teves VOLKSWAGEN PASSAT 1995 B3, B4 / 3.G Service Owner's Manual

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Installing
Note:
Before installing new brake pads, press piston back
into the cylinder with resetting tool. Before pressing
the piston back, remove some brake fluid from the
reservoir with a bleeder bottle. If reservoir has been
topped up, fluid may overflow and cause damage. - Remove both guide pins from brake caliper. - Remove brake caliper housing and lay to one side
so that weight of brake caliper does not stress or
damage brake hose.
- Take brake pads out of brake caliper housing or
from brake carrier. - Pressing piston back. Page 6 of 7Front brakes, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.2

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- Install brake pad with retaining spring in brake
caliper housing (piston).

- Install outer brake pad in brake carrier.
- Secure brake caliper housing with both guide
pins to brake carrier.

- Install both protective caps.
- Install retaining spring into brake caliper
housing.

Note:
After replacing the brake pads, depress brake
pedal firmly several times with the vehicle
stationary, so that the brake pads are proper/y
seated in their normal operating position. Page 7 of 7Front brakes, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.2

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Front brake caliper,
servicing
(Teves/Ate)
Note: When repairing install all
parts supplied in repair kit. Apply thin coat of brake
cylinder paste to brake
cylinders, pistons and
seals.
1 - Protective seal Push onto bleed valve 2 - Bleed valve Apply thin coat of brake cylinder paste to threads before
threading in
3 - Cap Install in mounting
bushing
4 - Guide pin, 25 Nm (18 ft
lb)
5 - Mounting bushing Insert into brake
caliper housing Page 1 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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6 - Brake cylinder housing 7 - Brake carrier Install on brake caliper
housing
8 - Retaining spring Install with both ends
in the drillings in brake
caliper housing
9 - Piston seal Remove using a
screwdriver Fig. 2 10 - Piston Force piston out of
brake caliper using
compressed air Fig. 1 Installing Fig. 3 and
Fig. 4 and Fig. 5 First coat the piston
lightly with brake
cylinder paste. Piston diameter 54
mm
11 - Protective seal Do not damage when
installing piston Page 2 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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Note:
Place a piece of wood in the recess to prevent
damaging the piston. Fig. 1 Piston, pressing out of cylinder using
compressed air Fig. 2 Piston seal, removing Page 3 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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Fig. 3 Protective seal, installing Note:
Hold piston in front of caliper housing. Fig. 4 Protective seal, installing - Using a screwdriver, insert inner sealing lip into
cylinder groove Page 4 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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Note:
The protective seal outer sealing lip will then locate in
the piston groove. Fig. 5 Piston, installing Page 5 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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Brake pressure regulator,
checking and adjusting

Vehicles without ABS, vehicles with
ABS, ABS/EDS, Teves 04 The brake pressure regulator is mounted on a bracket
which is in turn fixed to a rear axle mounting bracket
and is controlled from the rear axle by a spring.
Checking operation
Firmly depress the brake pedal and release quickly
(vehicle standing on its wheels). This must cause the
brake pressure regulator lever to move.
Checking and adjusting pressure
Note:
The brake pressure regulator is set with the vehicle
unladened 1)
.
1)
The term "unladen" means: The weight of the
vehicle ready for the road (full fuel tank, spare wheel,
tool kit and jack). Page 1 of 4Brake pressure regulator, checking and adjusting12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.5