Volkswagen Passat 2011 Workshop Manual
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Volkswagen Passat 2011 Workshop Manual

Brake systems
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Workshop Manual
Passat 2011 ➤
Passat Variant 2011 ➤
Brake systems
Edition 02.2014
Service Department. Technical Information

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Summary of Contents for Volkswagen Passat 2011

  • Page 1 Service Workshop Manual Passat 2011 ➤ Passat Variant 2011 ➤ Brake systems Edition 02.2014 Service Department. Technical Information...
  • Page 2 In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2015 Volkswagen AG, Wolfsburg D3E8030ED9A...

  • Page 3: Table Of Contents

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Contents 00 - Technical data ........... .
  • Page 4 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Assembly overview - front brake caliper ........

  • Page 5: Technical Data

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 00 – Technical data Identification (VRL006456; Edition 02.2014) ⇒ “1.1 Allocation of PR number - brakes”, page 1 Allocation of PR number - brakes The type of brake system installed in the vehicle is indicated among other things by the corresponding PR number on the ve‐...

  • Page 6: Technical Data

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Technical data ⇒ “2.1 Technical data for brakes”, page 2 Technical data for brakes ⇒ “2.1.1 Brake master cylinder and brake servo”, page 2 ⇒ “2.1.2 Front brakes”, page 2 ⇒...
  • Page 7 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 2.1.3 Rear brakes Rear brakes CII 38: Item PR No. Brake caliper CII 38 (16") Brake pad, thickness Brake pad, wear limit without backplate Brake disc ∅ in...

  • Page 8: Brake Test

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Brake test ⇒ “3.1 General information”, page 4 ⇒ “3.2 Checking vehicles with front-wheel drive”, page 4 ⇒ “3.3 Checking vehicles with four-wheel drive”, page 4 General information ♦...

  • Page 9: Checking Parking Brake

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 3.3.2 Without roller dynamometer for four- wheel drive vehicles If no test rig is available for four-wheel drive vehicles, the brake test can also be carried out on a standard single-axle roller dy‐...
  • Page 10 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 • Ignition off. 3.4.2 Checking parking brake, vehicles with all-wheel drive Activate »TÜV mode«: • Seat belt is fitted • Rear axle on single-axle roller dynamometer •...

  • Page 11: Anti-Lock Brake System

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 45 – Anti-lock brake system General information The ABS brake system is divided diagonally. The servo-assis‐ tance is effected pneumatically by the vacuum brake servo unit. Vehicles with ABS are not fitted with a mechanical brake pressure regulator.

  • Page 12: Vehicle Diagnosis, Testing And Information System

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Absolute cleanliness is required when working on the anti-lock brake system. It is not permitted to use any products which contain mineral oil, such as oils, greases etc.
  • Page 13 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Switch on tester -arrow-. The tester is ready for operation when the selector buttons for the operating modes appear on the screen. – Switch on ignition.

  • Page 14: Overview Of Fitting Locations

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Overview of fitting locations ⇒ “2.1 ABS/ESP”, page 10 ABS/ESP ⇒ “2.1.1 ABS/ESP, LHD”, page 10 ⇒ “2.1.2 ABS/ESP, RHD”, page 12 2.1.1 ABS/ESP, LHD 1 - ABS control unit - J104- ❑...
  • Page 15 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 7 - Brake light switch - F- ❑ Location: on brake master cylinder. ❑ Removing and installing ⇒ page 86 8 - TCS and ESP button - E256- ❑...
  • Page 16 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 2.1.2 ABS/ESP, RHD 1 - ABS control unit - J104- ❑ Location: on hydraulic unit, on left in engine compartment. ❑ Do not separate con‐ nector before success‐...
  • Page 17 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 9 - Steering rack with steering angle sender - G85- ❑ Additionally a steering angle sensor - G85- is installed on the steering column ⇒ Item 11 (page 11) ❑...

