1996 VOLKSWAGEN PASSAT instrument panel

Downloaded from www.Manualslib.com manuals search engine 45-23

Hydraulic unit, removing and installing

Note:
For easier disassembling and assembling, it is
more practical to remove the hydraulic unit
complete with brake servo and brake master
cylinder.

Removing

- Disconnect battery Ground (GND) strap.
- Separate all electrical connections on ABS
unit.

- Remove as much brake fluid as possible from
brake fluid reservoir using a suction bottle.

- Disconnect brake lines from ABS hydraulic unit
and seal threaded holes with plugs from repair
kit, Part No. 1HO 698 311.

- Remove left-hand trim under instrument
panel.

- Disconnect brake pedal from brake servo unit
Page 46-44 . Page 6 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

Downloaded from www.Manualslib.com manuals search engine 45-24

- Remove nuts from brake servo/bulkhead.
- Carefully remove hydraulic unit and brake servo
with brake master cylinder from engine
compartment.

Installing

Note:
Hydraulic units supplied as replacement parts
are already filled with hydraulic fluid and bled.
Only remove sealing plugs on hydraulic unit
when the relevant brake line is going to be
connected.
If the sealing plugs are removed too early,
brake fluid can escape, it is then no longer
guaranteed that the unit is sufficiently filled or
adequately bled.

- Preassemble hydraulic unit and brake servo with tandem master cylinder away from vehicle.

- Secure hydraulic unit, brake servo with tandem
master cylinder to bulkhead.

- Connect brake lines.
- Reconnect all electrical connections on ABS unit (ensure correctly connected).

- Bleed brake system Page 47-27 .
- Install left-hand trim under instrument panel. Page 7 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

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