Teves 20 GI ABS and ABS/EDL electrical test Стр.

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01-136

Teves 20 GI ABS and

ABS/EDL electrical test
Electrical test steps (from Page 01-138 )
are valid when:

On Board Diagnostic (OBD) test program gives

no indication of the source of the malfunction:

- Work through complete electrical test.

On Board Diagnostic (OBD) provides direct

indication of the source of the malfunction:

- Only carry out the test steps recommended in

the Diagnostic Trouble Code (DTC) table (pin-
pointed entry).
Teves 20 GI ABS and ABS/EDL electrical test Стр. 2 из 18

01-137

Test requirements

Fuses -S4-, -S16- and -S20- OK

Fuses 1 and 2 for control module - ABS

-S123- and -S124- OK (remove fuses
from fuse holder to check).

Ignition and electrical consumers

switched-off before beginning test
(headlights, lighting, fan, etc.).

Disconnect multi-pin harness connector

from ABS control module -J104- and
connect VAG 1598/21 test box -1- to
harness connector -2-.

CAUTION!

The specifications listed in the electrical

test table are matched to the specified
multimeter (Fluke 83 or equivalent) and
are not necessarily valid for other test
equipment.

Test equipment and aids required:

Test box VAG 1598/21

VW 1594 connector test kit
Multimeter (Fluke 83 or equivalent)
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01-138

Electrical test table

Notes on electrical test table

The socket number designations on the VAG 1598 test box are identical to the terminal
designations on the ABS control module -J104- Electrical Wiring Diagrams,
Troubleshooting and Component Locations binder.

If the measured values deviate from the specifications, repair the malfunction as described
in the right-hand column of the table Electrical Wiring Diagrams, Troubleshooting and
Component Locations binder.

Conduct continuity checks with VW 1594 connector test kit (used for bridging
terminals/sockets).

If the measured values deviate only slightly from the specifications, clean sockets and
connectors for tester and adapter cables (with contact spray G 000 700 04 ) and repeat the
test.

Before replacing components, check wiring and connections and also, particularly for
specifications of less than 10 , repeat the resistance test on the component.
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01-139

Switch to voltage measuring range - 20 V

Test VAG Test of Test Specified Repairing
step 1598/21 conditions value malfunction
sockets
- Additional
operations
1 8 + 25 Voltage supply for 10.0 - 14.5 - Check wire from
Ignition
ABS hydraulic V
switched terminal 8 to Ground
pump motor
off (GND)
(terminal 30) on
ABS control
module -J104-

- Check wire from

terminal 25 via fuse 1
for control module -
ABS -S123- to battery
positive (B+)
2 9 + 24 Voltage supply for Ignition 10.0 - 14.5 - Check wire from
the inlet and outlet switched V terminal 24 to Ground
solenoid valves off (GND)
(terminal 30) on
ABS control
module -J104-

- Check wire from

terminal 9 via fuse 2
for control module -
ABS -S124- to battery
positive (B+)
Teves 20 GI ABS and ABS/EDL electrical test Стр. 5 из 18

01-140

Switch to voltage measuring range - 20 V

Test VAG Test of Test Specified Repairing
step 1598/21 conditions value malfunction
sockets
- Additional
operations
3 8 + 23 Voltage supply 10.0 - 14.5 - Check fuse -S4-
Ignition
(terminal X) on V
switched on
ABS control - Check wire from
module -J104- terminal 8 to Ground
(GND)
- Check wire from
terminal 23 to
terminal D/3 (relay
panel)
4 8 + 12 Function of brake Ignition - Check fuse -S20-
light switch -F- switched off and brake light
0.0 - 0.5 V switch -F-.
- Brake pedal
not depressed - Check wire from
terminal 8 to Ground
(GND)
10.0 - 14.5 - Check wire from
- Depress brake
V
pedal terminal 12 to
terminal W/4 (relay
panel)
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01-141

Switch to resistance measuring range - 2 k

Test VAG Test of Test Specified Repairing
step 1598/21 conditions value malfunction
sockets
- Additional
operations
5 3 + 18 Resistance of 1.0 - 1.3
Ignition - Check connector T2d
right front ABS k
switched
wheel speed off
sensor -G45-

- Check resistance of
ABS wheel speed
sensor (1.0 - 1.3 k )

- Check wire to ABS

wheel speed sensor,
move wire while
checking (loose
connection)
6 4 + 11 Resistance of left 1.0 - 1.3
Ignition - Check connector T2f
front ABS wheel k
switched
speed sensor -
off
G47-

- Check resistance of
ABS wheel speed
sensor (1.0 - 1.3 k )

- Check wire to ABS

wheel speed sensor,
move wire while
checking (loose
connection)
Teves 20 GI ABS and ABS/EDL electrical test Стр. 7 из 18

