1997 VOLKSWAGEN PASSAT lock

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Brake pedal/brake servo,
removing and installing
CAUTION!
The brake pedal travel must
not be restricted by
additional floor coverings.
Note:
Grease all mountings before
installing with G 000 602
grease.
1 - Securing clip Ensure securely
seated
2 - Pin
3 - Brake servo push rod
clevis
4 - Self-locking hex nut, 20 Nm (15 ft lb)
5 - Brake pedal pivot pin Page 5 of 9Parking brake lever assembly overview12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.46.6

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Assembly
overview: brake
master
cylinder/brake
servo
Note:
Brake master cylinders and
brake servos from different
manufacturers are installed.
Complete master cylinders and
brake servos can be replaced
independently of each other.
1 - Seal For brake servo 2 - Self-locking hex nut, 20 Nm (15 ft lb)
3 - Mounting bracket
4 - Mounting bracket For brake servo 5 - Seal Page 1 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1

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7 - Sealing ring Always replace 8 - Self-locking hex nut, 20 Nm (15 ft lb)
9 - Brake master cylinder Cannot be repaired. If
faulty, replace
complete.
10 - Sealing plug Moisten with brake
fluid and press into
reservoir
11 - Seal Page 3 of 4Assembly overview: brake master cylinder/brake servo12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.1

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Girling front brake
caliper, servicing
Note: When repairing install all
parts supplied in repair kit. Apply thin coat of brake
cylinder paste to brake
cylinders, pistons and
sea/s.
1 - Protective seal
2 - Bleed valve Apply thin coat of brake cylinder paste to threads before
screwing in
3 - Brake caliper housing
4 - Self-locking hex bolt,
35 Nm (26 ft lb) Always replace When loosening and
tightening counter-hold on guide pin Page 1 of 5Girling front brake caliper, servicing12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.47.2

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Rear brake caliper,
servicing
Note: Apply thin coat of brake
cylinder paste to brake
cylinder pistons and seal. When repairing install all
parts supplied in repair kit. New brake calipers are
filled with brake fluid and
are pre-bled. When repairing it is
essential to pre-bleed the
brake calipers (without
brake pads) before
installing in the vehicle
Page 47-21 1 - Self-locking bolts, 35
Nm (26 ft lb) Always replace When loosening and
tightening counter-hold on guide pin Page 1 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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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

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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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Steering

Assembly overview: steering column,
column tube, steering wheel and airbag
steering wheel

Airbag system functional check and
interrogating Diagnostic Trouble Code (DTC)
Memory.
Repair Manual, Body Exterior, Interior, Repair Group 68; General body repairs
Safety precautions when working on airbag
Repair Manual, Body Exterior, Interior, Repair Group 68, General body repairs
Note:
All parts marked with a "1)
" can be pre-
assembled outside of the vehicle
Pre-assembling steering column Page 48-6 Always replace self-locking nuts and bolts. Welding and straightening work on steering
components is not permitted. Page 1 of 99Steering12/7/2004http://ebahn.bentleypublishers.com/vw/servlet/Display?action=Goto&type=repair&id=VW.B4.SU01.48.1