display VOLKSWAGEN PASSAT 1995 B3, B4 / 3.G Service Workshop Manual

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Front wheel camber, adjusting Note: - Install special tool as shown in illustration and
slightly pre-tension.
- Loosen suspension strut/wheel bearing housing
connection.
- Adjust camber by turning the spindle to specified
setting.
- Tighten suspension strut/wheel bearing housing
connection.
- Check camber and if necessary, repeat
adjustment. Slight cant of tool is permitted. Do not move steering with tool in place! Before adjusting camber, it is essential to
examine all suspension components for damage
(visual inspection) and to replace any damaged
parts. Because bolts with a shank diameter of 11 mm
diameter have been installed as standard it is no
longer necessary to replace bolts to correct
camber. Page 6 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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Calculating the direction of travel:

- If both toe figures have the same preceding sign
(+/+ or -/-), subtract the smaller figure from the
larger figure and divide by 2 Example.
Left rear wheel
toe
Right rear wheel
toe
+ 15' + 5'
15' - 5' =
10'
10' : 2 = 5'
Deviation from direction of travel = 5'

- Add figures with different sign (+/-) and divide by 2 Example.
Left rear wheel
toe
Right rear wheel
toe
+ 15' - 5'
15' + 5' =
20'
20' : 2 =
10'
Deviation from direction of travel = 10'
The individual result is the actual alignment
deviation from the vehicle longitudinal axis. Page 7 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

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Anti-locking Brake System
(ABS) and Anti-locking Brake
System with Electronic
Differential Lock (ABS/EDL)
Teves 04
The ABS, ABS/EDL brake system is divided
diagonally. The servo-assist is effected
pneumatically, by the vacuum brake servo unit.
Located between the brake master cylinder and
the vacuum servo unit is a mounting bracket for
the hydraulic unit with pump.
The hydraulic unit together with pump, supplies
only the anti-locking brake system (ABS) or anti-
locking brake system and traction control system
(ABS/EDL).
Malfunctions on the ABS, ABS/EDL systems do
not influence the brake system and servo. The
vehicle can be driven without the ABS, ABS/EDL
functions operating. Page 1 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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Notes for repair work on ABS, ABS/EDL
Before doing any repair work on the anti-locking system, determine the cause of the malfunction
using On Board Diagnostic (OBD).
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Before working on the ABS, ABS/EDL system,
disconnect the battery Ground strap. On
vehicles with coded radio, obtain cooling.
When working with brake fluid, observe the
relevant safety precautions and notes Page 47-27 . After work for which the brake system had to be opened, bleed the brake system with brake filler and bleeder unit VAS 5234 Page 47-27 . During the final road test, make sure that a
controlled brake test is performed at least once
(pulsations must be felt at the brake pedal).
Absolute cleanliness is required when working
on the anti-locking brake system; it is not
permitted to use any products which contain
mineral oils, such as oils, greases etc. Page 2 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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Thoroughly clean all unions and the adjacent
areas before loosening, do not use aggressive
cleaning agents such as brake cleaner, petrol,
thinners or similar.
Place removed parts on a clean surface and
cover.
Do not use fluffy cloth. Carefully cover or seal open components if
repairs cannot be carried out immediately.
Only remove replacement parts from packaging
immediately prior to installation.
Only use genuine packed parts. When the system is open do not work with
compressed air and do not move the vehicle.
Make sure that no brake fluid enters harness
connectors.
During painting operations, the electronic
control module can be exposed to a max.
temperature of 95C (203F) for only a short
period, and to a maximum of 85C (185F) for
longer periods (approx. 2 hours). Page 3 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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Control module, removing and installing

Location
Under the rear seat, left

Note:
Switch off ignition before disconnecting and
connecting connectors.

Removing

- Fold up rear seat.
- Press control module securing clips together
and pull out.

- To pull connector off control module, release
control module locking bar.

Installing

- Install in reverse order. - Engage connector catch in control module slots
(arrow A), press connector on (arrow B) and
secure with locking bar (arrow C). Page 4 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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Wheel speed sensor and rotor for speed
sensor, removing and installing

Speed sensor
When installing speed sensor ensure wiring is
not twisted.
Before installing speed sensor, clean mounting
hole and coat with lubricating paste, G 000 650.
Rotors
Before installing check that rotor is clean and
undamaged.

Front axle
Vehicles with base suspension Page 40-14 . Vehicles with plus suspension Page 40-23 .
Rear axle
Vehicles with rear drum brakes Page 42-15 . Vehicles with rear disc brakes (front and four
wheel drive Page 42-24 . Page 5 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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Anti-lock Brake System (ABS)
and ABS with Electronic
Differential Lock (ABS/EDL),
Teves 20 GI

General information The ABS or ABS/EDL braking system is divided
diagonally. Brake pedal pressure is boosted
pneumatically, by the vacuum brake booster.
Vehicles with Teves 20 GI ABS or ABS/EDL do not
have a mechanical brake pressure regulator.
Specially matched software in the ABS control
module regulates rear axle brake pressure. The ABS hydraulic unit -a- and ABS control module -
b- together make up one component. Separating
them for service is only possible after the assembly
has been removed.
New ABS control units supplied as replacement parts
from the Parts department are not coded, and require
coding after installation:
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01
Malfunctions of the ABS or ABS/EDL system do not
influence the brake system or the vacuum brake
booster. The conventional brake system remains
functional even without ABS.
Before working on the ABS or ABS/EDL system,
determine the cause of the malfunction using the On
Board Diagnostic (OBD) program % Repair Manual,
ABS & ABS/EDL On Board Diagnostic. Page 1 of 3Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.2

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Safety precautions

WARNING!

Brake fluid is poisonous.

CAUTION!
Before working on the ABS or ABS/EDL
system, disconnect the battery Ground
(GND) strap. For anti-theft coded radios, first
make sure that the radio code is available.
Brake fluid must not contact painted parts. Brake fluid absorbs moisture from the air
and must therefore be replaced every two
years. Use only new, approved brake fluid
that complies with MVSS 116 DOT 4.
DO NOT use silicone-brake fluid (DOT 5).
Even the smallest traces can cause sever
corrosion in the brake system.
Before doing any welding repairs on the
vehicle using electric welding equipment,
disconnect the ABS control module.
After work that requires opening the brake
hydraulic system, bleed the system Page 47-29 . Page 2 of 3Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.2

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CAUTION!
During the final road test, make sure that at
least one controlled brake test is included
(pulsations must be felt at the brake pedal).
Absolute cleanliness is required when
working on the ABS or ABS/EDL system. DO
NOT use any products that contain mineral
oil, such as oils, greases, etc.
Thoroughly clean all connections and the
immediate vicinity before loosening. DO NOT
use aggressive cleaning agents such as
brake cleaner, gasoline or thinners.
Place removed parts on a clean surface and
cover. DO NOT use fluffy cloths.
Carefully seal or cover opened components
if a repair cannot be completed immediately.
After separating the ABS hydraulic unit and
ABS control module, always use the plastic
foam transportation protection for the valve
dome, and always use the sealing plug kit
Part No. 1 H0 693 311 A.
Only install replacement parts that were
packed in their original packaging. Only
remove them immediately before installation. When the hydraulic system is open DO NOT
work with compressed air in the vicinity and
DO NOT move the vehicle.
Take precautions to make sure that brake
fluid does not enter any wiring harness
connectors. Page 3 of 3Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.2