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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Passat B6 (from the year 2004)

general info. full specifications. diagnostics. hints. tips. tricks
Volkswagen Passat B6
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Volkswagen
Passat B6
Operation and maintenance of car
Engine
Transmission
Chassis
Steering Gear
Brakes
Overview
General verification procedure
Brake system repairs
Removing and installing brake pads
Removing and installing control unit electromechanical parking brake
Removal and installation of the parking brake
Disconnecting the brake pedal from the brake booster
Connecting the brake pedal to the brake booster
Removal and installation of the piston to the brake caliper FN 3
Removing and installing piston brake caliper
Removing and installing brake light switch F
Removal and installation of the main brake cylinder
Removing and installing brake booster
Repair the brake pipe
General information on the anti-lock system
Removing and installing speed sensor on the front axle
Removing and installing speed sensor on the rear axle
Removing and installing speed sensor on the rear axle
Removal and installation of the gauge of low pressure in the brake booster
Tables
Onboard electric
Body
diagrams
 


Hit Counter by Digits


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Removing and installing piston brake caliper



Withdrawal
Rotate the axis in the direction of the arrow using a socket wrench T45.

Squeezing the piston by allen key T45
Fig. 6.34. Squeezing the piston by allen key T45


Locknut squeeze out the piston from the brake caliper (Fig. 6.34).
Remove the protective cap from the piston from the brake caliper.

Removal of the seal ring
Fig. 6.35. Removal of the seal ring


Remove the O-ring with a mounting wedge 3409 (Fig. 6.35).

Setting
Surface of the piston and O-rings clean only alcohol and then dried.
Before installing the piston and apply a thin coat of o-ring assembly paste G 052 150 A2.
Insert O-ring in the brake caliper.

Setting the seal on the piston
Fig. 6.36. Setting the seal on the piston


Slide the outer sealing lip on the piston (Fig. 6.36).

Setting the A
Fig. 6.37. Setting the A


Turn the lock nut on the axle until it reaches the value of A 15 mm (Fig. 6.37).

Setting the working edge of the protective cap with a wedge into the groove in the brake caliper
Fig. 6.38. Setting the working edge of the protective cap with a wedge into the groove in the brake caliper


Insert the inner lip of the protective cap with a wedge into the groove in the brake caliper (Fig. 6.38).
Click on the piston locknut, this is only possible in four positions.
Gently pressed in a piston brake caliper, while the piston move.

The compression piston
Fig. 6.39. The compression piston


Push the plunger in the brake caliper so that it is pressed against the lock nut (Fig. 6.39).

Tightening the nut
Fig. 6.40. Tightening the nut


Gently turn the axle clockwise until the nut is not screwed up to the stop (Fig. 6.40).

The installed position of the protective cap
Fig. 6.41. The installed position of the protective cap


Make sure that the cap rests on the brake caliper around the perimeter (Fig. 6.41).

Forcing the piston in the brake caliper
Fig. 6.42. Forcing the piston in the brake caliper


Press the brake caliper piston in by hand (Fig. 6.42).
Thus the outer sealing lip of the protective cap enters the groove on the piston.

Checking the check valve

Checking the check valve
Fig. 6.43. Checking the check valve


The air must pass through the check valve in the direction of arrow A (Fig. 6.43).
In the opposite direction the valve should remain closed.
Watch out for the correct mounting position.

Removing and installing brake servo pressure sensor
Remove the engine cover.
Remove the vacuum hose with a pressure sensor for brake booster from the brake booster.

Unlock clips
Fig. 6.44. Unlock clips


Unlock the clip with pliers 1 (Fig. 6.44).
Carefully pry downward pressure sensor for brake booster 2.




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Removal and installation of the piston to the brake caliper FN 3
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Removing and installing brake light switch F

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