1997 VOLKSWAGEN PASSAT lock

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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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Installing

Note:
Before inserting new brake pads, press piston
back into the cylinder with resetting tool. Before
pressing the piston back, remove some brake
fluid from the reservoir with a bleeder bottle. If
reservoir has been topped up, fluid may overflow
and cause damage. Note: - Press piston back. - Install brake pads. - Swing brake caliper housing down and tighten bolt. The repair kit contains two self-locking bolts which must always be installed. After replacing the brake pads, depress brake
pedal firmly several times with the vehicle
stationary so that the brake pads are properly
seated in their normal operating position. Page 7 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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Rear wheel brakes,
servicing (drum
brakes)
Notes Page 42-15 1 - Grease cap Removing and
installing from
Page 42-19 2 - Cotter pin Always replace 3 - Locking ring
4 - Hex nut Adjusting wheel
bearing play Page 42-20 5 - Thrust washer Page 1 of 4Rear wheel brakes, servicing (drum brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.3

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4 - Brake hose bracket
5 - Hex socket head bolt,
65 Nm (48 ft lb)
6 - Self-locking bolt, 35
Nm (26 ft lb) Always replace When loosening and
tightening, counter-
hold on guide pin
7 - Guide pin
8 - Protective cap
9 - Pad retaining springs Always replace when
changing pads
10 - Backing plate ring Distance between ring
collar and backing
plate: 9.5 mm Page 2 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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14 - Outer wheel bearing
15 - Hex nut Adjusting wheel
bearing play Using a screwdriver it
must be possible to
move the thrust
washer by finger
pressure (without
leverage) Page 42-20 Secure with locking
ring and new cotter pin 16 - Cotter pin Always replace 17 - Grease cap Removing and
installing Page 42-29 18 - Lock ring
19 - Thrust washer
20 - Wheel bolt, 110 Nm (81
ft lb) Page 4 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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Installing

Note:
Before pressing the piston back, remove some
brake fluid from the reservoir. Use a bleeder
bottle or a plastic bottle which is only used for
brake fluid. Brake fluid is poisonous and must not
be siphoned by mouth through a hose. Note: - Thread in piston by turning knurled wheel of
special tool 3272 clockwise.
- Install brake pads. Install special tool 3272 so that the collar (arrow)
of the tool is seated against the brake caliper. If the piston is difficult to move, use a 13 mm
open end wrench on the 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 will be destroyed. Page 8 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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- Secure brake caliper housing with new self-
locking bolts. Note: - Attach parking brake cable (arrow) to brake caliper housing. After each brake pad change firmly depress brake
pedal several times with vehicle stationary, so
that the brake pads are properly seated in their
normal operating position. After changing brake pads check brake fluid level. Page 9 of 10Rear wheel brakes, servicing (disc brakes)12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.5

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4 - Lock nut
5 - Compensator
6 - Parking brake lever
trim First pull off parking
brake hand grip then
pull trim forward
Fig. 2 7 - Hex nut
8 - Parking brake cable Different versions for
rear drum and disc
brakes Allocation see Parts
catalog Page 2 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6