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

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Brake Light Switch, adjusting

Note:
The Brake Light Switch must be removed for
adjusting.

- Remove trim under instrument panel.
- Disconnect harness connector for Brake Light
Switch.

- Remove Brake Light Switch by turning to right
through 90.
- Pull Brake Light Switch plunger fully out.
- Depress brake pedal as far as possible by hand,
guide Brake Light Switch through the locating
hole and secure by turning through 90to left.
- Pull brake pedal back up by hand to stop (Brake
Light Switch is pushed back by one notch).

- Connect harness connector for Brake Light
Switch

- Check function of Brake Light Switch.
- Install instrument panel trim. Page 9 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6

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Assembly
overview: brake
master
cylinder/brake
servo
Note:
Brake master cylinders and
brake servos from different
manufacturers are installed.
Complete master cylinders and
brake servos can be replaced
independently of each other.
1 - Seal For brake servo 2 - Self-locking hex nut, 20 Nm (15 ft lb)
3 - Mounting bracket
4 - Mounting bracket For brake servo 5 - Seal Page 1 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1

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6 - Brake servo On gas engines the
vacuum required is
taken from the intake
manifold. On Diesel engines an
exhauster is installed
to create the required
vacuum. Functional check - With engine
switched off,
depress brake pedal
firmly several times
(to exhaust the
vacuum in the unit).
- Now depress brake
pedal with average
foot pressure, hold
and start engine. If
the servo unit is working properly, the pedal will be felt to
give slightly under
foot (servo
assistance becomes
effective). If faulty replace
complete. Check valve (item 14 )
is in vacuum hose Functional check - It must be possible
to blow through in
direction of arrow.
- Blowing against the arrow the valve must seat. Page 2 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1

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7 - Sealing ring Always replace 8 - Self-locking hex nut, 20 Nm (15 ft lb)
9 - Brake master cylinder Cannot be repaired. If
faulty, replace
complete.
10 - Sealing plug Moisten with brake
fluid and press into
reservoir
11 - Seal Page 3 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1

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12 - Cap
13 - Brake fluid reservoir
14 - Non-return valve Page 4 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1

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Girling front brake
caliper, servicing
Note: When repairing install all
parts supplied in repair kit. Apply thin coat of brake
cylinder paste to brake
cylinders, pistons and
sea/s.
1 - Protective seal
2 - Bleed valve Apply thin coat of brake cylinder paste to threads before
screwing in
3 - Brake caliper housing
4 - Self-locking hex bolt,
35 Nm (26 ft lb) Always replace When loosening and
tightening counter-hold on guide pin Page 1 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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5 - Seal Remove using a
screwdriver Page 47-7 6 - Piston Removing and
installing Page 47-7 Apply thin coat of
brake cylinder paste
before inserting
7 - Protective seal Do not damage when
inserting piston
8 - Brake carrier with
guide pins and
protective caps Brake carrier with
guide pins and
protective cap Supplied as
replacement part
assembled with
sufficient grease on
guide pins If protective caps or
guide pins are
damaged use repair
kit. Use grease packet
supplied to lubricate
guide pins Page 2 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Front brake caliper pistons, removing
and installing

Removing Note:
Place a piece of wood in the recess to prevent
damaging the piston. - Force piston out of brake caliper housing using
compressed air. Note:
When removing ensure that the surface of the
cylinder is not damaged. - Remove seal with a screwdriver. Page 3 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Installing - Place protective seal with the outer sealing lip on
the piston. Note:
Hold piston in front of caliper housing. - Using a screwdriver, insert the inner sealing lip into the cylinder groove. Page 4 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Note:
The protective seal outer sealing lip will then locate in
the piston groove. - Press piston into the brake caliper housing using
piston resetting tool. Page 5 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2