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

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Anti-locking Brake System
(ABS) and Anti-locking Brake
System with Electronic
Differential Lock (ABS/EDL)
Teves 04
The ABS, ABS/EDL brake system is divided
diagonally. The servo-assist is effected
pneumatically, by the vacuum brake servo unit.
Located between the brake master cylinder and
the vacuum servo unit is a mounting bracket for
the hydraulic unit with pump.
The hydraulic unit together with pump, supplies
only the anti-locking brake system (ABS) or anti-
locking brake system and traction control system
(ABS/EDL).
Malfunctions on the ABS, ABS/EDL systems do
not influence the brake system and servo. The
vehicle can be driven without the ABS, ABS/EDL
functions operating. Page 1 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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Notes for repair work on ABS, ABS/EDL
Before doing any repair work on the anti-locking system, determine the cause of the malfunction
using On Board Diagnostic (OBD).
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Before working on the ABS, ABS/EDL system,
disconnect the battery Ground strap. On
vehicles with coded radio, obtain cooling.
When working with brake fluid, observe the
relevant safety precautions and notes Page 47-27 . After work for which the brake system had to be opened, bleed the brake system with brake filler and bleeder unit VAS 5234 Page 47-27 . During the final road test, make sure that a
controlled brake test is performed at least once
(pulsations must be felt at the brake pedal).
Absolute cleanliness is required when working
on the anti-locking brake system; it is not
permitted to use any products which contain
mineral oils, such as oils, greases etc. Page 2 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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Thoroughly clean all unions and the adjacent
areas before loosening, do not use aggressive
cleaning agents such as brake cleaner, petrol,
thinners or similar.
Place removed parts on a clean surface and
cover.
Do not use fluffy cloth. Carefully cover or seal open components if
repairs cannot be carried out immediately.
Only remove replacement parts from packaging
immediately prior to installation.
Only use genuine packed parts. When the system is open do not work with
compressed air and do not move the vehicle.
Make sure that no brake fluid enters harness
connectors.
During painting operations, the electronic
control module can be exposed to a max.
temperature of 95C (203F) for only a short
period, and to a maximum of 85C (185F) for
longer periods (approx. 2 hours). Page 3 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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Control module, removing and installing

Location
Under the rear seat, left

Note:
Switch off ignition before disconnecting and
connecting connectors.

Removing

- Fold up rear seat.
- Press control module securing clips together
and pull out.

- To pull connector off control module, release
control module locking bar.

Installing

- Install in reverse order. - Engage connector catch in control module slots
(arrow A), press connector on (arrow B) and
secure with locking bar (arrow C). Page 4 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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Wheel speed sensor and rotor for speed
sensor, removing and installing

Speed sensor
When installing speed sensor ensure wiring is
not twisted.
Before installing speed sensor, clean mounting
hole and coat with lubricating paste, G 000 650.
Rotors
Before installing check that rotor is clean and
undamaged.

Front axle
Vehicles with base suspension Page 40-14 . Vehicles with plus suspension Page 40-23 .
Rear axle
Vehicles with rear drum brakes Page 42-15 . Vehicles with rear disc brakes (front and four
wheel drive Page 42-24 . Page 5 of 5Anti-locking Brake System (ABS) and Anti-locking Brake System with Electronic Differential Lock (A...12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.1

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ABS, ABS/EDL
hydraulic unit,
vacuum brake
booster and brake
master cylinder
(Teves 20 GI),
servicing
CAUTION!
DO NOT separate the ABS
hydraulic pump from the
valve block.
1 - Brake servo (vacuum
brake booster)
2 - Brake master cylinder
3 - Brake fluid reservoir
4 - Cap
5 - Self-locking nut Always replace 25 Nm (18 ft lb) 6 - Torx socket-head
bolt T25 4 Nm (35 in lb) 7 - Torx socket-head
bolt T25 8 Nm (71 in lb) Page 1 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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Repair Manual, Brake System On Board Diagnostic (OBD), Repair group 01 12 - Cap
13 - Hex socket head screw for brake fluid
reservoir
14 - Series resistor Only on vehicles with
ABS/EDL Checking 15 - Self-locking hex nut, 25 Nm (18 ft lb)
16 - Tandem brake master
cylinder
17 - Protective plate
18 - Hex bolt for protective
plate Page 3 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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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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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

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Rear wheel brakes,
servicing (drum
brakes)
Notes Page 42-15 1 - Grease cap Removing and
installing from
Page 42-19 2 - Cotter pin Always replace 3 - Locking ring
4 - Hex nut Adjusting wheel
bearing play Page 42-20 5 - Thrust washer Page 1 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