1995 VOLKSWAGEN PASSAT sensor

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16 - Circlip Ensure seated
correctly
17 - Wheel bearing 72 mm diameter Pressing out Page 42-64 Pressing in page. Page 42-65 18 - Hex bolt, 10 Nm (7 ft lb) 19 - Backing plate
20 - Parking brake cable Adjusting parking
brake Page 46-36 21 - Spring clip
22 - Hex socket head bolt,
10 Nm (7 ft lb)
23 - Speed sensor Before inserting, clean
and coat with
lubricating paste G
000 650 Page 4 of 8Wheel bearings, servicing - disc brakes (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.6

Downloaded from www.Manualslib.com manuals search engine 42-63

24 - Drive shaft with speed
sensor rotor Removing and
installing drive shaft
Page 42-37 and
Page 42-38 Removing and
installing rotor, Fig. 6 25 - Brake line Page 5 of 8Wheel bearings, servicing - disc brakes (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.6

Downloaded from www.Manualslib.com manuals search engine 42-66
Note:
First install backing plate on control arm.
Tightening torque: 10 Nm (7 ft lb) Fig. 5 Hub, pressing in Fig. 6 Speed sensor rotor, pressing in - Drive rotor off outer joint using a drift (rotor will be
destroyed).
- Drive new rotor carefully onto stop using a plastic
hammer. Page 8 of 8Wheel bearings, servicing - disc brakes (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.6

Downloaded from www.Manualslib.com manuals search engine 45-5

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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Assembly overview
- hydraulic unit,
brake servo/brake
master cylinder
Note:
Repair Manual, Brake System On Board Diagnostic (OBD), Repair group 01 Pump and valve block must
not be separated from one
another. Illustration shows an
exploded view of the
ABS/EDL unit. Servicing of
ABS unit is identical.
Distinguishing features 1 - Brake Pedal Position
Sensor Removing and
installing Page 45-25 . Checking Page 1 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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Brake Pedal Position Sensor, removing
and installing

Note:
The Brake Pedal Position Sensor is only
supplied as a repair kit. Apart from the sender,
this repair kit contains a sealing ring, circlip and
four different spacer caps.

- - one white spacer cap
- - one green spacer cap
- - one blue spacer cap
- - one red spacer cap The spacer caps are of differing length. When replacing the sensor note the color of
spacer cap. The new sensor must have the
same color cap as the old sensor.
On the brake servo housing in the vicinity of the
sever location there is a colored spot, which is
identical to that of the spacer cap. Page 8 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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Removing

- Release brake servo vacuum by operating the
brake pedal several times.

- Remove connector from expansion tank.
- Swing coolant expansion tank to side.
- Pull connector off sensor. - Expand circlip with a small screwdriver in a
clockwise direction and pull sensor (arrow) out of
brake servo. Page 9 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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Installing

Note: When installing new circlip ensure opening is
uppermost - installation position (arrow).
- Install new sealing ring to sensor. (Coat sealing
ring with lubricant e.g. soft soap). Note: - Sensor notch must point downward when inserting
into brake servo and be heard to engage.
- Connect sensor unit connection and ensure
correctly located. To ensure correctly seated pull senor by hand. Leaks at the sensor sealing ring, result in
insufficient braking vacuum and poor engine
idling. For ease of illustration, shows installing the
sensor with brake fluid reservoir removed. Page 10 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