01-142

Switch to resistance measuring range - 2 k

Test VAG Test of Test Specified Repairing malfunction
step 1598/21 conditions value
sockets
- Additional
operations
7 1 + 17 Resistance of 1.0 - 1.3
Ignition - Check connector T2c
right rear ABS k
switched
wheel speed off
sensor -G44-

- Check resistance of
ABS wheel speed
sensor (1.0 - 1.3 k )

- Check wire to ABS

wheel speed sensor,
move wire while
checking (loose
connection)
8 2 + 10 Resistance of left 1.0 - 1.3
Ignition - Check connector T2e
rear ABS wheel k
switched
speed -G46-
off

- Check resistance of
ABS wheel speed
sensor (1.0 - 1.3 k )

- Check wire to ABS

wheel speed sensor,
move wire while
checking (loose
connection)
Teves 20 GI ABS and ABS/EDL electrical test Стр. 8 из 18

01-143

Switch to voltage measuring range - 2 V

Test VAG Test of Test Specified Repairing malfunction
step 1598/21 conditions value
sockets
- Additional
operations
9 3 + 18 Right front
Vehicle - Check installation of
ABS wheel raised ABS wheel speed
speed
sensor and impulse rotor
sensor -
G45- voltage
signal

Ignition
switched off
Min. 65 mV
- Rotate right - Check whether ABS
alternating
front wheel at wheel speed sensor has
voltage
approx. 1 been interchanged.
rev./sec. Read measuring value
block, Page 01-112
10 4 + 11 Left front Vehicle - Check installation of
ABS wheel raised ABS wheel speed
speed sensor and impulse rotor
sensor -
G47- voltage
signal

Ignition
switched off
Min. 65 mV
- Rotate left front - Check whether ABS
alternating
wheel at approx. wheel speed sensor has
voltage
1 rev./sec. been interchanged.
Reading measured
value Page 01-112
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01-144

Switch to voltage measuring range - 2 V

Switch to resistance measurement - 200 for test step 13

Test VAG Test of Test Specified Repairing malfunction
step 1598/21 conditions value
sockets
- Additional
operations
11 1 + 17 Right rear Vehicle - Check installation of
ABS wheel raised ABS wheel speed sensor
speed and impulse rotor
sensor -G44-
voltage
signal

Ignition
switched off
190 mV to
- Rotate right - Check whether ABS
1140 mV
rear wheel at wheel speed sensor has
approx. 1 been interchanged. Read
rev./sec. measuring value block,
Page 01-112
12 2 + 10 Left rear Vehicle - Check installation of
ABS wheel raised ABS wheel speed sensor
speed and impulse rotor
sensor -G46-
voltage
signal

Ignition
switched off
190 mV to
- Rotate left rear - Check whether ABS
1140 mV
wheel at approx. wheel speed sensor has
1 rev./sec. been interchanged. Read
measuring value block,
Page 01-112
13 15 + 21 Coding 0.0 -1.0
Ignition - Check wire and wiring
bridge switched off connections in harness
connector
- Replace if value
deviates from
specifications
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01-145

Switch to voltage measuring range - 20 V for test step 14, Resistance measurement -
200 for test step 15
Test VAG Test of Specified Repairing
Test conditions
step 1598/21 value malfunction
sockets - Additional operations
14 - Voltage supply - Connect multimeter - Check wire
for VAG 1551
(Fluke 83/equivalent) to from T16/4 to
scan tool, data T16 (black) using adapter Ground (GND)
link connector cables from VW 1594
T16 - Check wire
connector test kit
from T16/16
via -S22- to
terminal 30
10.0 -
Terminal 41): Ground 14.5 V

Terminal 161): positive

(B+)
15 - Resistance of K
Ignition switched off - Check wire
wire for On from TV14 to
Board terminal 13
Diagnostic
(OBD) data link
connector T16
Max. 1.5
- Connect multimeter - Check wire
(Fluke 83/equivalent) to from T16/7 via
VAG 1598/21 test box TV14 to
socket 6 and data link terminal 13
connector T16, terminal
71) using adapter cables
from VW 1594 connector
test kit
1) Page 01-150 , terminal assignment of connectors for voltage supply and On Board
Diagnostic (OBD) with the VAG 1551 scan tool.
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01-146

Functional check: ABS warning light -K47-

Test VAG Test of Test Specified Repairing malfunction
step 1598/21 conditions value
sockets
- Additional
operations
16 - Function of
Ignition - Check wire from
ABS warning switched terminal W/2 (relay
light -K47-
off panel) to Ground (GND)
Warning light
- Switch - Check wire from
-K47- lights
ignition on terminal X/8 (relay panel)
up via -K47- to terminal X/3
(relay panel), -K47- (12
V; 1.2 W) replace if
necessary

- Check wire from

terminal 16 to terminal
W/2 (relay panel)
17 - Function of
Ignition - Check wire from
warning light
switched terminal U2/10 (replay
for brake
off plate) to Ground (GND)
system -
K118-

- Switch Warning light - Check wire from

for brake
ignition on terminal U2/10 (relay
system - panel) via -K47- to
K118- lights terminal W/2
up

- Check wire from

terminal 16 to terminal
W/2 (relay panel)
- Check wire from
terminal U2/10 to
terminal 28/18
(instrument cluster
connector)
Teves 20 GI ABS and ABS/EDL electrical test Стр. 12 из 18

01-147

ABS control module, removing and

installing
Location: bolted to ABS hydraulic unit, left side of
engine compartment

Removing:

CAUTION!

