Head VOLKSWAGEN PASSAT 1997 B3, B4 / 3.G Service User Guide

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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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-
Remove Torx socket-head bolts (T25) from
ABS hydraulic unit bracket.
- Remove ABS hydraulic unit/ABS control module
assembly.

- Disconnect ABS hydraulic pump connector from
ABS control module. CAUTION! - Remove ABS control module mounting bolts
(arrows) and pull off ABS control module. Pull control module straight off. Do not tilt. Cover control unit magnetic coils with a lint-
free cloth. After separating the ABS hydraulic unit and
ABS control module, always use the plastic
foam valve dome transportation protection
Page 45-11 . Page 6 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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Note:
For vehicles equipped with ABS/EDL, on which
the brake fluid reservoir has been completely
empty (e.g. leaks in brake system), it is
necessary to initiate the "Basic Setting" function
of the On Board Diagnostic (OBD) program:
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Otherwise the standard brake bleeding
procedures apply.

- Code ABS control module: Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01
Tightening torques

ABS control unit to ABS
hydraulic unit 4 Nm (35 in.
lb)
ABS hydraulic unit to bracket
(Torx T25 socket-head bolts) 8 Nm (71 in.
lb)
Brake master cylinder to
vacuum booster 25
Nm (18 ft
lb)
Heat shield to brake master
cylinder 8 Nm (71 in.
lb)
Brake lines to ABS hydraulic
unit
M10 x 1 15
Nm (11 ft
lb)
M12 x 1 15
Nm (11 ft
lb) Page 8 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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- 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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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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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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11 - Backing plate
12 - Hex socket head bolt,
10 Nm (7 ft)
13 - Wheel cylinder Checking for leaks
Fig. 1 14 - Wedge To remove and install
the brake drum, push
upwards through a
wheel bolt hole
Page 46-18 15 - Push rod Lubricate contact
points with G 000 650
paste
16 - Locating spring Unhook with pliers Page 3 of 8Rear wheel brakes, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.4

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Rear wheel brakes,
servicing (disc
brakes)
Girling rear wheel disc
brakes (front and four
wheel drive vehicles)
Note:
Only items 5, 6, 7, 8, 9, 10, 11
and 12 apply for four wheel
drive.
1 - Axle beam
2 - Hex socket head bolt,
10 Nm (7 ft lb)
3 - Wheel speed sensor Only for vehicles with
ABS Insert with lubricating
paste, G 000 650 Page 1 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5