  • Page 18: Control Unit And Hydraulic Unit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Control unit and hydraulic unit ⇒ “3.1 Assembly overview”, page 14 ⇒ “3.2 Removing and installing control unit and hydraulic unit”, page 17 ⇒ “3.3 Connecting brake lines to hydraulic unit”, page 25 Assembly overview ⇒...
  • Page 19 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 7 - Brake line ❑ From primary piston circuit of brake master cylinder to hydraulic unit. ❑ Identification: ∅ 6 mm and union nut with long thread M12 x 1 ❑...
  • Page 20 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 3.1.2 Assembly overview - control unit and hydraulic unit, RHD 1 - Brake line ❑ To rear right brake cali‐ ❑ Identification: ∅ 5.25 mm and flare nut with thread M 10 x 1 ❑...

  • Page 21: Removing And Installing Control Unit And Hydraulic Unit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 11 - Bracket 12 - Nut, 20 Nm 13 - Brake servo ❑ Removing and installing ⇒ page 104 Removing and installing control unit and hydraulic unit ⇒...
  • Page 22 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Sealing plug - 5Q0 698 311- 1 - Sealing plug M10 2 - Sealing plug M12 Removing: Location: The control unit is bolted to the hydraulic unit and is located on right in the engine compartment.
  • Page 23 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Disconnect connector from pressure differential sender - G505- -2-, and lay it to one side together with cable. – Unscrew securing bolts -1- from bracket. – Unclip lines for pressure differential sender - G505- from upper toothed belt guard.
  • Page 24 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Press red locking slide to rear in direction of -arrow-. – Release connector from control unit in direction of -arrow- and pull off. – Apply brake pedal depressor - V.A.G 1869/2- .
  • Page 25 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Connect bleed hose of bleed bottle -1- to bleed valve of rear left brake caliper. – Open bleed valve. – Depress brake pedal at least 60mm using brake pedal de‐...
  • Page 26 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Tightening sequence of brake lines: – Remove brake pedal depressor - V.A.G 1869/2- . – Bleed brake system ⇒ page 134 – Code radio. – Code control unit -J104- with ⇒ Vehicle diagnostic tester in "Guided Fault Finding".
  • Page 27 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Sealing plug - 5Q0 698 311- 1 - Sealing plug M10 2 - Sealing plug M12 Removing: Location: The ABS control unit - J104- is bolted to the ABS hydraulic unit - N55- and is located on the left in the engine compartment.
  • Page 28 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Release connector from control unit -in direction of arrow- and pull off. – Apply brake pedal depressor - V.A.G 1869/2- . – Connect bleed bottle bleed hose -1- to bleed valve of front left brake caliper.

  • Page 29: Connecting Brake Lines To Hydraulic Unit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – First identify the two brake master cylinder brake lines -A- and -B-, and unscrew from ABS hydraulic unit - N55- . – Immediately seal brake lines and threaded holes with sealing plugs - 5Q0 698 311- .
  • Page 30 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ⇒ “3.3.2 Connecting brake lines to hydraulic unit, RHD”, page 26 3.3.1 Connecting brake lines to hydraulic unit, On tandem brake master cylinder: A - Primary piston circuit of brake master cylinder to hydraulic unit.
  • Page 31 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 To ABS hydraulic unit - N55- : A - ABS hydraulic unit - N55- to primary piston circuit of brake master cylinder - Marking on ABS hydraulic unit - N55- -HZ1-...

  • Page 32: Sensors

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Sensors ⇒ “4.1 Assembly overview - speed sensor on front axle”, page 28 ⇒ “4.2 Removing and installing speed sensor on front axle”, page ⇒ “4.3 Assembly overview - speed sensor on rear axle”, page 29 ⇒...

  • Page 33: Removing And Installing Speed Sensor On Front Axle

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Removing and installing speed sensor on front axle Removing – Raise vehicle. – Separate connector -1- from speed sensor wire and from speed sensor. – Remove bolt -2- from wheel bearing housing.
  • Page 34 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 1 - ABS speed sensor ❑ Before inserting sensor, clean hole inner surface and coat with high-tem‐ perature paste G 052 112 A3. ❑ Removing and installing ⇒...

