Skoda KODIAQ 2017 Instruction manual

Workshop Manual
Kodiaq 2017 ➤
Kodiaq 2019 ➤
Brake systems
Edition 11.2018
Service
Service Department. Technical Information

List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on vehicles with start-stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions during road tests in which testing and measuring equipment is used . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 PR number assignment – brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Brake inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Testing vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.4 Check the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 General points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Installation location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 ABS/ESP installation location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Exploded view – control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 . . . . . . . . . . . . . . 19
3.3 Disconnecting the control unit from the hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4 Fitting the control unit to the hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.5 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.3 Removing and installing the brake pressure sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.4 Removing and installing the handbrake switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.5 Removing and installing the sensor unit for stabilisation program G419 . . . . . . . . . . . . . . 43
4.6 Removing and installing front speed sensors G45 / G47 . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.7 Removing and installing the rear speed sensors G44 / G46 . . . . . . . . . . . . . . . . . . . . . . . . 43
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.2 Removing and installing brake pads, front brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.3 Removing and installing brake caliper, front brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.4 Removing and installing brake discs, front brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.5 Removing and installing brake shield plates, front brake . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.2 Removing and installing brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.3 Removing and installing brake caliper, rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.4 Removing and installing brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.5 Removing and installing brake shield plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1 Assembly overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.2 Removing and installing control unit for electronic handbrake J540 . . . . . . . . . . . . . . . . . . 69
3.3 Removing and installing handbrake motor V282 / V283 . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
Contents i

4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.2 Removing and installing bearing bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.3 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.4 Clipping the brake pedal onto the brake servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.5 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1 Front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.1 Summary of components - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2 Rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.1 Summary of components - rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2.2 Removing and installing protective cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3 Brake servo unit and master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.1 Summary of components - brake servo unit and master brake cylinder . . . . . . . . . . . . . . 88
3.2 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.3 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.4 Removing and installing master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.5 Check the operation of the brake servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.1 Exploded view – vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.2 Checking the non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.3 Removing and installing vacuum sensor G608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.4 Checking the vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
5 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
5.1 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.2 Prebleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.3 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.4 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.5 Testing leak-tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
ii Contents

00 – Technical data
1 Safety instructions
(SRL001300; Edition 11.2018)
⇒ “1.1 Safety precautions when working on vehicles with start-
stop system”, page 1
⇒ “1.2 Safety precautions during road tests in which testing and
measuring equipment is used”, page 1
1.1 Safety precautions when working on ve‐
hicles with start-stop system
When working on vehicles with start/stop system, please observe
the following instructions:
CAUTION
Risk of injury as a result of automatic engine start in vehicles
with start/stop system.
♦ In vehicles with the start/stop system activated (identifiable
by an indication in the dash panel insert) the engine can start
automatically if required.
♦ Make sure that the start-stop system is deactivated when
carrying out work on the vehicle (switch ignition off, if nec‐
essary switch ignition on again).
1.2 Safety precautions during road tests in
which testing and measuring equipment
is used
Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
There is a risk of accident from deflection and insufficient se‐
curing of testers and measuring instruments.
♦ Using testers and measuring instruments during driving cau‐
ses distraction.
♦ There is an increased risk of injury from unsecured testers
and measuring instruments.
♦ Always attach the testing and measurement equipment to
the rear seat.
♦ Always have the testing and measurement equipment op‐
erated by a 2nd person.
♦ Always operate the testing and measurement equipment
from the rear seat.
♦ Do not operate the testing and measurement equipment
from the front passenger seat.
♦ Persons can be injured by the release of the passenger air‐
bag in the event of an accident.
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
1. Safety instructions 1

2 Identification
⇒ “2.1 PR number assignment – brake”, page 2
2.1 PR number assignment – brake
The brake type installed in the vehicle is indicated by PR num‐
bers.
The PR numbers are listed in the service plan. The information
about the brakes that have been installed (PR number) can be
found in the ELSA Pro system “vehicle data” section.
Search the PR number of the brakes in the category “vehicle da‐
ta”: enter a brake family (front brakes - BAV family, rear brakes -
BAH family) in the search engine.
Assignment is dependent on the engine type ⇒ Electronic Cata‐
logue of Original Parts .
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
2 Rep. gr.00 - Technical data

