit, brake
booster/brake master cylinder, assembly overview .
- Release and disconnect electrical connection - 1 -
- - Remove screws - 1 -
Components of ESP system, removing and installing Page 8 / 17
- - Without twisting, separate control module - 2 - from
hydraulic unit/valves.
- - Thoroughly clean sealing surface - 2 - using plastic
scraper - 1 - . Check valves - 3 - for damage.
Note:
Do not use aggressive cleaning materials or
solvents. Where applicable, use cleaning materials
supplied with replacement control module.
Check sealing surface for damage.
Installing
Caution!
Ensure internal areas of the control module are free
from contaminates and remains dry at all times.
Should the sealing surface or contacts be damaged,
the hydraulic unit must be replaced.
Impacts of any kind (i.e.: by dropping or collision
damage) can damage the hydraulic unit. Do not use a
hydraulic unit that has experienced impact damage.
Components of ESP system, removing and installing Page 9 / 17
- Without twisting, carefully insert control module - 1 - onto
hydraulic unit/valves - 2 - in direction of - arrow - .
- Edge of control module must slide over corresponding
recess in hydraulic unit.
Note:
Always use new screws.
In order to ensure proper sealing of the gasket
material, a new control module must not be removed
and installed more than two times on the same
hydraulic unit.
A removed control module that has been in
operation must always be replaced.
In the event a new hydraulic unit is also installed,
leave brake circuit protective caps in place until just
prior to installing brake lines.
Should the brake circuit protective caps be removed
prior to brake line installation, any brake fluid loss
will adversely affect the system capacity and
subsequent bleeding operation.
Components of ESP system, removing and installing Page 10 / 17
- Ensure control module is centered on hydraulic unit and
then install new screws - 1 - and - 2 - evenly (do not
tighten) so the gap between control module and hydraulic
unit is equal on all sides.
- Install remaining screws - 3 - to - 6 - evenly (do not
tighten).
- Torque screws - 1 - to - 6 - in numbered sequence to
2.5 Nm.
- Reconnect and secure electrical connection - 1 - .
- Reinstall hydraulic 45-5, Hydraulic unit, brake
booster/brake master cylinder, assembly overview .
Components of ESP system, removing and installing Page 11 / 17
- Bleed brakes 47-4, Braking system, bleeding .
- Connect and use VAS 5051 / 5052 in operating mode
"Guided Fault Finding" and perform On Board Diagnostic
(OBD) program "Code ABS Control Module" .
Rotation Rate Sensor G202 , removing and installing
On vehicles with a single Rotation Rate Sensor G202 ,
the control module cannot be coded.
The Rotation Rate Sensor G202 is located in the left front
footwell under the floor covering.
Removing
- Remove left front seat
Repair Manual, Body Interior, Repair Group 72, Front
seats; Seat, removing and installing
- Remove trim from A-pillar in left footwell
Repair Manual, Body Interior, Repair Group 70,
Instrument panel; Instrument panel, removing and installing
- Remove left door sill strip from rocker panel
Repair Manual, Body Interior, Repair Group 68, Door sill
strips; Door sill strips, removing and installing
Components of ESP system, removing and installing Page 12 / 17
- Pull back left front floor covering so far that the sender for
rotation rate packaged in its protective Styrofoam, is
accessible in the area of the bulkhead.
- Remove protective Styrofoam packaging.
- Disconnect connector from sender for rotation rate.
- Remove three nuts.
Installing
Caution!
Strong vibrations can destroy the Rotation Rate
Sensor G202 .
- Installation is in reverse order of removal.
When installing Rotation Rate Sensor G202 make sure it is
correctly seated in its mounting and is free of stress.
Do not use the securing nuts to forcibly position the
Rotation Rate Sensor G202 .
- Tighten securing nuts to 5 Nm.
Transverse Acceleration Sensor G200 , removing and
installing
On vehicles with a single Transverse Acceleration
Sensor G200 , the control module cannot be coded.
The Transverse Acceleration Sensor G200 is located on
the driver side, beneath the floor covering and behind the
seat cross member.
Removing
- Remove left front seat
Components of ESP system, removing and installing Page 13 / 17
Repair Manual, Body Interior, Repair Group 72, Front
seats; Seat, removing and installing
- Remove rear seat bench
Repair Manual, Body Interior, Repair Group 72, Rear
seats
- Remove left door sill strip from rocker panel
Repair Manual, Body Interior, Repair Group 68, Door sill
strips; Door sill strips, removing and installing
- Pull back left floor covering so far that the Transverse
Acceleration Sensor G200 can be removed.
- Remove two securing nuts - arrows - .
- Remove Transverse Acceleration Sensor G200 with
protective housing.
Installing
Caution!
Strong vibrations can destroy the sensor for
transverse acceleration.
- Installation is in reverse order of removal.
Components of ESP system, removing and installing Page 14 / 17
When installing sensor for transverse acceleration, make
sure it is correctly seated in its mounting and is stress free.
Do not use the securing nuts to forcibly position the
Transverse Acceleration Sensor G200 .
- Tighten securing nuts to 5 Nm.
Transverse Acceleration Sensor G200 and Rotation Rate
Sensor G202 , removing and installing
On vehicles with a combined Transverse Acceleration
Sensor G200 and Rotation Rate Sensor G202 , the
control module can be coded.
The Transverse Acceleration Sensor G200 and the
Rotation Rate Sensor G202 are combined in a single
housing. It is located beneath the rear seat bench.
Removing
- Remove rear seat bench
Repair Manual, Body Interior, Repair Group 72, Rear
seats
- Disconnect connector from sensor for transverse
acceleration/sender for rotation rate.
- Remove two securing nuts - arrows - .
- Remove sensor for transverse acceleration/sender for
rotation rate.
Installing
Caution!
Components of ESP system, removing and installing Page 15 / 17
Strong vibrations can destroy the sensor for
transverse acceleration/sender for rotation rate.
- Installation is in reverse order of removal.
When installing sensor for transverse acceleration/sender
for rotation rate, make sure it is correctly seated in its
mounting and is stress free.
Do not use the securing nuts to forcibly position the
sensor for transverse acceleration/sender for rotation
rate.
- Tighten securing nuts to 6 Nm.
Steering angle sensor G85 , removing and installing
The steering angle sensor G85 is located between the
steering wheel and steering column switch.
Removing
- The front wheels and steering wheel must be in the
straight ahead position.
- Remove steering wheel
Repair Manual, Body Interior, Repair Group 69, Airbag;
Steering wheel, removing and installing
- Carefully remove the four securing clips - arrows - and
then pull the steering angle sensor in the steering column
toward the steering wheel and out.
Components of ESP system, removing and installing Page 16 / 17
- Disconnect connections - arrows - .
Installing
- The front wheels and steering wheel must be in the
straight ahead position.
The steering angle sensor G85 must be in the centered
position before installing.
- Press steering angle sensor G85 on until tabs engage.
- Remove transport protection.
- A yellow spot must be visible in hole - arrow 1 - .
- Also, the markings - arrows - must be aligned.
Make sure that the centered position is maintained.
Installation in reverse order
- Afterwards, a base setting must be performed Perform
Components of ESP system, removing and installing Page 17 / 17
base setting in "Guided Fault Finding" with the vehicle
diagnosis, testing and information system VAS 5051 .
For this, use the Go to button in the
"Functions/Component selection" .