  • Page 35: Removing And Installing Speed Sensor On Rear Axle

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 4.3.2 Assembly overview - speed sensor on rear axle, all-wheel drive 1 - ABS speed sensor ❑ Before inserting sensor, clean hole inner surface and coat with high-tem‐...

  • Page 36: Removing And Installing Esp Sensor Unit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Separate connector -1- from speed sensor wire and from speed sensor. – Remove bolt -2- from wheel bearing housing. – Pull ABS speed sensor out of wheel bearing housing.

  • Page 37: Removing And Installing Steering Angle Sender

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Pull connector -1- off ESP sensor unit - G419- . – Remove the three securing nuts -arrows-. – Remove ESP sensor unit - G419- . Installing: –...
  • Page 38 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Disconnect connector -1- from brake servo vacuum sender - G483- -2-. – Insert screwdriver into circlip groove between stop and one end of circlip. – Now press circlip -1- out of groove until brake servo vacuum sender - G483- -2- can be pulled out of brake servo.

  • Page 39: Brakes - Mechanism

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 46 – Brakes - mechanism Front brakes ⇒ “1.1 Assembly overview - front brakes”, page 35 ⇒ “1.2 Removing and installing brake pads/linings”, page 38 ⇒ “1.3 Removing and installing brake caliper”, page 43 Assembly overview - front brakes ⇒...
  • Page 40 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 1 - Splash plate 2 - Torx bolt, 12 Nm 3 - Brake disc ❑ Ventilated, ∅ 312 mm ❑ Thickness: 25 mm ❑ Wear limit: 22 mm.
  • Page 41 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 1.1.2 Assembly overview- front brakes C60 Note After every brake pad change, depress brake pedal firmly sev‐ ♦ eral times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

  • Page 42: Removing And Installing Brake Pads/Linings

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ❑ Repairing ⇒ page 71 8 - Self-locking hexagon bolt, 35 Nm ❑ Renew 9 - Ribbed bolt, 200 Nm ❑ Clean if reused. 10 - Wheel bearing housing ❑...
  • Page 43 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Removing: Mark brake pads/linings when removing if they are to be reused. Fit in same position when installing, or braking will be uneven. – Remove wheels. – Lever brake pad retaining spring out from brake caliper -arrow- with a screwdriver and remove.
  • Page 44 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Unscrew both guide pins -arrows- and remove from brake cal‐ iper. – Remove brake caliper and secure with wire so that weight of brake caliper does not strain or damage brake hose.
  • Page 45 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 1.2.2 Removing and installing brake pads, front brakes C60 Special tools and workshop equipment required ♦ Torque wrench - V.A.G 1331- ♦ Piston resetting appliance - T 10145- Removing: Mark brake pads/linings when removing if they are to be reused.
  • Page 46 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Unscrew both securing bolts from brake caliper; to do this, counterhold on guide pin. – Remove brake caliper -1- and secure with wire so that weight of brake caliper does not strain or damage brake hose.

  • Page 47: Removing And Installing Brake Caliper

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Place brake pads -1- together with retaining springs -2- in re‐ cess in brake carrier -3-. Note After fitting brake pads, check that all retaining springs -2- are properly seated -arrow-.
  • Page 48 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Torque wrench - V.A.G 1331- ♦ Brake pedal depressor - V.A.G 1869/2- This procedure applies only to exchanging or the following repair work on the brake caliper.
  • Page 49 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Insert retaining spring into brake caliper. – Reconnect connector for brake pad wear indicator. – Bleed brake system ⇒ page 134 – Fit wheels. Specified torque for wheel bolts ⇒ Running gear, axles, steering;...
  • Page 50 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Connect bleeder bottle hose to brake caliper bleeder valve and open bleeder valve. – Apply brake pedal depressor - V.A.G 1869/2- . – Close bleed valve and remove bleed bottle.

  • Page 51: Rear Brakes

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Rear brakes ⇒ “2.1 Assembly overview - rear brakes”, page 47 ⇒ “2.2 Removing and installing brake pads/linings”, page 50 ⇒ “2.3 Removing and installing brake caliper”, page 53 Assembly overview - rear brakes ⇒...
  • Page 52 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 7 - Brake pad ❑ Thickness: 11 mm not including backplate. ❑ Wear limit: 2 mm not including backplate. ❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads: Checking condition of discs and thickness of pads ❑...
  • Page 53 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 2.1.2 Assembly overview - rear brakes, CII 41 Note Use the brake filling and bleeding equipment - VAS 5234- to ♦ draw off brake fluid from the brake fluid reservoir.

