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

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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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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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Installing

Note:
Remove the sealing plugs from a new ABS
hydraulic unit one at a time, and only when the
corresponding brake line is to be connected.
If the plugs are removed too soon, brake fluid
can escape and it can no longer be certain that
the unit is sufficiently filled or adequately bled.

- Mount ABS control module to hydraulic unit
using new bolts.

Tightening torque: 4 Nm (35 in lb)
- Reconnect ABS hydraulic pump connector. The remainder of the installation procedure is the
reverse of removal, with the following additions:

- Bleed brake system Page 47-29 . Page 7 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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Brake hydraulic system, bleeding and
filling

Vehicles with ABS/EDL
For vehicles with ABS/EDL, when the brake fluid
reservoir has been completely emptied (e.g. due
to leaks in the 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 Page 47-29 . Page 9 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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2 - Spacer cap Various versions
Page 45-25 3 - Sealing ring Always replace 4 - Circlip Always replace 5 - Brake line Brake master
cylinder/primary piston
circuit to hydraulic unit
6 - Brake servo
7 - Carrier plate
8 - Sealing ring
9 - Pin
10 - Securing clip
11 - Brake fluid reservoir Page 2 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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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