3 Technical data
⇒ “3.1 Technical data for brakes”, page 3
3.1 Technical data for brakes
⇒ “3.1.1 Master brake cylinder and brake servo”, page 3
⇒ “3.1.2 Front brakes”, page 3
⇒ “3.1.3 Rear brake”, page 4
⇒ “3.1.4 Brake fluid”, page 5
3.1.1 Master brake cylinder and brake servo
Assignment is dependent on the engine type ⇒ Electronic Cata‐
logue of Original Parts .
Master brake cyl‐
inder - ∅ mm 23.81; 25.4
Brake servo unit
- ∅ Inc hLeft-hand drive: 11
Right-hand drive: 8"/8"
3.1.2 Front brakes
Assignment is dependent on the engine type ⇒ Electronic Cata‐
logue of Original Parts .
Explanations concerning PR Numbers
⇒ “2.1 PR number assignment – brake”, page 2 .
Front brake PC 57
Front brake caliper (type denomination) PC 57 (16")
PR number 1ZA
Front brake caliper, piston - ∅ m
m57
Front brake disc – ∅ m
m312
Brake disc, thickness m
m25
Brake disc, minimum thickness m
m22
Pad thickness without supporting plate m
m14
Minimum pad thickness without sup‐
porting plate m m2
Front brake C 60
Front brake caliper (type denomination) C 60 (16")
PR number 1LW
Front brake caliper, piston - ∅ m
m60
Front brake disc – ∅ m
m314
Brake disc, thickness m
m30
Brake disc, minimum thickness m
m27
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
3. Technical data 3

Front brake caliper (type denomination) C 60 (16")
PR number 1LW
Pad thickness without supporting plate m
m14
Minimum pad thickness without sup‐
porting plate m m2
Front brake C 60
Front brake caliper (type denomination) C 60 (17")
PR number 1LA, 1LG
Front brake caliper, piston - ∅ m
m60
Front brake disc – ∅ m
m340
Brake disc, thickness m
m30
Brake disc, minimum thickness m
m27
Pad thickness without supporting plate m
m14
Minimum pad thickness without sup‐
porting plate m m2
3.1.3 Rear brake
Assignment is dependent on the engine type ⇒ Electronic Cata‐
logue of Original Parts .
Explanations concerning PR Numbers
⇒ “2.1 PR number assignment – brake”, page 2 .
Rear brake FNcM42
Rear brake caliper (type denomination) FNc-M42 (16”)
PR number 1KU
Rear brake caliper, piston - ∅ m
m42
Rear brake disc – ∅ m
m300
Brake disc, thickness m
m12
Brake disc, minimum thickness m
m10
Pad thickness without supporting plate m
m11
Minimum pad thickness without sup‐
porting plate m m2
Rear brake FNcM42
Rear brake caliper (type denomination) FNc-M42 (17”)
PR number 1KJ
Rear brake caliper, piston - ∅ m
m42
Rear brake disc – ∅ m
m310
Brake disc, thickness m
m22
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
4 Rep. gr.00 - Technical data

Rear brake caliper (type denomination) FNc-M42 (17”)
PR number 1KJ
Brake disc, minimum thickness m
m20
Pad thickness without supporting plate m
m11
Minimum pad thickness without sup‐
porting plate m m2
3.1.4 Brake fluid
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
3. Technical data 5

Classification Only use new original brake fluid N.052.766.Z0 as per US standard FMVSS 571.116, DOT 4 and VW standard 501 14
Top-up ⇒ Maintenance ; Booklet Kodiaq
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
6