  • Page 54: Removing And Installing Brake Pads/Linings

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ❑ Wear limit: 2 mm not including backplate. ❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads: Checking condition of discs and thickness of pads ❑...
  • Page 55 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Diagnostic cable -VAS 5051/1- or -VAS 5051/3- ♦ Torque wrench - V.A.G 1331- ♦ Piston resetting appliance - T10145- Removing: Mark brake pads when removing if they are to be reused. Fit in same position when installing, or braking will be uneven.
  • Page 56 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Do do this, select electromechanical parking brake and “mov‐ ing parking brake motor pistons forwards and backwards” function. – Move the pistons back using ⇒ Vehicle diagnostic tester.

  • Page 57: Removing And Installing Brake Caliper

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Insert pad retainers -arrows- and brake pads into brake carrier. – Ensure that brake pads are seated correctly in pad retainers -arrows-. – Secure brake caliper with new self-locking bolts.
  • Page 58 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Brake pedal depressor - V.A.G 1869/2- ♦ Vehicle diagnostic, testing and information system - VAS 5051- ♦ Diagnostic cable -VAS 5051/1- or -VAS 5051/3- Removing: This procedure applies only to exchanging or the following repair work on the brake caliper.
  • Page 59 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Unscrew brake line or brake hose from brake caliper. – Remove both securing bolts from brake caliper; to do this, counterhold on guide pin. – Pull brake caliper off brake carrier.

  • Page 60: Handbrake

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Handbrake ⇒ “3.1 Overview of fitting locations - parking brake”, page 56 ⇒ “3.2 Removing and installing control unit”, page 57 ⇒ “3.3 Removing and installing parking brake motor”, page 57...

  • Page 61: Removing And Installing Control Unit

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Removing and installing control unit The control unit for electromechanical parking brake - J540- and the ESP sensor unit - G419- are installed in a housing below the centre console.
  • Page 62 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Torque wrench - V.A.G 1331- ♦ Vehicle diagnostic, testing and information system - VAS 5051- ♦ Diagnostic cable -VAS 5051/1- or -VAS 5051/3- Removing Note Switch off ignition for at least 30 seconds before disconnecting connector.
  • Page 63 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Unscrew both Torx bolts -arrows- from parking brake motor. – Pull parking brake motor off brake caliper. – Remove sealing ring. Take care not to damage annular groove for seal and contact surface on parking brake motor.

  • Page 64: Brake Pedal

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Brake pedal ⇒ “4.1 Assembly overview - brake pedal”, page 60 ⇒ “4.2 Separating brake pedal from brake servo”, page 62 ⇒ “4.3 Connecting brake pedal to brake servo”, page 63 ⇒...
  • Page 65 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 1 - Mounting bracket ❑ Removing and installing ⇒ page 67 2 - Self-locking hexagon nut, 25 Nm 3 - Self-locking hexagon nut, 25 Nm 4 - Brake pedal ❑...

  • Page 66: Separating Brake Pedal From Brake Servo

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Brake light switch - F- is located on brake master cylinder. 1 - Bolt ❑ 25 Nm 2 - Mounting bracket ❑ Removing and installing ⇒ page 68...

  • Page 67: Connecting Brake Pedal To Brake Servo

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – First press brake pedal in direction of brake servo and hold. 2 - Plunger rod 3 - Retaining lugs – Insert release tool - T10159- and pull in direction of driver seat.
  • Page 68 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Torque wrench - V.A.G 1331- Removing – Undo bolts -arrows- and remove footwell trim -1-. – Release diagnostics connector -3- and pull off. – Remove footwell trim -1- in -direction of arrow-.
  • Page 69 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Unbolt earth strap -arrow-. Vehicles without crash bars – Remove bolts -1- to unbolt steering column -2-. – Place steering column carefully on trim and secure it.

