brake sensor VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service User Guide

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Brake Pedal Position Sensor, removing
and installing

Note:
The Brake Pedal Position Sensor is only
supplied as a repair kit. Apart from the sender,
this repair kit contains a sealing ring, circlip and
four different spacer caps.

- - one white spacer cap
- - one green spacer cap
- - one blue spacer cap
- - one red spacer cap The spacer caps are of differing length. When replacing the sensor note the color of
spacer cap. The new sensor must have the
same color cap as the old sensor.
On the brake servo housing in the vicinity of the
sever location there is a colored spot, which is
identical to that of the spacer cap. Page 8 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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Removing

- Release brake servo vacuum by operating the
brake pedal several times.

- Remove connector from expansion tank.
- Swing coolant expansion tank to side.
- Pull connector off sensor. - Expand circlip with a small screwdriver in a
clockwise direction and pull sensor (arrow) out of
brake servo. Page 9 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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Installing

Note: When installing new circlip ensure opening is
uppermost - installation position (arrow).
- Install new sealing ring to sensor. (Coat sealing
ring with lubricant e.g. soft soap). Note: - Sensor notch must point downward when inserting
into brake servo and be heard to engage.
- Connect sensor unit connection and ensure
correctly located. To ensure correctly seated pull senor by hand. Leaks at the sensor sealing ring, result in
insufficient braking vacuum and poor engine
idling. For ease of illustration, shows installing the
sensor with brake fluid reservoir removed. Page 10 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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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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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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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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6 - Outer wheel bearing
7 - Wheel speed sensor
rotor Only on vehicles with
ABS
8 - Brake drum Vehicles with front
wheel drive Brake drum diameter:
230 mm Wear limit: 231.5 mm Clean thoroughly,
check for wear,
damage, tolerances,
damaged wheel bolt
threads and condition
of braking surface Fill hub with multi-
purpose grease Check for ovality 9 - Stub axle Page 2 of 4Rear wheel brakes, servicing (drum brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.3

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10 - Hex socket head bolt,
10 Nm (7 ft lb)
11 - Wheel speed sensor Only on vehicles with
ABS Insert with lubricating
paste, G 000 650
12 - Backing plate with
brake shoes Release adjustment
before removing brake
drum Page 46-18 13 - Dished washer Large contact surface
faces back plate
14 - Hex bolt, 60 Nm (44 ft
lb) Page 3 of 4Rear wheel brakes, servicing (drum brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.3

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Repair Manual, Maintenance 4 - Upper return spring Unhook with pliers 5 - Lower return spring Lubricate contact
points with G 000 650
paste
6 - Wedge spring
7 - Brake shoe Removing and
installing Page 46-23 Minimum lining
thickness 2.5 mm Checking thickness 8 - Cap Remove to check
brake lining thickness
9 - Pin
10 - Wheel speed sensor Only on vehicles with
ABS Page 2 of 8Rear wheel brakes, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.4