4 Brake inspection
⇒ “4.1 General points”, page 7
⇒ “4.2 Checking vehicles with front-wheel drive”, page 7
⇒ “4.3 Testing vehicles with four-wheel drive”, page 7
⇒ “4.4 Check the parking brake”, page 8
4.1 General points
♦ The test stand is used as drive.
♦ During the testing, the idling speed must be set on vehicles
with manual gearbox and the driving position »N« must be
engaged on vehicles with automatic gearbox.
♦ When conducting the test, observe the specifications provided
by the manufacturer of the test rig.
Note
The brake regulation systems do not function when ignition is off.
4.2 Checking vehicles with front-wheel drive
The brake test must be performed on a single-axle roller dyna‐
mometer.
The test speed must not exceed 6 km/h.
The test stands approved by Škoda comply with these conditions.
4.3 Testing vehicles with four-wheel drive
The brake inspection must be performed on a contra-rotative sin‐
gle axle roller type test stand for vehicles with four-wheel drive.
Contra-rotative means: The test stand rollers of the single axle
roller type test stand rotate forwards on the one side and back‐
wards on the other side.
Thus, a transfer of the braking forces in the drive train is preven‐
ted.
The wheel which rotates forwards is measured each time during
the test, this requires the need of two braking tests per axle.
The test speed must not exceed 6 km/h.
The test stands approved by Škoda comply with these conditions.
If a test stand is not available for vehicles with four-wheel drive,
the brake inspection can also be performed on a standard single
axle roller type test stand as follows:
– Drive the vehicle forwards onto the rollers.
– Switch off engine and wait 2 seconds.
– Perform brake inspection at the front.
– Start engine and wait approx. 5 seconds until adequate vac‐
uum has built up.
– Drive the vehicle forwards until the rear wheels are standing
on the rollers.
– Switch off engine and wait 2 seconds.
– Perform brake inspection at the rear.
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
4. Brake inspection 7

– Start engine and wait approx. 5 seconds until adequate vac‐
uum has built up.
4.4 Check the parking brake
⇒ “4.4.1 Check electromechanical parking brake, vehicles with
front drive”, page 8
⇒ “4.4.2 Check electromechanical parking brake, vehicles with
all-wheel drive”, page 8
4.4.1 Check electromechanical parking
brake, vehicles with front drive
Enable »MOT mode«
• Safety belt is installed.
• Rear axle is on the 1-axle roller test stand
• Ignition is switched on.
• »Auto Hold« is switched off.
• Front wheels must be stationary.
• The rear wheels must rotate constantly between 2.5 and 9 km /
h for at least 5 seconds.
Enabled »MOT mode« is signalled by the yellow Electric parking
and handbrake fault lamp - K214- lighting up.
Note
The electromechanical parking brake does not fully close in
»MOT mode« when the button for the electromechanical parking
brake - E538- is pressed for the first time.
After the Button for the electromechanical parking brake - E538-
is pressed four times in succession, the parking brake fuly locks.
Pressing the button for the electromechanical parking brake -
E538- leads to the electromechanical parking brake being re‐
leased.
End »MOT mode«
• Front wheels have a speed greater than 0 km / h.
• Rear wheels have a speed less than 2.5 km / h or greater than
9 km / h.
• The ignition is switched off.
4.4.2 Check electromechanical parking
brake, vehicles with all-wheel drive
Enable »MOT mode«
• Safety belt is installed.
• Rear axle is on the 1-axle roller test stand
• Ignition is switched on.
• »Auto Hold« is switched off.
• Front wheels must be stationary.
• The rear wheels must rotate constantly between 2.5 and 9 km /
h for at least 5 seconds.
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
8

Enabled »MOT mode« is signalled by the yellow Electric parking
and handbrake fault lamp - K214- lighting up.
Note
The electromechanical parking brake does not fully close in
»MOT mode« when the button for the electromechanical parking
brake - E538- is pressed for the first time.
After the Button for the electromechanical parking brake - E538-
is pressed four times in succession, the parking brake fuly locks.
Pressing the button for the electromechanical parking brake -
E538- leads to the electromechanical parking brake being re‐
leased.
– Start engine and wait approx. 5 seconds until adequate vac‐
uum has built up.
End »MOT mode«
• Front wheels have a speed greater than 0 km / h.
• Rear wheels have a speed less than 2.5 km / h or greater than
9 km / h.
• The ignition is switched off.
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
4. Brake inspection 9

