1997 VOLKSWAGEN PASSAT brakes

Downloaded from www.Manualslib.com manuals search engine 44-5
Rear axle
Semi-trailing arm axle
Engine 85 kW, 128 kW
(115 hp, 172 hp)
Camber1)

Maximum permissible difference between sides -1 15' 30'

max. 30' Total toe 1)
(at specified camber)
Maximum permissible deviation from direction of travel +15' 20'


max. 20' 1)
Camber and toe corrections possible using eccentric rubber mounting Repair Manual, Suspension, Wheels, Brakes, Steering, Repair Group 42 . Page 5 of 7Vehicle alignment12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.44.1

Downloaded from www.Manualslib.com manuals search engine 45-5

Wheel speed sensor and rotor for speed
sensor, removing and installing

Speed sensor
When installing speed sensor ensure wiring is
not twisted.
Before installing speed sensor, clean mounting
hole and coat with lubricating paste, G 000 650.
Rotors
Before installing check that rotor is clean and
undamaged.

Front axle
Vehicles with base suspension Page 40-14 . Vehicles with plus suspension Page 40-23 .
Rear axle
Vehicles with rear drum brakes Page 42-15 . Vehicles with rear disc brakes (front and four
wheel drive Page 42-24 . Page 5 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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Front brakes,
servicing (Girling
caliper)
Note: After replacing brake pads,
depress brake pedal firmly
several times with vehicle
stationary so that the brake
pads are properly seated in
their normal operating
position. To remove brake fluid from
the reservoir, use a bleeder
bottle which is used only for
brake fluid. Brake fluid is
poisonous and must on not
be siphoned by mouth
using a hose! Wheel bolt tightening
torque: 110 Nm (81 ft lb) Page 1 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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1 - Brake disc, not
ventilated When worn always
replace on both sides Brake disc diameter:
256 mm Brake disc thickness:
13 mm Wear limit: 11 mm 2 - Brake disc, ventilated When worn always
replace on both sides Brake disc diameter:
256 mm Brake disc thickness:
20 mm Wear limit: 18 mm 3 - Screw
4 - Countersunk screw To secure rotor Only on vehicles with
ABS Page 2 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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Repair Manual, Maintenance 5 - Brake pad With brake pad wear
indicator Always replace on
both sides Removing and
installing Page 46-6 Pad thickness: non-
ventilated brake disc,
14 mm Pad thickness:
ventilated brake disc,
11 mm Checking thickness Wear limit: 7 mm
(including backplate)
6 - Hub Removing and
installing from
Page 40-14 7 - Wheel speed sensor
rotor Only on vehicles with
ABS
8 - Hex bolt, 10 Nm (7 ft lb) 9 - Splash plate Page 3 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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10 - Wheel bearing housing 11 - Brake carrier with
guide pins and
protective caps Supplied as
replacement part
assembled with
sufficient amount of
grease on guide pins If protective caps are
damaged use repair kit Use grease packet
supplied to lubricate
guide pins
12 - Heat shield Install in piston 13 - Brake caliper housing Do not disconnect
brake hose when
changing brake pads Page 4 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

Downloaded from www.Manualslib.com manuals search engine 46-5

14 - Self-locking hex bolt,
35 Nm (26 ft lb) Always replace 15 - Guide pin
16 - Ribbed bolt, 125 Nm
(92 ft lb)
17 - Protective cap
18 - Hex socket head bolt,
10 Nm (7 ft lb)
19 - Speed sensor Only on vehicles with
ABS Before inserting sensor clean mounting hole inner surface and
coat with lubricating
paste, G 000 650 Page 5 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1

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Brake pads, removing and installing

Removing - Remove lower brake caliper housing securing bolt. Counter-hold on guide pin. - Swing brake caliper housing upward. - Remove brake pads. Page 6 of 7Front brakes, servicing (Girling caliper)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.1