1996 VOLKSWAGEN PASSAT brake

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12 - Cap
13 - Brake fluid reservoir
14 - Non-return valve Page 4 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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Girling front brake
caliper, servicing
Note: When repairing install all
parts supplied in repair kit. Apply thin coat of brake
cylinder paste to brake
cylinders, pistons and
sea/s.
1 - Protective seal
2 - Bleed valve Apply thin coat of brake cylinder paste to threads before
screwing in
3 - Brake caliper housing
4 - Self-locking hex bolt,
35 Nm (26 ft lb) Always replace When loosening and
tightening counter-hold on guide pin Page 1 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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5 - Seal Remove using a
screwdriver Page 47-7 6 - Piston Removing and
installing Page 47-7 Apply thin coat of
brake cylinder paste
before inserting
7 - Protective seal Do not damage when
inserting piston
8 - Brake carrier with
guide pins and
protective caps Brake carrier with
guide pins and
protective cap Supplied as
replacement part
assembled with
sufficient grease on
guide pins If protective caps or
guide pins are
damaged use repair
kit. Use grease packet
supplied to lubricate
guide pins Page 2 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Front brake caliper pistons, removing
and installing

Removing Note:
Place a piece of wood in the recess to prevent
damaging the piston. - Force piston out of brake caliper housing using
compressed air. Note:
When removing ensure that the surface of the
cylinder is not damaged. - Remove seal with a screwdriver. Page 3 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Installing - Place protective seal with the outer sealing lip on
the piston. Note:
Hold piston in front of caliper housing. - Using a screwdriver, insert the inner sealing lip into the cylinder groove. Page 4 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Note:
The protective seal outer sealing lip will then locate in
the piston groove. - Press piston into the brake caliper housing using
piston resetting tool. Page 5 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Front brake caliper,
servicing
(Teves/Ate)
Note: When repairing install all
parts supplied in repair kit. Apply thin coat of brake
cylinder paste to brake
cylinders, pistons and
seals.
1 - Protective seal Push onto bleed valve 2 - Bleed valve Apply thin coat of brake cylinder paste to threads before
threading in
3 - Cap Install in mounting
bushing
4 - Guide pin, 25 Nm (18 ft
lb)
5 - Mounting bushing Insert into brake
caliper housing Page 1 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3

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6 - Brake cylinder housing 7 - Brake carrier Install on brake caliper
housing
8 - Retaining spring Install with both ends
in the drillings in brake
caliper housing
9 - Piston seal Remove using a
screwdriver Fig. 2 10 - Piston Force piston out of
brake caliper using
compressed air Fig. 1 Installing Fig. 3 and
Fig. 4 and Fig. 5 First coat the piston
lightly with brake
cylinder paste. Piston diameter 54
mm
11 - Protective seal Do not damage when
installing piston Page 2 of 5Front brake caliper, servicing (Teves/Ate)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.3