ABS VOLKSWAGEN PASSAT 1997 B3, B4 / 3.G Service Owner's Manual

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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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Anti-lock Brake System (ABS)
and ABS with Electronic
Differential Lock (ABS/EDL),
Teves 20 GI

General information The ABS or ABS/EDL braking system is divided
diagonally. Brake pedal pressure is boosted
pneumatically, by the vacuum brake booster.
Vehicles with Teves 20 GI ABS or ABS/EDL do not
have a mechanical brake pressure regulator.
Specially matched software in the ABS control
module regulates rear axle brake pressure. The ABS hydraulic unit -a- and ABS control module -
b- together make up one component. Separating
them for service is only possible after the assembly
has been removed.
New ABS control units supplied as replacement parts
from the Parts department are not coded, and require
coding after installation:
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01
Malfunctions of the ABS or ABS/EDL system do not
influence the brake system or the vacuum brake
booster. The conventional brake system remains
functional even without ABS.
Before working on the ABS or ABS/EDL system,
determine the cause of the malfunction using the On
Board Diagnostic (OBD) program % Repair Manual,
ABS & ABS/EDL On Board Diagnostic. Page 1 of 3Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.2

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Safety precautions

WARNING!

Brake fluid is poisonous.

CAUTION!
Before working on the ABS or ABS/EDL
system, disconnect the battery Ground
(GND) strap. For anti-theft coded radios, first
make sure that the radio code is available.
Brake fluid must not contact painted parts. Brake fluid absorbs moisture from the air
and must therefore be replaced every two
years. Use only new, approved brake fluid
that complies with MVSS 116 DOT 4.
DO NOT use silicone-brake fluid (DOT 5).
Even the smallest traces can cause sever
corrosion in the brake system.
Before doing any welding repairs on the
vehicle using electric welding equipment,
disconnect the ABS control module.
After work that requires opening the brake
hydraulic system, bleed the system Page 47-29 . Page 2 of 3Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.2

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CAUTION!
During the final road test, make sure that at
least one controlled brake test is included
(pulsations must be felt at the brake pedal).
Absolute cleanliness is required when
working on the ABS or ABS/EDL system. DO
NOT use any products that contain mineral
oil, such as oils, greases, etc.
Thoroughly clean all connections and the
immediate vicinity before loosening. DO NOT
use aggressive cleaning agents such as
brake cleaner, gasoline or thinners.
Place removed parts on a clean surface and
cover. DO NOT use fluffy cloths.
Carefully seal or cover opened components
if a repair cannot be completed immediately.
After separating the ABS hydraulic unit and
ABS control module, always use the plastic
foam transportation protection for the valve
dome, and always use the sealing plug kit
Part No. 1 H0 693 311 A.
Only install replacement parts that were
packed in their original packaging. Only
remove them immediately before installation. When the hydraulic system is open DO NOT
work with compressed air in the vicinity and
DO NOT move the vehicle.
Take precautions to make sure that brake
fluid does not enter any wiring harness
connectors. Page 3 of 3Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock (ABS/EDL), Teves 20 GI12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.45.2

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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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8 - Rubber damper
9 - Retainer
10 - ABS hydraulic unit
11 - ABS control module
12 - Brake line connection ABS hydraulic unit to
right-front brake
caliper
13 - Brake line connection ABS hydraulic unit to
left-rear brake caliper
or wheel cylinder
14 - Brake line connection ABS hydraulic unit to
right-rear brake caliper or wheel cylinder
15 - Brake line connection ABS hydraulic unit to
left-front brake caliper
16 - Brake line Brake master cylinder
(secondary piston
circuit) to ABS
hydraulic unit
17 - Brake line Brake master cylinder
(primary piston circuit)
to ABS hydraulic unit Page 2 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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ABS hydraulic unit and ABS control
module (Teves 20 GI), removing and
installing
Carefully read and follow all cautions and
warnings Page 45-7 before beginning work.
Location
The ABS control module is bolted to the ABS
hydraulic unit, located on the left-side of the
engine compartment.

CAUTION!
Do not bend brake lines at or near the ABS
hydraulic unit.
Switch ignition OFF when disconnecting and
reconnecting the ABS control module
connector.
Part numbers are listed here for reference
only. Always check with your Parts
department for the latest information. Sealing plug kit Part No. 1H0 698 311 A:
1 - Valve dome transportation protection (plastic
foam)
2 - Sealing plugs -M10- 3 - Sealing plugs -M12- Page 3 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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After separating ABS control module from ABS
hydraulic unit, always install valve dome
transportation protection on hydraulic unit.
Warranty claims for ABS hydraulic units on which
the valve dome transportation protection was not
used will not be accepted.

Removing

CAUTION!

Determine correct radio anti-theft coding
before disconnecting the battery.

- Disconnect battery Ground (GND) strap.
- Remove coolant expansion tank and swing to
one side. Page 4 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