  • Page 70: Removing And Installing Mounting Bracket

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Remove bolts -1- to unbolt steering column. – Place steering column carefully on trim and secure it. Continuation for all vehicles – Remove bolt -1- for brake pedal towards the left, while holding the nut -arrow-.
  • Page 71 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ⇒ “4.5.2 Removing and installing mounting bracket, right-hand drive vehicle”, page 68 4.5.1 Removing and installing mounting bracket, LHD – Remove driver side footwell cover ⇒ General body repairs, interior;...
  • Page 72 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Unscrew nuts -1 and 2-. – Carefully remove foot pedal cluster. Installing Install in reverse order. Note the following points: – Connect brake pedal to brake servo ⇒...
  • Page 73 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Vehicles with diesel engine – Remove engine cover panel ⇒ Rep. gr. 10 ; Engine cover panel; Removing and installing engine cover panel – Remove upper timing belt guard by detaching clips -arrows-.
  • Page 74 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Specified torque Component Specified torque Brake servo to mounting bracket and plenum chamber 25 Nm bulkhead Mounting bracket to plenum chamber bulkhead 25 Nm ♦ Use new nut and bolt...

  • Page 75: Brakes - Hydraulics

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 47 – Brakes - hydraulics Front brake calipers ⇒ “1.1 Assembly overview - front brake caliper”, page 71 ⇒ “1.2 Removing and installing brake caliper piston”, page 72 Assembly overview - front brake caliper ⇒...

  • Page 76: Removing And Installing Brake Caliper Piston

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 1.1.2 Assembly overview - brake caliper C60 1 - Dust cap ❑ Fit onto bleeder valve. 2 - Bleeder valve, 13 Nm ❑ Apply thin coat of as‐...
  • Page 77 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 1.2.1 Removing and installing piston for brake caliper FN 3 Special tools and workshop equipment required ♦ Removal wedge - 3409- ♦ Piston resetting appliance - T 10145- ♦...
  • Page 78 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Lever off protective cap from brake caliper using wedge 3409. – Remove seal using wedge 3409. When removing ensure that the surface of the cylinder is not damaged.
  • Page 79 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – At this stage it should not be possible to remove protective cap from brake caliper by hand. – Press piston lightly onto protective seal and lock it in this po‐...
  • Page 80 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Piston resetting appliance - T10145- Removing: – Press piston out of brake caliper using compressed air. Place a piece of wood in the recess to prevent damage to the piston.
  • Page 81 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Insert inner sealing lip into groove in cylinder using wedge 3409. When doing this, hold piston in front of brake caliper. – Press piston into brake caliper using piston resetting tool.

  • Page 82: Rear Brake Calipers

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Rear brake calipers ⇒ “2.1 Assembly overview - rear brake caliper”, page 78 ⇒ “2.2 Removing and installing rear brake caliper piston”, page 79 Assembly overview - rear brake caliper ♦...

  • Page 83: Removing And Installing Rear Brake Caliper Piston

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 11 - Protective cap ❑ Pull on so that outer sealing lip goes over piston. ❑ Removing and installing ⇒ page 79 12 - Piston ❑ Removing and installing ⇒...
  • Page 84 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Place protective cap with outer sealing lip on piston. – Screw thrust nut onto spindle until dimension -a- 15 mm is achieved. – Insert inner sealing lip of protective cap into groove -arrows- in brake caliper using removal wedge - 3409- .
  • Page 85 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Carefully turn spindle clockwise until thrust nut is located on stop. – Ensure that protective cap lies flush all around on brake caliper -arrows-. – Press piston into brake caliper by hand.

