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

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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

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ABS hydraulic unit and ABS control
module (Teves 20 GI), removing and
installing
Carefully read and follow all cautions and
warnings Page 45-7 before beginning work.
Location
The ABS control module is bolted to the ABS
hydraulic unit, located on the left-side of the
engine compartment.

CAUTION!
Do not bend brake lines at or near the ABS
hydraulic unit.
Switch ignition OFF when disconnecting and
reconnecting the ABS control module
connector.
Part numbers are listed here for reference
only. Always check with your Parts
department for the latest information. Sealing plug kit Part No. 1H0 698 311 A:
1 - Valve dome transportation protection (plastic
foam)
2 - Sealing plugs -M10- 3 - Sealing plugs -M12- Page 3 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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- 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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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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Hydraulic unit, removing and installing

Note:
For easier disassembling and assembling, it is
more practical to remove the hydraulic unit
complete with brake servo and brake master
cylinder.

Removing

- Disconnect battery Ground (GND) strap.
- Separate all electrical connections on ABS
unit.

- Remove as much brake fluid as possible from
brake fluid reservoir using a suction bottle.

- Disconnect brake lines from ABS hydraulic unit
and seal threaded holes with plugs from repair
kit, Part No. 1HO 698 311.

- Remove left-hand trim under instrument
panel.

- Disconnect brake pedal from brake servo unit
Page 46-44 . Page 6 of 10Assembly overview - hydraulic unit, brake servo/brake master cylinder12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.4

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- Remove nuts from brake servo/bulkhead.
- Carefully remove hydraulic unit and brake servo
with brake master cylinder from engine
compartment.

Installing

Note:
Hydraulic units supplied as replacement parts
are already filled with hydraulic fluid and bled.
Only remove sealing plugs on hydraulic unit
when the relevant brake line is going to be
connected.
If the sealing plugs are removed too early,
brake fluid can escape, it is then no longer
guaranteed that the unit is sufficiently filled or
adequately bled.

- Preassemble hydraulic unit and brake servo with tandem master cylinder away from vehicle.

- Secure hydraulic unit, brake servo with tandem
master cylinder to bulkhead.

- Connect brake lines.
- Reconnect all electrical connections on ABS unit (ensure correctly connected).

- Bleed brake system Page 47-27 .
- Install left-hand trim under instrument panel. Page 7 of 10Assembly overview - hydraulic unit, brake servo/brake master cylinder12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.4

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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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Instead of plastic sealing plugs a plug consisting of
Part No.113 301 229 A and banjo bolt, Part No. N
904 674 01 can be used. But when using these,
several 16 mm diameter sealing rings must be used
so that the holes in the banjo bolt are sealed. - Support engine/transmission assembly with 10-
222 A and 10-222 A/1 (support VR6 engine with
10-222A and 10-222A/3).
- Remove boot from seat on steering gear. - Remove subframe bolts. - Lower engine/transmission assembly; this will pull
the two halves of the universal joint apart.
- Disconnect hoses from steering gear and seal with plastic bag and adhesive tape.
- Seal power steering gear threaded holes with
plastic sealing plugs.
- Remove steering gear securing nuts (bolts remain
in subframe).
- Remove steering gear rearward. Page 17 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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7 - O-ring Is assembled on
toothed rod guide
(item -6-) contained in
the repair kit
8 - Pressure
compensating tube Check for damage
(dents and kinks)
9 - Toothed rod Check for scoring After removing
lubricate immediately
with hydraulic oil
(corrosion protection) Supplied as a
replacement part, for
assignment see
replacement parts
fiche
10 - Plug Is only installed if the
toothed rod was
replaced To install, drill hole in
the adjusting bolt
Page 48-51 Supplied in repair kit Page 27 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Needle run-out max. 0.10 mm
If needle run-out is greater than 0.10 mm, screw
pressure piece slightly into housing
If the needle run-out is less than 0.10 mm, screw
pressure piece slightly out of housing

- Tighten lock nut
- Check needle run-out again, if necessary repeat
adjustment

- Remove gauge Close hole in adjusting screw with a stopper from
repair kit
Tie rods, installing - First install clip -2- with gasket -1- in the hole - Apply 1 drop sealing compound, Part No. AMV
188 001 02, in the hole of the clip -arrow- and
press plug -3- into the clip
- See tie rods, removing and installing (TRW and ZF steering gear), Page 48-77 Page 53 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1