1996 VOLKSWAGEN PASSAT Vacuum

Downloaded from www.Manualslib.com manuals search engine Rear axle, servicing (four wheel drive vehicles)
Rear drive shafts, servicing
Reworking cap nut in side member (four wheel drive vehicles)
Suspension strut, disassembling and assembling (four wheel drive
vehicles)
Wheel bearings, servicing - disc brakes (four wheel drive vehicles)
44 - Wheels, Tires, Wheel alignment
Vehicle alignment
Test requirements:
Vehicle alignment specifications (front wheel drive vehicles)
Vehicle alignment specifications (four wheel drive vehicles)
Front wheel camber, adjusting
Calculating the direction of travel:
45 - Anti-lock brake system
Anti-locking Brake System (ABS) and Anti-locking Brake System with
Electronic Differential Lock (ABS/EDL) Teves 04
Notes for repair work on ABS, ABS/EDL
Control module, removing and installing
Wheel speed sensor and rotor for speed sensor, removing and installing
Anti-lock Brake System (ABS) and ABS with Electronic Differential Lock
(ABS/EDL), Teves 20 GI
Safety precautions
ABS, ABS/EDL hydraulic unit, vacuum brake booster and brake master
cylinder (Teves 20 GI), servicing
ABS hydraulic unit and ABS control module (Teves 20 GI), removing and
installing
Brake hydraulic system, bleeding and filling
Assembly overview - hydraulic unit, brake servo/brake master cylinder
Hydraulic unit, removing and installing
Brake Pedal Position Sensor, removing and installing
46 - Brakes - Mechanical components
Front brakes, servicing (Girling caliper)
Brake pads, removing and installing

Downloaded from www.Manualslib.com manuals search engine 40-56
The large diameter of vent chamber -A- must fit on
the larger diameter. Fig. 6 Installation position of right drive shaft
transmission end joint boot
B - Vent hole Often the boot is pushed in when installing on the
joint body. This creates a vacuum inside the boot
which draws a fold in (arrow) while driving. After
installing, lift the boot at small diameter end to
equalize pressure. Fig. 7 Joint boot, ventilating Page 56 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

Downloaded from www.Manualslib.com manuals search engine 40-68
Fig. 1 Constant velocity joint, outer, removing - Drive off from drive shaft with forceful blow using
an alloy hammer. The boot is pressed on forcefully when installing on
the joint body. This creates a vacuum in the boot that
makes a dent during driving (arrow). Briefly ventilate
the boot at the small diameter after installation to
provide equalize pressure. Fig. 2 Boot, ventilating Page 68 of 82Front Wheel Suspension, Shafts and Axle12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.40.1

Downloaded from www.Manualslib.com manuals search engine 42-33

Rear axle,
servicing (four
wheel drive
vehicles)
Note: When removing and
installing the rear axle, it is
recommended to remove
axle and differential
together and to separate
away from the vehicle. If
only the axle beam is to be
removed and installed, the
wishbones can remain
attached to the shock
absorber. In both cases,
disconnect vacuum lines
and wiring before lowering
the assembly. Always replace self-locking
nuts and bolts. Always replace corroded
nuts and bolts. The ABS speed sensor
wiring connections are
located under the rear seat. Page 1 of 13Rear axle, servicing (four wheel drive vehicles)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.42.3

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Anti-locking Brake System
(ABS) and Anti-locking Brake
System with Electronic
Differential Lock (ABS/EDL)
Teves 04
The ABS, ABS/EDL brake system is divided
diagonally. The servo-assist is effected
pneumatically, by the vacuum brake servo unit.
Located between the brake master cylinder and
the vacuum servo unit is a mounting bracket for
the hydraulic unit with pump.
The hydraulic unit together with pump, supplies
only the anti-locking brake system (ABS) or anti-
locking brake system and traction control system
(ABS/EDL).
Malfunctions on the ABS, ABS/EDL systems do
not influence the brake system and servo. The
vehicle can be driven without the ABS, ABS/EDL
functions operating. Page 1 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

Downloaded from www.Manualslib.com manuals search engine 45-9

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