  • Page 86: Brake Servo And Brake Master Cylinder

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Brake servo and brake master cylin‐ ⇒ “3.1 Assembly overview - brake servo/brake master cylinder”, page 82 ⇒ “3.2 Removing and installing brake light switch”, page 86 ⇒...
  • Page 87 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 1 - Pedal cluster 2 - Self-locking hexagon nut, 25 Nm ❑ Renew after removing 3 - Seal ❑ For brake servo. 4 - Brake servo ❑ On petrol engines, the required vacuum is tak‐...
  • Page 88 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 12 - Brake line, 14 Nm ❑ From secondary piston circuit of brake master cylinder to hydraulic unit. 13 - Brake line,14 Nm ❑ From primary piston circuit of brake master cylinder to hydraulic unit.
  • Page 89 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 1 - Brake servo ❑ On petrol engines, the required vacuum is tak‐ en either from the intake manifold or generated by a mechanical vac‐ uum pump.

  • Page 90: Removing And Installing Brake Light Switch

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 10 - Bolt, 25 Nm 11 - Bolt, 5 Nm 12 - Brake light switch - F- ❑ Removing and installing ⇒ page 87 13 - Nut, 50 Nm ❑...
  • Page 91 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Separate connector -1- from brake light switch - F- . – Remove bolt -2- from brake master cylinder. – Pull brake light switch - F- -3- from brake master cylinder at top and remove from clip at bottom.

  • Page 92: Removing And Installing Brake Master Cylinder

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Continuation for all vehicles – Separate connector -A- from brake light switch - F- and pull off. Note The brake light switch - F- must then be removed from below.
  • Page 93 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Torque wrench - V.A.G 1331- Removing: – Note or request radio code on vehicles with coded radio if necessary. – Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Battery;...
  • Page 94 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Disconnect brake lines -1- on brake master cylinder and seal brake lines with plugs from repair kit Part No. 1H0 698 311 A. – Remove nuts -2- from brake master cylinder.
  • Page 95 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Special tools and workshop equipment required ♦ Release tool - T10159 A- ♦ Sealing tool - T10249- ♦ Torque wrench - V.A.G 1331- ♦ Brake filling and bleeding equipment - VAS 5234- 3.
  • Page 96 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Lambda probe open ring spanner set - 3337- ♦ Ring ratchet spanner 13 mm - T10384- ♦ Assembly tool - T10365- ♦ Transport lock - T10404- ♦...
  • Page 97 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Remove upper timing belt guard by detaching clips -arrows-. Vehicles with diesel engine and SCR system (Selective Catalytic Reduction) WARNING ♦ The reducing agent can irritate the skin, eyes and respi‐...
  • Page 98 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Remove tunnel cross member by undoing bolts -arrows-. – Remove clamping sleeve -1-. – Remove exhaust pipe -1- by loosening nuts -arrows-. – Remove exhaust pipe together with reducing agent injection valve - N474- .
  • Page 99 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Release connectors -1- to -4- on plenum chamber bulkhead and pull off. – Unclip connector from holder and uncover lines/cables. – Undo and remove securing bolt -1-.
  • Page 100 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Release connector -1- and pull off. – Unclip bracket -2- for electrical wiring to oil level and oil tem‐ perature sender - G266- on subframe. – Unclip wiring harness -1- from retainer -arrow-.
  • Page 101 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Remove bolts -1- and take out shield plate. – Undo nuts -1- with ratchet wrench 13 mm - T10384- . – Undo nuts -2- and take out bracket.
  • Page 102 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Remove bolts -arrows- of bracket. – Remove tunnel cross member by undoing bolts -arrows-. – Remove clamping sleeve -1-. – Remove particulate filter and place on subframe.
  • Page 103 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Continuation for all vehicles – Release and pull off connector -2- from brake fluid level warn‐ ing contact - F34- . – Unscrew brake pipes -1- from brake master cylinder -3-.
  • Page 104 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Vehicles with diesel engine and particulate filter Note Replace seals, self-locking nuts and the clamp for particulate ♦ filter. Fit cable ties and electrical wires and cables in the same place ♦...
  • Page 105 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Angled end facing left side of vehicle. – Angle -α- to mark -arrow- = approx. 17°. – Tighten bolts of exhaust gas temperature sender with tool set 17 mm - T10395- and torque wrench - V.A.G 1331- .

