1996 VOLKSWAGEN PASSAT brake

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Brake pedal/brake servo,
removing and installing
CAUTION!
The brake pedal travel must
not be restricted by
additional floor coverings.
Note:
Grease all mountings before
installing with G 000 602
grease.
1 - Securing clip Ensure securely
seated
2 - Pin
3 - Brake servo push rod
clevis
4 - Self-locking hex nut, 20 Nm (15 ft lb)
5 - Brake pedal pivot pin Page 5 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6

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Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30
Repair Manual, 5 Spd. Manual Transmission 02A, Repair Group 30 6 - Brake pedal return
spring
7 - Return spring
mounting tube
8 - Brake pedal mounting
bushing
9 - Brake pedal
10 - Clutch pedal Removing and
installing 11 - Pedal cluster mounting bracket
12 - Clutch pedal pivot pin
13 - Clutch pedal mounting
bushing
14 - Over-center spring
mounting
15 - Over-center spring Before removing,
remove clutch pedal Page 6 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6

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16 - Securing clip Ensure seated
securely
17 - Brake Light Switch Adjusting Page 46-45 Page 7 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6

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Brake pedal, removing and installing

Note:
Grease all mounting and contact surfaces with
MoS
2 grease.
To remove brake servo disconnect brake pedal
at clevis only.

Removing

- Before removing brake pedal remove trim
- Remove brake pedal clevis pin connection
securing clip.

- Remove pin.
- Remove brake pedal pivot pin securing clip.
- Remove pivot pin.
- Remove mounting sleeve, return spring
mounting tube with brake pedal.

Installing

- Install in reverse order. Page 8 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6

Downloaded from www.Manualslib.com manuals search engine 46-45

Brake Light Switch, adjusting

Note:
The Brake Light Switch must be removed for
adjusting.

- Remove trim under instrument panel.
- Disconnect harness connector for Brake Light
Switch.

- Remove Brake Light Switch by turning to right
through 90.
- Pull Brake Light Switch plunger fully out.
- Depress brake pedal as far as possible by hand,
guide Brake Light Switch through the locating
hole and secure by turning through 90to left.
- Pull brake pedal back up by hand to stop (Brake
Light Switch is pushed back by one notch).

- Connect harness connector for Brake Light
Switch

- Check function of Brake Light Switch.
- Install instrument panel trim. Page 9 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6

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Assembly
overview: brake
master
cylinder/brake
servo
Note:
Brake master cylinders and
brake servos from different
manufacturers are installed.
Complete master cylinders and
brake servos can be replaced
independently of each other.
1 - Seal For brake servo 2 - Self-locking hex nut, 20 Nm (15 ft lb)
3 - Mounting bracket
4 - Mounting bracket For brake servo 5 - Seal Page 1 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1

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6 - Brake servo On gas engines the
vacuum required is
taken from the intake
manifold. On Diesel engines an
exhauster is installed
to create the required
vacuum. Functional check - With engine
switched off,
depress brake pedal
firmly several times
(to exhaust the
vacuum in the unit).
- Now depress brake
pedal with average
foot pressure, hold
and start engine. If
the servo unit is working properly, the pedal will be felt to
give slightly under
foot (servo
assistance becomes
effective). If faulty replace
complete. Check valve (item 14 )
is in vacuum hose Functional check - It must be possible
to blow through in
direction of arrow.
- Blowing against the arrow the valve must seat. Page 2 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1

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7 - Sealing ring Always replace 8 - Self-locking hex nut, 20 Nm (15 ft lb)
9 - Brake master cylinder Cannot be repaired. If
faulty, replace
complete.
10 - Sealing plug Moisten with brake
fluid and press into
reservoir
11 - Seal Page 3 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1