Anti-lock Brake System (ABS), Bosch 5.

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Anti-lock Brake System (ABS),

Bosch 5.0
CAUTION!

The anti-lock brake system is basically

maintenance-free.

Specialist knowledge is required for

performing any work on this system.

Failure to observe the instructions presented

in this Repair Manual may result in damage
to the system and to loss of vehicle safety.

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ABS hydraulic unit and brake lines

The tightening torque for all brake lines on the Audi

A4 is 15 Nm (11 ft lb).

1 - Brake master cylinder with brake servo

unit
Brake master cylinder is shown without
brake fluid reservoir
2 - Brake line
Brake master cylinder/secondary piston
circuit to hydraulic unit
Bolted connection at brake master cylinder:
M12x1
Bolted connection at ABS hydraulic unit:
M12x1
3 - Brake line
Brake master cylinder/primary piston circuit
to hydraulic unit
Bolted connection at brake master cylinder:
M12x1
Bolted connection at ABS hydraulic unit:
M12x1

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4 - Rubber grommet
5 - ABS wiring harness connector
Release and remove
The connector is part of the ABS wiring
harness. Be aware of different versions for
FWD and AWD models
Make sure connector is in the correct
position and properly locked
6 - Screw
5 Nm (44 in lb)
7 - Cover panel
8 - ABS solenoid valve relay
9 - ABS return flow pump relay

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10 - ABS hydraulic unit

CAUTION!

Apart from replacing the two relays, repair work

on the ABS hydraulic unit is not permitted. Do
not loosen bolted connections.

Be aware of different versions:

ABS FWD models
ABS/EDL FWD models, ABS/EDL/ASR
FWD models Fig. 1
ABS/EDL AWD models 05.95 Fig. 2
ABS/EDL AWD models 05.95 Fig. 3
Replace complete ABS hydraulic unit, if
necessary.
The ABS hydraulic unit is supplied as a
replacement part that is pre-bled.

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Removing and installing:

- Disconnect battery Ground (GND) strap.
- Seal brake lines and connections
immediately with dummy plugs.
- Bolt new hydraulic control unit to bracket,
item 13 . Remove dummy plugs from
brake line connections. Brake lines
should be connected in accordance with
designations on hydraulic control unit.
Brake line tightening torque: 15 Nm (11 ft
lb)
- Bleed brake system page 47-23 .
- Carry out high- and low-pressure test
page 45-5 .
- Carry out On board Diagnostic (OBD)
Repair Manual, ABS/EDL/ASR On Board
Diagnostic (OBD), Repair Group 01.
11 - Screw
15 Nm (11 ft lb)

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12 - Washer
13 - Bracket for ABS hydraulic unit
Removing and installing page 45-15
14 - Bolt and washer assembly
8 Nm (71 in lb)
15 - Serrated washer
16 - Ground (GND) cable
Ensure good contact
17 - Hex nut
10 Nm (7 ft lb)
18 - Brake line
ABS hydraulic unit to right-front brake
caliper
19 - Brake line
ABS hydraulic unit to left-front brake caliper
20 - Brake line
ABS hydraulic unit to right-rear brake
caliper
21 - Brake line
ABS hydraulic unit to left-rear brake caliper

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Fig. 1 Brake line connections at the hydraulic unit for ABS/EDL,

front wheel drive and ABS/EDL/ASR front wheel drive
1 - Hydraulic unit to brake master cylinder (primary piston circuit)
2 - Hydraulic unit to right-rear brake caliper
3 - Hydraulic unit to left-front brake caliper
4 - Hydraulic unit to brake master cylinder (secondary piston circuit)
5 - Hydraulic unit to left-rear brake caliper
6 - Hydraulic unit to right-front brake caliper

Brake line connections: 15 Nm (11 ft lb)

Note:
Pressure dampers are not installed on models with all wheel drive and
EDL suction control (from 05.95) Fig. 2 .
EDL suction control minimizes control noises.
The working range of the pressure limiting valve in the hydraulic unit is
raised from 90 25 bar (1323 368 psi) to 170 25 bar (2499
368 psi).

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FIg. 2 Brake line connections at the hydraulic unit, all wheel drive
and ABS/EDL pressure control ( 05.95)
Two pressure dampers are threaded into the hydraulic unit
(arrows) on models with all wheel drive and EDL pressure control
(they smooth out pressure peaks in the brake lines and minimize
control noises).
Counter-hold at the hex on the pressure damper when loosening
the brake line.
1 - Hydraulic unit to brake master cylinder (primary piston circuit)
2 - Hydraulic unit to right-rear brake caliper
3 - Hydraulic unit to left-front brake caliper
4 - Hydraulic unit to brake master cylinder (secondary piston circuit)
5 - Hydraulic unit to left-rear brake caliper
6 - Hydraulic unit to right-front brake caliper

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Fig. 3 Brake line connections at the hydraulic unit for ABS/EDL,

all-wheel-drive models, suction control (05.95 )

EDL suction control was introduced on models with all wheel drive from
05.95. This system reduces the control noises during an EDL control
cycle.

The pressure dampers threaded into the hydraulic unit ( Fig. 2 arrows)
previously used to reduce working noises have been discontinued. The
working range of the pressure limiting valve in the hydraulic unit is raised
from 90 25 bar (1323 368 psi) to 170 25 bar (2499 368 psi).

Connector coding eliminates the risk of incorrectly connecting the

hydraulic unit.

1 - Brake line tightening torque: 15 Nm (11 ft lb)

Pressure damper discontinued. The brake line is now the same
length as for FWD.
4 - Brake line tightening torque: 15 Nm (11 ft lb)
Pressure damper discontinued. The brake line is now the same
length as for FWD.

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ABS hydraulic unit mounting bracket,

removing and installing

1 - Angle bracket
2 - Bearing bushing
3 - Buffer
4 - Mounting bracket for ABS hydraulic unit
5 - Washer
6 - Bolt and washer assembly
10 Nm (7 ft lb)

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7 - Brake line
ABS hydraulic unit to left-rear brake caliper
8 - Brake line
ABS hydraulic unit to right-rear brake
caliper
9 - Brake line
ABS hydraulic unit to left-front brake caliper
10 - Fixture
11 - Bolt and washer assembly
10 Nm (7 ft lb)

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ABS control module (ABS/EDL or ASR),

removing and installing

Location:

Under rear seat, left side

- Switch ignition off when removing and

installing.

- Lift rear seat out of its fixtures.

- Remove both securing bolts (arrows).

- Release harness connector (arrow) and separate from ABS control

module -J104-.
- Install in reverse order of removal.

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