45 – Anti-lock brake system
1 General points
⇒ “1.1 Repair instructions for repair work on ABS”, page 10
1.1 Repair instructions for repair work on
ABS
The ABS brake system is split diagonally. Brake servo assistance
is provided pneumatically by the vacuum brake servo.
Vehicles fitted with ABS do not have a mechanical brake pressure
regulator. Specifically matched software in the ABS control unit -
J104- regulates the brake pressure distribution on the rear axle.
Note
♦ If the ABS hydraulic unit - N55- is damaged, the ABS control
unit - J104- and the ABS hydraulic unit - N55- must be fully
replaced.
♦ The ABS control unit - J104- can be separated from the ABS
hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”,
page 34 .
♦ The hydraulic pump and the ABS hydraulic unit - N55- must
not be separated from each other.
♦ Faults in the ABS do not influence the brake system and servo
assistance. The conventional braking system remains fully
functional even without ABS. There will be a change in braking
behaviour. After the ABS warning lamp comes on, the rear
wheels may lock prematurely during braking.
Arrangement of the ABS, left-hand drive vehicle
1 - ABS hydraulic unit - N55- with ABS control unit - J104-
2 - Brake servo
Arrangement of the ABS in right-hand drive vehicles
1 - Brake servo
2 - ABS hydraulic unit - N55- with ABS control unit - J104-
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
10 Rep. gr.45 - Anti-lock brake system

The ABS control unit - J104- -1- and the ABS hydraulic unit - N55-
-2- form a single unit. They can only be separated after the
complete unit is removed. The ABS control unit - J104- can be
separated from the ABS hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page
34 . The hydraulic pump -3- must not be separated from the ABS
hydraulic unit - N55- -2-.
New control units supplied by the spare parts area are not coded.
They must be coded after installation ⇒ Vehicle diagnostic tester.
♦ Before starting work on anti-lock brake systems, query the
event memory to check for complaints and conduct guided
fault finding ⇒ Vehicle diagnostic tester.
♦ Do not separate plug connections unless the ignition is switch‐
ed off.
♦ Before working on anti-lock braking systems, switch off the
ignition and disconnect the ground strap from the battery ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnect and con‐
nect battery .
♦ If the battery earth strap is disconnected and connected, carry
out additional operations ⇒ Electrical System; Rep. gr. 27 ;
Battery .
♦ Welding work using electric welding equipment may affect the
ABS system.
♦ Do the following before commencing welding work using elec‐
trical welding tool:
– Disconnect the earth strap from the negative terminal of the
battery and cover the negative terminal.
– Connect the earth connection of the electric welding tool di‐
rectly to the part to be welded. There must not be any electri‐
cally insulated parts between the earth connection and the
welding point.
– Electronic control units and electrical wiring must not touch the
earth connection or the welding electrode.
♦ During painting operations, the ABS control unit - J104- may
be exposed to a maximum temperature of 95 °C for only a
short period, and to a maximum of 85 °C for longer periods
(approx. 2 hours).
♦ Do not drive the vehicle if the connector is unplugged from the
ABS control unit - J104- .
♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean connection points and the surrounding area
before disconnecting, but do not use any aggressive cleaning
agents, such as brake cleaner, petroleum, thinner or similar.
♦ Place removed parts on a clean surface and cover.
♦ Carefully cover or close opened components if the repair is not
completed immediately (use plugs from the repair kit - 1H0 698
311 A- ).
♦ Only use lint-free cloths.
♦ Do not remove spare parts from their wrappings until immedi‐
ately before installation.
♦ Use only genuine wrapped parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
1. General points 11

