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ABSESP ITT Mark 20 system components_ removing and installing

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					Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System
                                                                                                                                45-11




                                                    ABS/ESP ITT Mark 20 system
                                                    components, removing and
                                                    installing
                                                    Brake light switch (square housing),
                                                    removing and installing

                                                    Note:

                                                    To ensure a secure fit, the switch may only be
                                                    installed once.

                                                    Removing

                                                    - Remove storage compartment on driver's
                                                      side.

                                                      Repair Manual, Body Interior, Repair Group
                                                    68; Storage compartments, covers

                                                    - Unplug electrical connector.

                                                    - Remove brake light switch -1- by turning counter-clockwise through 90 .
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                                            45-12




                                                    Installing

                                                    Install in reverse sequence; note the following
                                                    points:

                                                    - Pull brake light switch plunger fully out.

                                                    - Press brake pedal down as far as possible by
                                                      hand.

                                                    - Guide switch through installation hole and secure by turning 90 clockwise -arrows-.
                                                    - Release brake pedal.
                                                    - Make sure proper function of brake lights when brake pedal is pressed and released.
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                       45-13




                                                                     Brake light switch (round housing),
                                                                     removing and installing

                                                                     Note:

                                                                     To ensure a secure fit, the switch may only be
                                                                     installed once.

                                                                     Removing

                                                                     - Remove storage compartment on driver's
                                                                       side.

                                                                       Repair Manual, Body Interior, Repair Group
                                                                     68; Storage compartments, covers

                                                                     - Unplug electrical connector.

                                                                     - Remove brake light switch by turning counter-
                                                                       clockwise 45 .
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                                                     45-14




                                                    Installing

                                                    Install in reverse sequence; note the following
                                                    points:

                                                    - Pull brake light switch plunger fully out (arrow).
                                                    - Install retainer tabs -1- and -2- on switch into recesses of installation hole and secure by
                                                      turning clockwise 45 .

                                                    Note:
                                                       When installing brake light switch, do not operate brake pedal.
                                                       The plunger is adjusted automatically when the brake light switch is inserted.
                                                    - Make sure proper function of brake lights when brake pedal is pressed and released.
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                                45-15




                                                    Sensor for transverse acceleration -
                                                    G200- and Sender for rotation rate -
                                                    G202-, removing and installing

                                                    Work procedure

                                                    - Remove storage compartment on driver's
                                                      side.

                                                      Repair Manual, Body Interior, Repair Group
                                                    68; Storage compartments, covers

                                                    - Unplug electrical connectors (arrows) on senders -G200-/-G202-.
                                                    - Remove bolt -1- and remove mounting bracket for senders --G200-/-G202-.
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                                                     45-16




                                                    Removing and installing sender for rotation
                                                    rate -G202-

                                                    - Remove nuts -a- and remove sender for rotation rate -G202- -1-.
                                                    - To install: insert sender for rotation rate -G202- into mounting bracket and align straight before
                                                      tightening.

                                                    Note:
                                                       The sender for rotation rate is sensitive to shocks or impact.
                                                       Do not install a sender which has dropped to the ground otherwise proper operation is not
                                                       ensured.

                                                    Removing and installing sensor for transverse acceleration -G200-

                                                    - Use screwdriver to pry mount -1- off sensor for transverse acceleration -G200- -2- and remove
                                                      sender.
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                                                      45-17




                                                    - To install: insert sensor for transverse
                                                      acceleration -G200- -1- in holder.

                                                            Installation position: sloping side (arrow) of sensor for transverse acceleration -G200- must
                                                            face mount -2-.
                                                    - Slip mount over sensor for transverse acceleration -G200- until it engages with a click.

                                                    Note:
                                                       The sensor for transverse acceleration is not resistant to shocks or impact.
                                                       Do not install a sender which has dropped to the ground otherwise proper operation is not
                                                       ensured.
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                           45-18




                                                                     Installing

                                                                     The remaining installation steps are carried out in
                                                                     the reverse sequence; note the following points:

                                                                     - Initiate basic setting for sensor for transverse
                                                                       acceleration -G200- and sender for rotation rate
                                                                       -G202-.

                                                                        Repair Manaual, Brake System On Board
                                                                     Diagnostic (OBD), Repair Group 01

                                                                     Tightening torques

                                                                     Component                                       Nm
                                                                     Sender for rotation rate to holder               9
                                                                     Holder for sender to mounting bracket for       20
                                                                     steering column
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                                                   45-19




                                                    Longitudinal acceleration sensor -G251-,
                                                    removing and installing

                                                    Removing

                                                    - Remove glove box:

                                                      Repair Manual, Body Interior, Repair Group
                                                    68; Trays, compartments and trim

                                                    - Unplug electrical connector -2-
                                                    - Use a screwdriver to pry mount off longitudinal acceleration sensor -arrows- and remove
                                                      sensor -G251- -1-.

