teves VOLKSWAGEN PASSAT 1995 B3, B4 / 3.G Service User Guide

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- Release retainer and disconnect ABS control
module connector (arrows).
- Connect bleeder hose and bleeder bottle to left-
front brake caliper bleeder screw, and open
bleeder screw.
- Depress brake pedal at least 60 mm (2-3/8 in.). - Install brake pedal loading device from special tool
VAG 1238B.
- Close left-front bleeder screw. - Remove heat shield from brake master cylinder. - Disconnect brake lines from brake master cylinder
and ABS hydraulic unit.
- Seal lines and threaded holes with plugs from
repair kit Page 45-11 . Page 5 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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-
Remove Torx socket-head bolts (T25) from
ABS hydraulic unit bracket.
- Remove ABS hydraulic unit/ABS control module
assembly.

- Disconnect ABS hydraulic pump connector from
ABS control module. CAUTION! - Remove ABS control module mounting bolts
(arrows) and pull off ABS control module. Pull control module straight off. Do not tilt. Cover control unit magnetic coils with a lint-
free cloth. After separating the ABS hydraulic unit and
ABS control module, always use the plastic
foam valve dome transportation protection
Page 45-11 . Page 6 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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Installing

Note:
Remove the sealing plugs from a new ABS
hydraulic unit one at a time, and only when the
corresponding brake line is to be connected.
If the plugs are removed too soon, brake fluid
can escape and it can no longer be certain that
the unit is sufficiently filled or adequately bled.

- Mount ABS control module to hydraulic unit
using new bolts.

Tightening torque: 4 Nm (35 in lb)
- Reconnect ABS hydraulic pump connector. The remainder of the installation procedure is the
reverse of removal, with the following additions:

- Bleed brake system Page 47-29 . Page 7 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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Note:
For vehicles equipped with ABS/EDL, on which
the brake fluid reservoir has been completely
empty (e.g. leaks in brake system), it is
necessary to initiate the "Basic Setting" function
of the On Board Diagnostic (OBD) program:
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Otherwise the standard brake bleeding
procedures apply.

- Code ABS control module: Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01
Tightening torques

ABS control unit to ABS
hydraulic unit 4 Nm (35 in.
lb)
ABS hydraulic unit to bracket
(Torx T25 socket-head bolts) 8 Nm (71 in.
lb)
Brake master cylinder to
vacuum booster 25
Nm (18 ft
lb)
Heat shield to brake master
cylinder 8 Nm (71 in.
lb)
Brake lines to ABS hydraulic
unit
M10 x 1 15
Nm (11 ft
lb)
M12 x 1 15
Nm (11 ft
lb) Page 8 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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Brake hydraulic system, bleeding and
filling

Vehicles with ABS/EDL
For vehicles with ABS/EDL, when the brake fluid
reservoir has been completely emptied (e.g. due
to leaks in the brake system) it is necessary to
initiate the "Basic Setting" function of the On
Board Diagnostic (OBD) program.
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Otherwise the standard brake bleeding
procedures apply Page 47-29 . Page 9 of 9ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master cylinder (Teves 20 GI), servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.3

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Front brakes,
servicing
(Teves/Ate)
Repair Manual, Maintenance 1 - Screw
2 - Brake disc When worn always
replace on both sides Remove brake caliper
prior to removing Ventilated brake disc
diameter: 288 mm Brake disc thickness:
25 mm Wear limit: 23 mm 3 - Brake pads Always replace on
both sides Pads are different; pad on piston side has
retaining spring Removing and
installing Page 46-12 Pad thickness: 14 mm Checking thickness Wear limit: 7 mm
(including backing
plate) Page 1 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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4 - Retaining spring Insert in both brake
caliper housing
drillings
5 - Brake carrier Supplied as
replacement part
assembled with
sufficient amount of
grease on guide pins If protective caps are
damaged use repair kit Use grease packet
supplied to lubricate
guide pins
6 - Brake caliper housing Do not disconnect
brake hose when
changing brake pads Removing and
installing Page 46-12 Page 2 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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7 - Guide pins, 25 Nm (18
ft lb) Removing and
installing from
Page 46-12 8 - Protective cap
9 - Seal Always replace Pry out with suitable
tool
10 - Brake hose
11 - Banjo bolt, 30 Nm (22 ft lb)
12 - Ribbed bolt, 125 Nm
(92 ft lb)
13 - Wheel bearing housing 14 - Hex socket head bolt,
10 Nm (7 ft lb)
15 - Speed sensor Only on vehicles with
ABS Before inserting
sensor, clean
mounting hole inner
surface and coat with
lubricating paste, G
000 650 Page 3 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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16 - Splash plate
17 - Hex bolt, 10 Nm (7 ft lb) 18 - Speed sensor rotor Only on vehicles with
ABS
19 - Hub Removing and
installing Page 40-14 20 - Countersunk bolt Page 4 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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Brake pads, removing and installing

Removing

Note:
If reusing brake pads mark location and install in
same position or uneven braking may result. - Remove protective caps. - Pry off brake pad retaining spring from brake
caliper housing with a screwdriver and remove. Page 5 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