VOLKSWAGEN PASSAT 1997 B3, B4 / 3.G Service Workshop Manual

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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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Brake pads, removing and installing

Removing - Remove lower brake caliper housing securing bolt. Counter-hold on guide pin. - Swing brake caliper housing upward. - Remove brake pads. Page 6 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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Front brakes,
servicing
(Teves/Ate)
Repair Manual, Maintenance 1 - Screw
2 - Brake disc When worn always
replace on both sides Remove brake caliper
prior to removing Ventilated brake disc
diameter: 288 mm Brake disc thickness:
25 mm Wear limit: 23 mm 3 - Brake pads Always replace on
both sides Pads are different; pad on piston side has
retaining spring Removing and
installing Page 46-12 Pad thickness: 14 mm Checking thickness Wear limit: 7 mm
(including backing
plate) Page 1 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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4 - Retaining spring Insert in both brake
caliper housing
drillings
5 - Brake carrier Supplied as
replacement part
assembled with
sufficient amount of
grease on guide pins If protective caps are
damaged use repair kit Use grease packet
supplied to lubricate
guide pins
6 - Brake caliper housing Do not disconnect
brake hose when
changing brake pads Removing and
installing Page 46-12 Page 2 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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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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Brake pads, removing and installing

Removing

Note:
If reusing brake pads mark location and install in
same position or uneven braking may result. - Remove protective caps. - Pry off brake pad retaining spring from brake
caliper housing with a screwdriver and remove. Page 5 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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Installing
Note:
Before installing 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. - Remove both guide pins from brake caliper. - Remove brake caliper housing and lay to one side
so that weight of brake caliper does not stress or
damage brake hose.
- Take brake pads out of brake caliper housing or
from brake carrier. - Pressing piston back. Page 6 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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- Install brake pad with retaining spring in brake
caliper housing (piston).

- Install outer brake pad in brake carrier.
- Secure brake caliper housing with both guide
pins to brake carrier.

- Install both protective caps.
- Install retaining spring into brake caliper
housing.

Note:
After replacing the brake pads, depress brake
pedal firmly several times with the vehicle
stationary, so that the brake pads are proper/y
seated in their normal operating position. Page 7 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