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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Passat B5 (from 1996 to 2004, the year of issue)

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Volkswagen Passat B5
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Check the brake servo
Replacing the front brake pads
Replacing the front brake pads to the caliper Lucas
Replacing the rear brake pads
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Replacing the front brake pads



Withdrawal

PERFORMANCE ORDER
1. Loosen the bolts of the front wheel, then lift the front of the car and fix on supports. Unscrew the bolts and remove the wheel.
A warning

Be sure to make replacement of all pads on one axis of the car even if deterioration borders were reached only one shoe. If the brake pads will be repeatedly established, before removal they are necessary for marking.



2. If there is clear wear on the inside brake pad and disconnect the sensor electrical connector.
3. Using the screwdriver blade as a lever on the outside of the caliper, remove the retaining spring.
4. Remove the dust caps from the inner ends of the guide bolts.
5. Remove the guide pins from the support.
6. Lift the support with inner lining and a soft wire, tie it to the front of the rack.
A warning

Caliper should not hang on the brake hose. Brake hose should not stretch or be overwound.


7. Remove the internal block with an external piston caliper and pad from the holder of a support.

Setting

Location of the front brake pads before installing the calipers


A warning

Do not press the brake pedal with the brake pads removed.

After installing new brake pads, avoid sharp braking during the first 200 kilometers of the car.


PERFORMANCE ORDER
1. Clean dust and dirt from the caliper, and rust from the edge of the brake disc. If the pads are suitable for further use, clean them using a wire brush and rags.
2. Check the brake rotor for cracks, especially around the holes for the bolts fastening the wheel, as well as for wear or mechanical damage and, if necessary, replace it.
3. Measure the thickness of the brake disc.
4. If will be established new brake pads, using a special device, press the piston in the caliper. For pressing the piston in the caliper can use a wooden core or the hammer handle. At the same time, make sure that the piston has not warped also surfaces of the piston and the boot are not damaged. When retracted, the piston brake liquid is superseded from the brake cylinder in a broad tank, so constantly observe of liquid level in the tank and, if necessary, pump out from a tank its small amount.
5. Make sure that the notches on the support piston are located along the vertical axis. If necessary turn the piston in correct position.
6. Apply a thin layer of grease to the brake system on the surface of the brake pads, interfaced with a caliper.
7. Install the inner pad to the caliper, with the spring bracket should be established in the recess of the piston.
8. Install the outer brake pad.
9. Establish a support with internal block on the holder support. Screw in the caliper guide pins and tighten them to 25 Nm.
10. Install the dust caps on directing fingers of a support.
11. Install the retaining spring on the caliper. At the ends of the spring must be positioned in the holes of a support.
12. If you have set on the inner brake pad wear new.
13. Similarly replace brake pads on the second front wheel.
14. Establish a wheel and lower the car to the ground. Tighten the bolts to 120 Nm.
15. Repeatedly press the brake pedal to the brake pads pressed against the brake disk.
16. Check brake fluid level in the reservoir.




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Replacing the front brake pads to the caliper Lucas

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