                                                    Note:
                                                       The longitudinal acceleration sensor is not resistant to shocks or impact.
                                                       Do not install a sensor which has dropped to the ground otherwise proper operation is not
                                                       ensured.

                                                    Installing

                                                    Install in reverse sequence; note the following points:

                                                    - Initiate basic setting for longitudinal acceleration sensor -G251-.
                                                      Repair Manaual, Brake System On Board Diagnostic (OBD), Repair Group 01
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                               45-20




                                                    Steering angle sensor -G85-, removing
                                                    and installing

                                                    Note:

                                                    The coil connector with slip ring is enclosed in
                                                    the housing of the steering angle sensor -G85-.

                                                    Removing

                                                    - Turn wheels to straight ahead position.

                                                    - Remove airbag unit and steering wheel.

                                                       Repair Manual, Suspension, Wheels,
                                                    Steering, Repair Group 48; Steering column and
                                                    steering wheel with airbag

                                                    - Remove storage compartment on driver's
                                                      side.

                                                       Repair Manual, Body Interior, Repair Group
                                                    68; Storage compartments, covers; Removing
                                                    driver's storage compartment

                                                    - Remove bolts -1- and detach handle for steering column adjustment -5-.
                                                    - Remove bolts -2- to -4-.
                                                    - Remove upper and lower sections of steering column trim.
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                                                        45-21




                                                    - Disconnect electrical connectors -1- and -2-.




                                                    - Carefully lift upper retainer tabs (arrows).
                                                    - Carefully lift lower retainer tabs and pull off housing with coil connector, slip ring and steering
                                                      angle sensor from steering column switch.
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                                                   45-22




                                                    Installing

                                                    Install in reverse sequence; note the following
                                                    points:

                                                    - Push on housing with coil connector, slip ring
                                                      and steering angle sensor onto steering column
                                                      switch until all retainer tabs engage with a click.

                                                    - Break off transportation protection.

                                                    - Adjust steering angle sensor to center position:
                                                          Yellow dot must be visible in hole (arrow -1-) and the two marks (arrows) must also be
                                                          aligned.
                                                    - Install airbag unit and steering column.
                                                       Repair Manual, Suspension, Wheels, Steering, Repair Group 48; Steering column and
                                                    steering wheel with airbag
                                                    - Initiate basic settings for steering angle sensor -G85-.
                                                      Repair Manaual, Brake System On Board Diagnostic (OBD), Repair Group 01
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                       45-23




                                                    Brake pressure sensors, removing and
                                                    installing

                                                    Special tools and equipment

                                                       Brake filler and bleeder unit VAS 5234

                                                    Removing




                                                    - Remove forward left-hand cover panel (arrows).
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                                                    45-24




                                                    - If installed, disconnect secondary air intake hose -1- from air cleaner.
                                                    - Disconnect air hose -2- from mass air flow sensor.
                                                    - Unplug connector -3- from mass air flow sensor.
                                                    - Remove bolts -4- and -5-.
                                                    - Remove air cleaner housing.
                                                    - Lay out sufficient lint-free cloths in area below brake master cylinder to catch escaping brake
                                                      fluid.
                                                    - Draw off as much brake fluid as possible from brake fluid reservoir using brake filler and
                                                      bleeder unit VAS 5234.

                                                    - Disconnect connector off relevant pressure sensor (the one to be removed) -arrows-.
                                                    a - Sender 1 for brake booster -G201- in primary piston circuit
                                                    b - Sensor -2- for brake pressure -G214- in secondary piston circuit
                                                    - Remove brake pressure sensor.
Audi TT Coupe 2000-2004, Audi TT Roadster 2001-2004 - Brake System

                                                                                                                            45-25




                                                                     Installing

                                                                     Install in reverse sequence; note the following
                                                                     points:

                                                                     - Bleed brake system      Page 47-25 .

                                                                     - Bleed hydraulic system for clutch:

                                                                       Repair Manual, Manual Transmission, Repair
                                                                     Group 30

                                                                     - Initiate basic settings for brake pressure
                                                                       sensors.

                                                                        Repair Manaual, Brake System On Board
                                                                     Diagnostic (OBD), Repair Group 01

                                                                     Tightening torques

                                                                     Component                                         Nm
                                                                     Brake pressure sensor to brake master             14
                                                                     cylinder
                                                                     Air cleaner housing                               10

				
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posted:2/18/2010
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