1997 VOLKSWAGEN PASSAT Engine

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2 - Sealing ring Remove using a
screwdriver Page 47-19 3 - Piston with automatic
adjustment Removing and
installing Page 47-19 4 - Protective seal Pull outer sealing lip
onto piston Install inner sealing lip
in brake caliper
housing groove
Page 47-20 5 - Dust cap
6 - Bleeder valve Apply thin coat of
brake cylinder paste
before screwing in. Page 2 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

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7 - Brake caliper housing
with parking brake
cable lever If a leak exists at the
parking brake cable
lever replace brake
caliper housing After repairing, pre-
bleed caliper housing
Page 47-21 8 - Guide pins Grease before pulling
on protective cap
9 - Protective cap Pull onto brake carrier
and guide pin Page 3 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

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10 - Brake carrier with
guide pin and
protective cap Supplied as
replacement part,
assembled with
sufficient grease on
guide pins If protective caps or
guide pins are damaged, install repair kit. Use grease packet
supplied to lubricate
the guide pins. Page 4 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

Downloaded from www.Manualslib.com manuals search engine 47-19

Rear brake caliper piston, removing and
installing

Removing Note: - Thread piston out of brake caliper housing by
turning the knurled wheel counter-clockwise. If piston is difficult to move, use a 13 mm open
end wrench on the flats (arrow A) provided for this
purpose. Install special tool 3272 so that the collar (arrow)
is before the piston. Note:
Make sure that the surface of the cylinder is not
damaged during removal. - Remove seal with a screwdriver Page 5 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

Downloaded from www.Manualslib.com manuals search engine 47-20

Installing - Place protective seal with the outer sealing lip on
the piston. Note:
Hold piston in front of brake caliper housing. - Insert protective seal inner sealing lip into the
caliper housing groove using a screwdriver. Page 6 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

Downloaded from www.Manualslib.com manuals search engine 47-21
Note: - Thread piston into housing by turning knurled
wheel clockwise. Install special tool 3272 so that the collar (arrow)
of the tool is seated against the brake carrier. If piston is difficult to move, use a 13 mm open
end wrench on flats (arrow A) provided for this
purpose. If the piston is pushed back with a piston resetting
tool or by operating the foot brake the automatic
adjustment in the brake caliper is destroyed.
- Install brake pads. Page 7 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

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Pre-bleeding brake caliper Note:
Position brake caliper as illustrated to pre-bleed. - Open bleeder valve and using a standard bleeder
bottle, fill with brake fluid until bubble-free brake
fluid flows from the threaded hole (brake hose
connection). Close bleeder screw. Page 8 of 8Rear brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.4

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Brake pressure regulator,
checking and adjusting

Vehicles without ABS, vehicles with
ABS, ABS/EDS, Teves 04 The brake pressure regulator is mounted on a bracket
which is in turn fixed to a rear axle mounting bracket
and is controlled from the rear axle by a spring.
Checking operation
Firmly depress the brake pedal and release quickly
(vehicle standing on its wheels). This must cause the
brake pressure regulator lever to move.
Checking and adjusting pressure
Note:
The brake pressure regulator is set with the vehicle
unladened 1)
.
1)
The term "unladen" means: The weight of the
vehicle ready for the road (full fuel tank, spare wheel,
tool kit and jack). Page 1 of 4Brake pressure regulator, checking and adjusting12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.5