♦ The valve coils in the ABS control unit - J104- must not be
calibrated.
♦ The valve coils in the ABS control unit - J104- cannot be re‐
placed.
♦ The pressure sensor must not be modified or damaged.
♦ The pressure sensor cannot be replaced.
♦ The sensor housing must not be subjected to mechanical load.
♦ No measurements must be carried out at the contact points of
the ABS control unit - J104- .
♦ No measurements must be carried out at the contact points of
the ABS hydraulic unit - N55- .
♦ The valve domes of the ABS hydraulic unit - N55- must not be
damaged or bent.
♦ The contacts on the ABS control unit - J104- and the ABS hy‐
draulic unit - N55- cannot be replaced.
♦ Do not use contact spray.
♦ No contamination or foreign object may located between ABS
control unit - J104- and ABS hydraulic unit - N55- .
♦ Ensure that no brake fluid enters connectors.
♦ Observe the relevant instructions when handling brake fluid.
♦ After completing work which involved opening the brake sys‐
tem, bleed the brake system with the brake filling and bleeding
device , e.g. -VAS 5234- ,
⇒ “6.3 Bleeding hydraulic system following standard proce‐
dure”, page 125 .
♦ During the subsequent road test, ensure that at least one con‐
trolled brake application is performed (pulsing must be felt on
the brake pedal).
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
12 Rep. gr.45 - Anti-lock brake system

2 Installation location overview
⇒ “2.1 ABS/ESP installation location overview”, page 13
2.1 ABS/ESP installation location overview
Note
♦ If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the
ABS hydraulic unit - N55- .
♦ The ABS control unit - J104- can be separated from the ABS hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 34 .
♦ The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.
1 - ABS hydraulic unit - N55-
with ABS control unit - J104-
❑ Fitting location
⇒ “1.1 Repair instruc‐
tions for repair work on
ABS”, page 10
❑ do not disconnect the
plug connection before
the self-diagnosis is
complete; switch off the
ignition before discon‐
necting the plug con‐
nection
The following components are
integrated in the ABS control
unit - J104- :
♦ Sensor unit for ESP - G419-
♦ Control unit for electronic
handbrake - J540-
♦ Lateral acceleration sender
- G200-
♦ Yaw rate sender - G202-
♦ Longitudinal acceleration
sender - G251- (depending
on equipment fitted)
♦ the components cannot be
changed individually
❑ Check ⇒ Vehicle diag‐
nostic tester
❑ Removing and installing
the ABS control unit -
J104- with the ABS hy‐
draulic unit - N55-
⇒ “3.2 Removing and
installing ABS control
unit J104 / ABS hydraul‐
ic unit N55 ”, page 19
❑ Disconnecting the control unit from the hydraulic unit
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 34
❑ Fitting the control unit to the hydraulic unit
⇒ “3.4 Fitting the control unit to the hydraulic unit”, page 35
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
2. Installation location overview 13

2 - Front right wheel speed sensor - G45-
❑ Check ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ “4.6 Removing and installing front speed sensors G45 / G47 ”, page 43
3 - Switch module 1 in centre console - EX23-
❑ includes depending on the vehicle equipment:
♦ Button for AUTO HOLD - E540-
♦ Control light for AUTO HOLD - K237-
♦ Indicator light for electro-mechanical parking brake - K213-
♦ Button for electro-mechanical parking brake - E538-
♦ Button for stability control ESC / traction control ASR
♦ Button for OFF ROAD mode
❑ 2 versions of ESC operation depending on vehicle equipment fitted
1. Button on the centre console
2. In the Infotainment system “settings” menu
❑ Check ⇒ Vehicle diagnostic tester
❑ The button is part of the switch module 1 central console - EX23- and can not be replaced individually
⇒ Electrical system; Rep. gr. 96 ; controls; Button for electromechanical parking brake - E538- / Button
for AUTO HOLD - E540- Removing and installing
4 - Rear right wheel speed sensor - G44-
❑ Check ⇒ Vehicle diagnostic tester
❑ Removing and installing
⇒ “4.7 Removing and installing the rear speed sensors G44 / G46 ”, page 43
5 - Brake line
❑ to rear right brake caliper
❑ 14 Nm
6 - Brake line
❑ to rear left brake caliper
❑ 14 Nm
7 - Speed sensor rear left - G46-
❑ Check ⇒ Vehicle diagnostic tester
❑ Removing and installing
⇒ “4.7 Removing and installing the rear speed sensors G44 / G46 ”, page 43
8 - Front left wheel speed sensor - G47-
❑ Check ⇒ Vehicle diagnostic tester
❑ Removing and installing ⇒ “4.6 Removing and installing front speed sensors G45 / G47 ”, page 43
9 - Brake light switch - F-
❑ Fitting location: on master brake cylinder
❑ Removing and installing ⇒ “3.2 Removing and installing brake light switch”, page 93
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
14 Rep. gr.45 - Anti-lock brake system

