Spring VOLKSWAGEN PASSAT 1996 B3, B4 / 3.G Service Owner's Guide

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Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30
Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 6 - Brake pedal return
spring
7 - Return spring
mounting tube
8 - Brake pedal mounting
bushing
9 - Brake pedal
10 - Clutch pedal Removing and
installing 11 - Pedal cluster mounting bracket
12 - Clutch pedal pivot pin
13 - Clutch pedal mounting
bushing
14 - Over-center spring
mounting
15 - Over-center spring Before removing,
remove clutch pedal Page 6 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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Brake pedal, removing and installing

Note:
Grease all mounting and contact surfaces with
MoS
2 grease.
To remove brake servo disconnect brake pedal
at clevis only.

Removing

- Before removing brake pedal remove trim
- Remove brake pedal clevis pin connection
securing clip.

- Remove pin.
- Remove brake pedal pivot pin securing clip.
- Remove pivot pin.
- Remove mounting sleeve, return spring
mounting tube with brake pedal.

Installing

- Install in reverse order. Page 8 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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6 - Brake cylinder housing 7 - Brake carrier Install on brake caliper
housing
8 - Retaining spring Install with both ends
in the drillings in brake
caliper housing
9 - Piston seal Remove using a
screwdriver Fig. 2 10 - Piston Force piston out of
brake caliper using
compressed air Fig. 1 Installing Fig. 3 and
Fig. 4 and Fig. 5 First coat the piston
lightly with brake
cylinder paste. Piston diameter 54
mm
11 - Protective seal Do not damage when
installing piston Page 2 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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Brake pressure regulator,
checking and adjusting

Vehicles without ABS, vehicles with
ABS, ABS/EDS, Teves 04 The brake pressure regulator is mounted on a bracket
which is in turn fixed to a rear axle mounting bracket
and is controlled from the rear axle by a spring.
Checking operation
Firmly depress the brake pedal and release quickly
(vehicle standing on its wheels). This must cause the
brake pressure regulator lever to move.
Checking and adjusting pressure
Note:
The brake pressure regulator is set with the vehicle
unladened 1)
.
1)
The term "unladen" means: The weight of the
vehicle ready for the road (full fuel tank, spare wheel,
tool kit and jack). Page 1 of 4Brake pressure regulator, checking and adjusting12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.5

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Adjusting regulator
Rear axle test pressure too high:

- Release tension on regulator spring. Rear axle test pressures too low:

- Tension regulator spring.
Note:
Do not adjust with brake pedal depressed,
therefore observe the following sequence:

- Read off figures.
- Release pedal.
- Adjust spring.
- Depress pedal again.
- Read off figures and if necessary, readjust.
- Remove pressure gauges and bleed brake
system Page 47-27 . Page 4 of 4Brake pressure regulator, checking and adjusting12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.5

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1 - Cover plate
2 - Hex nut, 50 Nm (37 ft
lb)
3 - Steering wheel Install in center
position
4 - Airbag unit Removing and
installing Page 48-7 5 - Steering wheel for
airbag Removing and
installing Page 48-8 Removing and
installing Airbag Spiral Spring Page 48-10 6 - Hex socket head bolt,
6.5 Nm (57 in lb) Always replace 7 - Connector
8 - Splined adapter sleeve Removing Page 48-5 Installing Page 48-5 Page 2 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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9 - Spring
10 - Steering column
switch/steering lock
housing1)
Distance between
steering
wheel/steering column
switch is not
adjustable
11 - Upper trim
12 - Support ring1)
With washer 13 - Steering column1)
Remove by pulling upwards out of column tube Checking length
Page 48-6 14 - Hex bolt, 30 Nm (22 ft
lb)
15 - Hex nut, 25 Nm (18 ft
lb)
16 - Hex nut, 30 Nm (22 ft
lb)
17 - Steering column
universal joint
18 - Spring Page 3 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Airbag steering wheel, removing and
installing

Removing

- Remove airbag unit. Page 48-7
- Remove trim below steering column switch. Note: - Separate connector (arrow). (Pull foam rubber
sleeve off connector, if installed).
- Remove nut and pull steering wheel off steering
column. After pulling steering wheel off, turn Airbag Spiral
Spring slightly so that the wire (arrow) faces
downward. (Hold steering wheel in installation
position). The spring then locates and is prevented
from turning.
If this step is not performed or if the spring is tufted in
an uncontrolled manner, it can lead to the spring
being overstressed at full lock, causing irreparable
damage. Page 8 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Airbag Spiral Spring, removing and
installing
Remove airbag unit Page 48-7 Remove steering wheel Page 48-8
- Separate single connector for horn. Install steering wheel Page 48-9
Install airbag unit Page 48-7
Note: - Remove screws -1- and remove Airbag Spiral
Spring -2- from steering wheel. When removing and installing the Airbag Spiral
Spring, ensure that it is in the center position. As a new part the Airbag Spiral Spring is secured
in the center position by a cable tie. Page 10 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1

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Column tube for height
adjustable steering
wheel, removing and
installing
The column tube can be
adjusted in height by approx.
50 mm
1 - Operating lever
2 - Packing plate
3 - Column tube Square housing fits
over mounting bracket
4 - Rubber stop
5 - Return spring Hooked into mounting
bracket and column
tube
6 - Thrust washer
7 - Packing plate Page 11 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1