1997 VOLKSWAGEN PASSAT Engine

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Note:
For vehicles equipped with ABS/EDL, on which
the brake fluid reservoir has been completely
empty (e.g. leaks in brake system), it is
necessary to initiate the "Basic Setting" function
of the On Board Diagnostic (OBD) program:
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Otherwise the standard brake bleeding
procedures apply.

- Code ABS control module: Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01
Tightening torques

ABS control unit to ABS
hydraulic unit 4 Nm (35 in.
lb)
ABS hydraulic unit to bracket
(Torx T25 socket-head bolts) 8 Nm (71 in.
lb)
Brake master cylinder to
vacuum booster 25
Nm (18 ft
lb)
Heat shield to brake master
cylinder 8 Nm (71 in.
lb)
Brake lines to ABS hydraulic
unit
M10 x 1 15
Nm (11 ft
lb)
M12 x 1 15
Nm (11 ft
lb) Page 8 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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Brake hydraulic system, bleeding and
filling

Vehicles with ABS/EDL
For vehicles with ABS/EDL, when the brake fluid
reservoir has been completely emptied (e.g. due
to leaks in the brake system) it is necessary to
initiate the "Basic Setting" function of the On
Board Diagnostic (OBD) program.
Repair Manual, Brake System On Board Diagnostic (OBD), Repair Group 01 Otherwise the standard brake bleeding
procedures apply Page 47-29 . Page 9 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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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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2 - Spacer cap Various versions
Page 45-25 3 - Sealing ring Always replace 4 - Circlip Always replace 5 - Brake line Brake master
cylinder/primary piston
circuit to hydraulic unit
6 - Brake servo
7 - Carrier plate
8 - Sealing ring
9 - Pin
10 - Securing clip
11 - Brake fluid reservoir Page 2 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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Repair Manual, Brake System On Board Diagnostic (OBD), Repair group 01 12 - Cap
13 - Hex socket head screw for brake fluid
reservoir
14 - Series resistor Only on vehicles with
ABS/EDL Checking 15 - Self-locking hex nut, 25 Nm (18 ft lb)
16 - Tandem brake master
cylinder
17 - Protective plate
18 - Hex bolt for protective
plate Page 3 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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19 - ABS Hydraulic unit Connections (arrow)
show pipe work from
tandem master
cylinder to ABS
hydraulic unit Removing and
installing Page 45-23 20 - ABS/EDL Hydraulic
unit Removing and
installing Page 45-23 21 - Brake line connection Hydraulic unit to front
right brake caliper Thread connection:
M10 x 1, 15 Nm (11 ft
lb)
22 - Torx bolts (T 25)
23 - Brake line connection Hydraulic unit to rear
left wheel cylinder Thread connection:
M10 x 1, 15Nm (11 ft
lb) Page 4 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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24 - Brake line connection Hydraulic unit to rear
right wheel cylinder Thread connection:
M12 x1, 18 Nm (13 ft
lb)
25 - Brake line connection Hydraulic unit to front
left brake caliper Thread connection:
M10 x1, 15 Nm (11 ft
lb)
26 - Brake line Master brake
cylinder/secondary
piston circuit to
hydraulic unit Page 5 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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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