3 Control unit and hydraulic unit
⇒ “3.1 Exploded view – control unit and hydraulic unit”,
page 15
⇒ “3.2 Removing and installing ABS control unit J104 / ABS hy‐
draulic unit N55 ”, page 19
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page
34
⇒ “3.4 Fitting the control unit to the hydraulic unit”, page 35
⇒ “3.5 Connecting brake lines to hydraulic unit”, page 36
3.1 Exploded view – control unit and hy‐
draulic unit
⇒ “3.1.1 Exploded view – control unit and hydraulic unit, left-hand
drive vehicle”, page 15
⇒ “3.1.2 Exploded view – control unit and hydraulic unit, right-
hand drive vehicle”, page 18
3.1.1 Exploded view – control unit and hydraulic unit, left-hand drive vehicle
Note
♦ Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after
removal.
♦ If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the
ABS hydraulic unit - N55- .
♦ The ABS control unit - J104- can be separated from the ABS hydraulic unit - N55-
⇒ “3.3 Disconnecting the control unit from the hydraulic unit”, page 34 .
♦ The hydraulic pump and the ABS hydraulic unit - N55- must not be separated from each other.
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
3. Control unit and hydraulic unit 15

1 - ABS control unit - J104-
❑ Removing and installing
⇒ “3.2 Removing and in‐
stalling ABS control unit
J104 / ABS hydraulic
unit N55 ”, page 19
❑ Disconnecting the con‐
trol unit from the hy‐
draulic unit
⇒ “3.3 Disconnecting
the control unit from the
hydraulic unit”,
page 34
❑ Fitting the control unit to
the hydraulic unit
⇒ “3.4 Fitting the control
unit to the hydraulic
unit”, page 35
2 - ABS hydraulic unit - N55-
❑ Removing and installing
⇒ “3.2 Removing and in‐
stalling ABS control unit
J104 / ABS hydraulic
unit N55 ”, page 19
3 - Screw
❑ tighten Torx screw in 2
stages alternately on af‐
ter the other
❑ 1st level: Preliminary
tightening torque: 1 Nm
to 1.5 Nm (to fit the seal)
❑ 2nd level: final tighten‐
ing torque: 2.5 Nm
4 - Brake line
❑ to rear right brake cali‐
per
❑ Distinguishing feature: ∅ 5.25 mm and pipe screw with long thread M12 x 1
❑ 14 Nm
5 - Brake line
❑ to front left brake caliper
❑ Distinguishing feature: ∅ 5.25 mm and pipe screw with long thread M10 x 1
❑ 14 Nm
6 - Brake line
❑ to front right brake caliper
❑ Distinguishing feature: ∅ 5.25 mm and pipe screw with long thread M12 x 1
❑ 14 Nm
7 - Brake line
❑ to rear left brake caliper
❑ Distinguishing feature: ∅ 5.25 mm and pipe screw with long thread M10 x 1
❑ 14 Nm
8 - Brake line
❑ from master brake cylinder (push rod piston circuit) to ABS hydraulic unit - N55-
❑ Distinguishing feature: ∅ 6 mm and pipe screw with long thread M12 x 1
❑ 14 Nm
Kodiaq 2017 ➤ , Kodiaq 2019 ➤
Brake systems - Edition 11.2018
16 Rep. gr.45 - Anti-lock brake system
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