Home ReviewsRefund
Home/Volkswagen/Passat/Volkswagen Passat B6 (2005-2010)/Repair manual/Mechanical - Hydraulic/Mechanical Components: Overview
Contents Wiring diagrams Section: Mechanical - Hydraulic All sections

Mechanical Components: Overview Volkswagen Passat B6

Mechanical - Hydraulic 5 illustrations ~1090 words

FRONT BRAKES ASSEMBLY OVERVIEW, FN 3

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal depressor V.A.G 1869/2 must be inserted (this dissipates pressure).

Scheme 67

Scheme 67: FRONT BRAKES ASSEMBLY OVERVIEW, FN 3
Scheme 67: FRONT BRAKES ASSEMBLY OVERVIEW, FN 3
  1. Cover Plate
  2. Bolt 12 Nm
  3. Brake Disc Internally vented: 312 mm diameter Thickness: 25 mm Wear limit: 22 mm Must always be replaced together on both sides of vehicle. To remove, first remove brake caliper and carrier.
  4. Bolt 4 Nm
  5. Brake Carrier Bolt to wheel bearing housing.
  6. Retaining Spring Insert in both holes of brake caliper.
  7. Ribbed Bolt 200 Nm Clean if using again.
  8. Brake Pads Thickness: 14 mm without backing plate With wear indicator (left front). When wear limit is reached (limit: approximately 4 mm without backing plate), the warning lamp in the instrument cluster comes on. Wear limit: 2 mm without backing plate. Check the thickness. Refer to «FRONT AND REAR BRAKE PAD THICKNESS AND BRAKE DISC CONDITION, CHECKING»(ref-460516-S14912906322012032900000) Must always be replaced together on both sides of vehicle. Removing and installing, refer to «FRONT BRAKE PADS, FN 3»(ref-460525-S27482557512012032900000)
  9. Brake Caliper Do not unscrew brake hose when replacing brake pad. Removing and installing, refer to «FRONT BRAKE CALIPER, FN 3»(ref-460525-S31953003472012032900000) . Servicing, refer to «FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FN 3»(ref-460521-S37479872912012032900000) .
  10. Guide Pins 30 Nm
  11. Cap Remove.
  12. Brake Hose with Banjo Fitting and Union Bolt 35 Nm
  13. Bolt 8 Nm
  14. Bracket
  15. Retaining Clip

FRONT BRAKES ASSEMBLY OVERVIEW, FNR-G

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal depressor V.A.G 1869/2 must be inserted (this dissipates pressure).

Scheme 68

Scheme 68: FRONT BRAKES ASSEMBLY OVERVIEW, FNR-G
Scheme 68: FRONT BRAKES ASSEMBLY OVERVIEW, FNR-G
  1. Cover Plate
  2. Bolt 12 Nm
  3. Brake Disc Internally vented: 345 mm diameter Thickness: 30 mm Wear limit: 27 mm Must always be replaced together on both sides of vehicle. Remove brake caliper before removing.
  4. Bolt 4 Nm
  5. Brake Carrier Bolt to wheel bearing housing.
  6. Retaining Spring Insert in brake pad retaining spring and press below brake carrier.
  7. Ribbed Bolt 190 Nm Clean if using again.
  8. Brake Pads Thickness: 14 mm without backing plate. With wear indicator. When wear limit is reached (limit: approximately 4 mm), the warning lamp lights up in instrument cluster. Wear limit: 2 mm without backing plate Check the thickness. Refer to «FRONT AND REAR BRAKE PAD THICKNESS AND BRAKE DISC CONDITION, CHECKING»(ref-460516-S14912906322012032900000) . Must always be replaced together on both sides of vehicle. Removing and installing, refer to «FRONT BRAKE PADS, FNR-G»(ref-460525-S24055564252012032900000) .
  9. Brake Caliper Do not bolt to brake hose/brake line when changing brake pads. Must not be removed. Removing and installing, refer to «FRONT BRAKE CALIPER, FNR-G»(ref-460525-S07009391832012032900000) . Servicing, refer to «FRONT BRAKE CALIPER ASSEMBLY OVERVIEW, FNR-G»(ref-460521-S27793895272012032900000) .
  10. Guide Pins 30 Nm
  11. Cap Remove
  12. Washer
  13. Vibration Damper Allocation.
  14. Bolt 10 Nm
  15. Dust Cap
  16. Bracket
  17. Bolt 15 Nm
  18. Brake Line 14 Nm
  19. Brake Hose
  20. Bolt 8 Nm
  21. Bracket
  22. Spring Clamp

