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

Downloaded from www.Manualslib.com manuals search engine Rear axle, servicing (four wheel drive vehicles)
Rear drive shafts, servicing
Reworking cap nut in side member (four wheel drive vehicles)
Suspension strut, disassembling and assembling (four wheel drive
vehicles)
Wheel bearings, servicing - disc brakes (four wheel drive vehicles)
44 - Wheels, Tires, Wheel alignment
Vehicle alignment
Test requirements:
Vehicle alignment specifications (front wheel drive vehicles)
Vehicle alignment specifications (four wheel drive vehicles)
Front wheel camber, adjusting
Calculating the direction of travel:
45 - Anti-lock brake system
Anti-locking Brake System (ABS) and Anti-locking Brake System with
Electronic Differential Lock (ABS/EDL) Teves 04
Notes for repair work on ABS, ABS/EDL
Control module, removing and installing
Wheel speed sensor and rotor for speed sensor, removing and installing
Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock
(ABS/EDL), Teves 20 GI
Safety precautions
ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master
cylinder (Teves 20 GI), servicing
ABS hydraulic unit and ABS control module (Teves 20 GI), removing and
installing
Brake hydraulic system, bleeding and filling
Assembly overview - hydraulic unit, brake servo/brake master cylinder
Hydraulic unit, removing and installing
Brake Pedal Position Sensor, removing and installing
46 - Brakes - Mechanical components
Front brakes, servicing (Girling caliper)
Brake pads, removing and installing

Downloaded from www.Manualslib.com manuals search engine Front brakes, servicing (Teves/Ate)
Brake pads, removing and installing
Rear wheel brakes, servicing (drum brakes)
Brake shoe adjustment, releasing
Rear wheel brakes, servicing
Brake shoes, removing and installing
Parking brake, adjusting (drum brakes)
Rear wheel brakes, servicing (disc brakes)
Girling rear wheel disc brakes (front and four wheel drive vehicles)
Brake pads, removing and installing
Parking brake, adjusting (disc brakes)
Parking brake lever assembly overview
Brake pedal/brake servo, removing and installing
Brake pedal, removing and installing
Brake Light Switch, adjusting
47 - Brakes - Hydraulic components
Assembly overview: brake master cylinder/brake servo
Girling front brake caliper, servicing
Front brake caliper pistons, removing and installing
Front brake caliper, servicing (Teves/Ate)
Rear brake caliper, servicing
Rear brake caliper piston, removing and installing
Pre-bleeding brake caliper
Brake pressure regulator, checking and adjusting
Vehicles without ABS, vehicles with ABS, ABS/EDS, Teves 04
Load dependent brake pressure regulator specifications
Adjusting regulator
Brake system, bleeding
Brake system, bleeding (vehicles with and without ABS, ABS/EDL)
Brake system, bleeding (with pressure bleeder VAS 5234)
Brake system, bleeding (without pressure bleeder)

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5 - Brake caliper Do not loosen brake
hose when working on
front suspension Hang up with wire or
similar Replacing brake pads
Page 46-6 6 - Countersunk screw
7 - Hub Pressing out Fig. 2 Pressing in Fig. 6 Pulling off inner race
Fig. 3 8 - Speed sensor rotor Only for vehicles with
ABS
9 - Hex bolt, 10 Nm (7 ft lb) 10 - Splash plate Page 37 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

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3 - Speed sensor Only on vehicles with
ABS Before installing
sensor, clean
mounting hole inner
surface and coat with
lubricating paste G
000 650
4 - Brake hose bracket
5 - Hex socket head bolt,
65 Nm (48 ft lb)
6 - Self-locking hex bolt,
35 Nm (26 ft lb) Always replace 7 - Guide pins
8 - Protective cap
9 - Pad retaining spring Replace when
changing pads Page 11 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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10 - Cover ring Always replace Installation position
Fig. 5 Drive on with tube VW
519
11 - Pad carrier
12 - Brake pads Removing and
installing Page 46-33 13 - Brake caliper Servicing Page 47-15 14 - Outer wheel bearing Drive out outer race
with copper drift Pressing in Fig. 6 15 - Hex nut Adjusting wheel
bearing play Fig. 4 16 - Cotter pin Always replace Page 12 of 18Wheel bearings, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.2

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Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 46
Repair Manual, Suspension, Wheels,Brakes, Steering, Repair Group 47 4 - Guide pins
5 - Protective cap
6 - Pad securing springs Always replace when
changing pads
7 - Brake pads Repair information 8 - Brake caliper Servicing 9 - Pad carrier
10 - Screw
11 - Wheel bolt, 110 Nm (81
ft lb) Page 2 of 8Wheel bearings, servicing - disc brakes (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.6

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Front brakes,
servicing (Girling
caliper)
Note: After replacing brake pads,
depress brake pedal firmly
several times with vehicle
stationary so that the brake
pads are properly seated in
their normal operating
position. To remove brake fluid from
the reservoir, use a bleeder
bottle which is used only for
brake fluid. Brake fluid is
poisonous and must on not
be siphoned by mouth
using a hose! Wheel bolt tightening
torque: 110 Nm (81 ft lb) Page 1 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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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