  • Page 106: Removing And Installing Brake Servo

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Removing and installing brake servo ⇒ “3.4.1 Removing and installing brake servo, left-hand drive”, page 102 ⇒ “3.4.2 Removing and installing brake servo, right-hand drive vehicle”, page 104 3.4.1...
  • Page 107 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Draw off as much brake fluid as possible from brake fluid res‐ ervoir using brake filling and bleeding equipment - VAS 5234- . Vehicles with manual gearbox: –...
  • Page 108 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Unscrew securing nuts -arrows- and remove footwell trim -1-. – Remove brake pedal crash bar ⇒ Running gear, axles, steer‐ ing; Rep. gr. 48 ; Steering column; Assembly overview - steering column .
  • Page 109 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Special tools and workshop equipment required ♦ Release tool - T10159 A- ♦ Sealing tool - T10249- ♦ Torque wrench - V.A.G 1331- ♦ Brake filling and bleeding equipment - VAS 5234- 3.
  • Page 110 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Support bracket - 10 - 222 ♦ Adapter - 10 - 222 A /3- ♦ Adapter - 10 - 222 A /8- ♦ Hook - 10 - 222 A /10- ♦...
  • Page 111 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Lambda probe open ring spanner set - 3337- ♦ Ring ratchet spanner 13 mm - T10384- ♦ Assembly tool - T10365- ♦ Transport lock - T10404- ♦...
  • Page 112 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Vehicles with diesel engine Caution The bracket for engine cover panel on the cylinder head cover can break if not removed correctly. Always remove engine cover panel according to following instructions.
  • Page 113 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Remove upper timing belt guard by detaching clips -arrows-. Vehicles with SCR system (Selective Catalytic Reduction) WARNING ♦ The reducing agent can irritate the skin, eyes and respi‐...
  • Page 114 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Remove tunnel cross member by undoing bolts -arrows-. – Remove clamping sleeve -1-. – Remove exhaust pipe -1- by loosening nuts -arrows-. – Remove exhaust pipe together with reducing agent injection valve - N474- .
  • Page 115 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Undo and remove securing bolt -1-. – Loosen bolt -2-. – Open clamp between particulate filter and turbocharger and remove. – Remove Lambda probe - G39- -3-.
  • Page 116 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Unclip wiring harness -1- from retainer -arrow-. – Release wiring harness connector from exhaust gas temper‐ ature sender and pull off in -direction of arrow-. – Unbolt exhaust gas temperature sender -arrow-.
  • Page 117 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Undo nuts -1- with 13 mm ratchet wrench - T10384- . – Undo retainer -2- and remove it. – Remove bracket -1- from top of cylinder head after undoing nuts -arrow-.
  • Page 118 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Remove tunnel cross member by undoing bolts -arrows-. – Remove clamping sleeve -1-. – Disconnect particulate filter. – Tie exhaust pipe up. – Swivel particulate filter downwards and place on subframe.
  • Page 119 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Attach support bracket - 10-222A- with adapter - 10-222A/8- , adapter - 10 - 222 A /18- , adapter - 10 - 222 A /3- and hooks - 10 - 222 A /10- as shown.
  • Page 120 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Unscrew bolts -arrows- of engine/gearbox support on the en‐ gine. – Lower engine/gearbox (first one side and then the other) via the spindles and pull towards the front as far as possible.
  • Page 121 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Pull vacuum line -1- out of brake servo unit -3-. – Unscrew brake master cylinder nut -4-. – Remove heat shield (if installed) -2-. – Unclip brake lines -A- and -B- on plenum chamber bulkhead -arrow-.
  • Page 122 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Vehicles with diesel engine and particulate filter Note Replace seals, self-locking nuts and the clamp for particulate ♦ filter. Fit cable ties and electrical wires and cables in the same place ♦...
  • Page 123 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Angled end facing left side of vehicle. – Angle -α- to mark -arrow- = approx. 17°. – Tighten bolts of exhaust gas temperature sender with tool set 17 mm - T10395- and torque wrench - V.A.G 1331- .

  • Page 124: Vacuum System

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Vacuum system ⇒ “4.1 Assembly overview - vacuum pump”, page 120 ⇒ “4.2 Assembly overview - electric vacuum pump”, page 121 ⇒ “4.3 Checking non-return valve”, page 122 ⇒...