Determine correct radio anti-theft coding

before disconnecting the battery.

- Disconnect battery.

- Remove coolant expansion tank and swing to

one side.

- Disconnect harness connector from ABS control

module.
- Connect bleeder bottle with bleeder hose 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 VAG
1238 B.
- Close front left bleeder screw.
- Remove heat shield from tandem master brake
cylinder.
- Disconnect brake lines from brake master
cylinder and ABS hydraulic unit and seal brake
lines and threaded holes with plugs from repair
kit Part No. 1H0 698 311 A.
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- Remove Torx socket-head bolts (T25) on ABS

hydraulic unit mounting bracket.

- Remove ABS hydraulic unit.

- Pull ABS hydraulic pump motor harness

connector off ABS control module.

- Remove bolts from ABS control module and pull

control module off.
Do not tilt ABS control module when pulling off.
- Cover control module solenoids with a lint-free
cloth.

After separating the ABS control module and ABS

hydraulic unit, protect the valve dome.

Installing:

CAUTION!

Only remove the sealing plugs on the ABS

hydraulic unit just before the particular brake
line is to be installed.
If the sealing plugs are removed too soon,
brake fluid can escape and it can then no
longer be guaranteed that the unit is
sufficiently filled or adequately bled.
There must not be anything in the area of the
ABS control module that can contaminate
the valve block.
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01-149

- Bolt ABS control module to ABS hydraulic

unit.

Maximum tightening torque: 4 Nm (35 in lb)

- Connect ABS hydraulic pump motor harness

connector.

The remainder of the installation is the reverse of

the removal sequence.

Bleeding brake system Repair Manual,

Suspension, Wheels, Brakes, Steering, Repair
Group 47 .

Coding ABS control module Page 01-110 .

Tightening torques

Control module to hydraulic unit

Max. 4 (35 in
Nm lb)
ABS hydraulic unit to bracket 8 (71 in
(Torx socket-head bolts) Nm lb)
Tandem master brake cylinder nut 25 (18 ft
to brake servo Nm lb)
Brake lines on ABS unit:
M10 x 1 15 (11 ft
Nm lb)
M12 x 1 15 (11 ft
Nm lb)
Teves 20 GI ABS and ABS/EDL electrical test Стр. 15 из 18

01-150

Multi-pin connector terminal

assignments

Note:

All terminals not listed are currently not

assigned and must never be connected to
other components!

ABS control module harness connector

T25

Terminal Connected to component ...

1 Right rear ABS wheel
speed sensor -G44-
2 Left rear ABS wheel
speed sensor - G46-
3 Right front ABS wheel
speed sensor -G45-
4 Left front ABS wheel
speed sensor -G47-

8 Ground (GND) terminal

31
9 Battery positive (B+) via -
S124-
10 Left rear ABS wheel
speed sensor - G46-
11 Left front ABS wheel
speed sensor -G47-
12 Brake light switch -F-
13 Connector T16/7, K wire
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15 Coding bridge to terminal 21

16 ABS warning light activation
17 Right rear ABS wheel speed sensor -
G44-
18 Right front ABS wheel speed sensor -
G45-

21 Coding bridge to terminal 15

23 Voltage supply terminal X

24 Ground (GND) terminal 31
25 Battery positive (B+) via -S123-
Teves 20 GI ABS and ABS/EDL electrical test Стр. 17 из 18

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Data Link Connector (DLC) for voltage

supply and On Board Diagnostic (OBD)
with VAG 1551 scan tool

Terminal = Ground (GND) (terminal

4 31)
Terminal = K wire via junction box
7 TV14 (above relay panel),
connector T2d/2 to ABS
control module -J104-
terminal 42
Terminal = Battery positive voltage (B+)
16 (terminal 30) via -S22-
Teves 20 GI ABS and ABS/EDL electrical test Стр. 18 из 18

01-153

Brake light switch, adjusting

Note:

Remove brake light switch to adjust.

- Remove brake light switch by rotating 90 to

right.

- Pull brake light switch plunger fully out.

- Press brake pedal down as far as possible by

hand.

- Guide brake light switch through assembly

opening and reinstall by turning 90 to left.

- Release brake pedal.

- Check function of brake light switch.