3.6.1 Brake Lamp Switch

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1 2002 TT/TTS Coupe/Roadster Report a problem with this article The ESP road test ascertains the plausibility of the signals transmitted from sender 1 for brake booster -1- -G201-, sensor -2- for brake pressure -G214-, Transverse Acceleration Sensor -G200-, Rotation Rate Sensor -G202- and the longitudinal acceleration sensor -G251- (vehicles with all wheel drive only). On vehicles from approx the three last-mentioned senders are integrated into the ESP sensor unit Brake Lamp Switch, page Transverse Acceleration Sensor and Rotation Rate Sensor, through 08.01, page Longitudinal Acceleration Sensor, through 08.01, page ESP Sensor Unit, page Steering Angle Sensor, page Brake Pressure Sensors, page Brake Lamp Switch For a secure fit, the switch may only be installed once. Remove storage compartment on driver's side. Refer to Unplug electrical connector. Remove brake light switch by turning counter-clockwise 45. Pull brake light switch plunger fully out (arrow). Install retainer tabs -1- and -2- on switch into recesses of installing hole and secure by turning clockwise 45. 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. 1/6

2 3.6.2 Transverse Acceleration Sensor and Rotation Rate Sensor, through Work Procedure Remove storage compartment on driver's side. Refer to Unplug electrical connectors -arrows- on sensors -G200- / - G202-. Mounting bracket maybe welded instead of being bolted. Remove bolt -1- and remove mounting bracket for sensors - G200- -/ -G202-. and installing Rotation Rate Sensor -G202- Unscrew nuts -a- and remove Rotation Rate Sensor -G To install: insert Rotation Rate Sensor -G202- into mounting bracket and align straight before tightening. 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. and installing Transverse Acceleration Sensor -G200- Use screwdriver to pry mount -1- off Transverse Acceleration Sensor -G and remove sender. To install insert Transverse Acceleration Sensor -G in holder. 2/6

3 Installation position: sloping side -arrow- of Transverse Acceleration Sensor -G200- must face mount -2-. Slip mount over Transverse Acceleration Sensor -G200- until it engages with a click The lateral acceleration sender is not resistant to shocks or impact. Do not install a sender which has dropped to the ground otherwise proper operation is not ensured. The remaining installation steps are carried out in the reverse sequence - note the following points: Initiate basic setting for Transverse Acceleration Sensor -G200- and Rotation Rate Sensor -G202-. Refer to Brake System On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing Perform ESP road test. Refer to Brake System On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing Tightening Specification Component Sender for rotation rate to holder 9 Holder for sender to mounting bracket for steering column Longitudinal Acceleration Sensor, through Remove glove box. Refer to Body Interior; Rep. Gr. 68 ; Removal and Installation Unplug electrical connector -2- Use a screwdriver to pry mount off longitudinal acceleration sensor -arrows- and remove Longitudinal acceleration sensor -G Nm 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. Initiate basic setting for longitudinal acceleration Longitudinal acceleration sensor -G251-. Refer to Brake System On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing Perform ESP road test. Refer to Brake System On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing 3/6

4 3.6.4 ESP Sensor Unit Remove storage compartment on driver's side. Refer to Remove bolts (arrows). Pull ESP sensor unit -1- in direction of travel and out of holder. Unplug electrical connector -2-. The ESP sensor unit is not resistant to shocks or impact. Do not install an ESP sensor which has dropped to the ground otherwise proper operation is not ensured. Initiate basic setting for the sensors in the ESP sensor unit. Refer to Brake System On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing Perform ESP road test. Refer to Brake System On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing Tightening Specification Component ESP sensor unit to holder Steering Angle Sensor Nm The coil connector with slip ring is enclosed in the housing of the steering angle sensor -G85-. Turn wheels to straight ahead position. airbag unit and steering wheel. Refer to Body Interior; Rep. Gr. 69 ; Removal and Installation Remove storage compartment on driver's side. Refer to 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. 4/6

5 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. 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. airbag unit and steering column. Refer to Body Interior; Rep. Gr. 69 ; Removal and Installation Initiate basic settings for Steering angle sensor -G85-. Refer to Brake System On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing Perform ESP road test. Refer to Brake System On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing Brake Pressure Sensors Special tools and workshop equipment required Brake Filler and Bleeder Unit -VAS /6

6 Remove screws (arrows). Remove forward left-hand cover panel. 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. Unscrew 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 Pull connector off relevant pressure sender (the one to be removed) -arrows-. -a- Brake Pressure Sensor 1 -G201- in primary piston circuit -b- Brake Pressure Sensor 2 -G214- in secondary piston circuit Remove brake pressure sender. Bleed brake system 1.5 Brake System, ABS/ESP, Mark 60, Bleeding, page 119 Bleed hydraulic system for clutch. Refer to Manual Transmission; Rep. Gr. 30 ; Removal and Installation Initiate basic settings for brake pressure sensors. Refer to Brake System On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing Perform ESP road test. Refer to Brake System On Board Diagnostic; Rep. Gr. 01 ; Diagnosis and Testing Tightening Specification Component Brake pressure sensor to brake master cylinder 14 Air cleaner housing 10 Nm 6/6