  • Page 125: Assembly Overview - Electric Vacuum Pump

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Must not be dismantled. Vacuum pump -B-. Vacuum hose to brake servo -A- with non-return valve. – Removing and installing vacuum pump ⇒ Rep. gr. 15 ; Cyl‐...

  • Page 126: Checking Non-Return Valve

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Checking non-return valve ♦ Air must pass through non-return valve -A- in direction of ar‐ row. ♦ Non-return valve must remain closed in opposite direction. Observe correct installation position!
  • Page 127 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Vacuum gauge for brake servo - VAS 6721- 4.5.1 Connecting vacuum gauge for brake servo - VAS 6721- – Pull vacuum hose out of brake servo.
  • Page 128 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 4.5.2 Checking vacuum generation Note The average air pressure of the earth's atmosphere at sea ♦ level is 1013 mbar and decreases steeply as the altitude in‐...
  • Page 129 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Close cut-off valves -B+C-. – Start warm engine (>60° C), press accelerator briefly (engine speed greater than 2000/min). Normally (see notes), the vacuum that is generated should be between 600 and 950 mbar (depending on engine size).
  • Page 130 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 4.5.4 Vacuum generation with manual vac‐ uum pump - VAS 6213- Instead of vacuum generation by means of engine or vacuum pump, the vacuum can be generated with the manual vacuum pump - VAS 6213- in certain cases.

  • Page 131: Brake Lines

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Brake lines ⇒ “5.1 Repairing brake lines”, page 127 Repairing brake lines The flanging tool for brake lines - VAS 6056- can be used to flange brake lines with an outer pipe diameter of 5 mm without damaging the coating.
  • Page 132 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 1 - Flanging tool - VAS 6056/1- ❑ Flanging tool - VAS 6056/1- contains flang‐ ing jaws - VAS 6056/6- 2 - Pipe cutter - VAS 6056/2-...
  • Page 133 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 5.1.1 Assembly overview - flanging tool 1 - Flanging tool upper part ❑ Unbolt to change flang‐ ing jaws. 2 - Fastening for handle ❑ Must be removed to ac‐...
  • Page 134 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Cut through brake line at a suitable point (straight, freely ac‐ cessible section) with pipe cutter -2-. – Remove section to be renewed. – Degrease brake line surface.
  • Page 135 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 – Turn spindle to stop in flanging tool. – Turn spindle back again. – Loosen hexagon socket head bolts diagonally. – Remove brake line from flanging tool, clean and check brake line and flange.

  • Page 136: Hydraulic System

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Hydraulic system ⇒ “6.1 General notes on brake fluid”, page 132 ⇒ “6.2 Pre-bleeding hydraulic system”, page 132 ⇒ “6.3 Bleeding hydraulic system following standard procedure”, page 134 ⇒...
  • Page 137 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 ♦ Tool set for brake bleeding - VAS 6564- Carry out pre-bleeding when: ♦ in vehicles with EDL, EDL/TCS or EDL/TCD/ESP a chamber in the brake fluid reservoir is completely empty. This occurs e.g.

  • Page 138: Bleeding Hydraulic System Following Standard Procedure

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Bleeding hydraulic system following standard procedure Bleeding the hydraulic system is described using brake filling and bleeding equipment - VAS 5234- . A pre-pressure of 2 bar is required for bleeding the ABS hydraulic unit - N55- .

  • Page 139: Subsequent Bleeding Of Hydraulic System

    Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 4 - Rear right brake caliper Use suitable bleeder hose. It must sit tightly on bleeder valve so that no air can enter brake system. – Leave bleeder valve of each brake caliper open with bleeder hose fitted until brake fluid discharges free of air bubbles.
  • Page 140 Passat 2011 ➤ , Passat Variant 2011 ➤ Brake systems - Edition 02.2014 Carry out the following work: Checking – Remove bleeder valve at one of front brake calipers. – Connect pressure gauge -V.A.G 1310 A- and bleed. – Apply pressure to brake pedal until gauge indicates a pressure of 50 bar.

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Passat variant 2011

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