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

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1 - Brake disc, not
ventilated When worn always
replace on both sides Brake disc diameter:
256 mm Brake disc thickness:
13 mm Wear limit: 11 mm 2 - Brake disc, ventilated When worn always
replace on both sides Brake disc diameter:
256 mm Brake disc thickness:
20 mm Wear limit: 18 mm 3 - Screw
4 - Countersunk screw To secure rotor Only on vehicles with
ABS Page 2 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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Repair Manual, Maintenance 5 - Brake pad With brake pad wear
indicator Always replace on
both sides Removing and
installing Page 46-6 Pad thickness: non-
ventilated brake disc,
14 mm Pad thickness:
ventilated brake disc,
11 mm Checking thickness Wear limit: 7 mm
(including backplate)
6 - Hub Removing and
installing from
Page 40-14 7 - Wheel speed sensor
rotor Only on vehicles with
ABS
8 - Hex bolt, 10 Nm (7 ft lb) 9 - Splash plate Page 3 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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10 - Wheel bearing housing 11 - Brake carrier with
guide pins and
protective caps 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
12 - Heat shield Install in piston 13 - Brake caliper housing Do not disconnect
brake hose when
changing brake pads Page 4 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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14 - Self-locking hex bolt,
35 Nm (26 ft lb) Always replace 15 - Guide pin
16 - Ribbed bolt, 125 Nm
(92 ft lb)
17 - Protective cap
18 - Hex socket head bolt,
10 Nm (7 ft lb)
19 - Speed sensor Only on vehicles with
ABS Before inserting sensor clean mounting hole inner surface and
coat with lubricating
paste, G 000 650 Page 5 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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Brake pads, removing and installing

Removing - Remove lower brake caliper housing securing bolt. Counter-hold on guide pin. - Swing brake caliper housing upward. - Remove brake pads. Page 6 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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Installing

Note:
Before inserting 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. Note: - Press piston back. - Install brake pads. - Swing brake caliper housing down and tighten bolt. The repair kit contains two self-locking bolts which must always be installed. After replacing the brake pads, depress brake
pedal firmly several times with the vehicle
stationary so that the brake pads are properly
seated in their normal operating position. Page 7 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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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