REAR BRAKES ASSEMBLY OVERVIEW

Note. Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal depressor V.A.G 1869/2 must be inserted (this dissipates pressure).

Scheme 69

Scheme 69: REAR BRAKES ASSEMBLY OVERVIEW
Scheme 69: REAR BRAKES ASSEMBLY OVERVIEW
  1. Cover Plate Allocation.
  2. Brake Disc 16 inches: 286 mm 17 inches: 310 mm Thickness 16 inches: 12 mm Thickness 17 inches: 22 mm Wear limit 16 inch: 10 mm Wear limit 17 inch: 20 mm Always replace pads on both sides of vehicle if worn. To remove, first remove brake caliper and carrier.
  3. Bolt 4 Nm
  4. Bolt 90 Nm + 90° turn Always replace if removed. With multipoint socket T10035.
  5. Brake Carrier with Guide Pins and Protective Cap Supplied as an assembled replacement part with sufficient grease on guide pins. If protective caps or guide pins are damaged, install repair kit. Use supplied grease packet to lubricate guide pins.
  6. Anti-Rattle Spring Always replace when pads are replaced.
  7. Brake Pads Thickness 11 mm without backing plate Wear limit: 2 mm without backing plate Check the thickness. Refer to «FRONT AND REAR BRAKE PAD THICKNESS AND BRAKE DISC CONDITION, CHECKING»(ref-460516-S14912906322012032900000) . Must always be replaced together on both sides of vehicle. Removing and installing, refer to «REAR BRAKE PADS»(ref-460525-S25940095352012032900000) .
  8. Brake Pads Thickness: 11 mm without backing plate Wear limit: 2 mm without backing plate Check the thickness. Refer to «FRONT AND REAR BRAKE PAD THICKNESS AND BRAKE DISC CONDITION, CHECKING»(ref-460516-S14912906322012032900000) . Must always be replaced together on both sides of vehicle. Removing and installing, refer to «REAR BRAKE PADS»(ref-460525-S25940095352012032900000)
  9. Anti-Rattle Spring Always replace when pads are replaced
  10. Brake Caliper Do not unscrew brake hose when replacing brake pad. Removing and installing, refer to «REAR BRAKE CALIPER»(ref-460525-S11215947922012032900000) . Servicing, refer to «REAR BRAKE CALIPER ASSEMBLY OVERVIEW»(ref-460521-S23847885712012032900000) . Perform a basic setting after servicing or replacing.
  11. Bolt Self-locking 35 Nm Replace
  12. Bracket
  13. Brake Line 14 Nm
  14. Retaining Clip
  15. Seal
  16. Parking Brake Motor
  17. Bolt 12 Nm
  18. Brake Hose
  19. Bolt 12 Nm

Scheme 70

Scheme 70: ELECTROMECHANICAL PARKING BRAKE COMPONENT OVERVIEW
Scheme 70: ELECTROMECHANICAL PARKING BRAKE COMPONENT OVERVIEW
  1. Electromechanical Parking Brake Button -E538- Component location: In the instrument panel, next to the light switch
  2. Electromechanical Parking Brake Indicator Lamp -K213- Component location: In electromechanical parking brake button.
  3. Electric Park/Handbrake Malfunction Indicator Lamp -K214- Component location: In the instrument cluster.
  4. Brake System Warning Lamp -K118- Component location: In the instrument cluster.
  5. Acoustic Signal
  6. AUTO HOLD- Button -E540- With -AUTO HOLD- Indicator Lamp 2 -K237- Component location: In center console.
  7. Electromechanical Parking Brake Control Module -J540- and ESP Sensor Unit -G419- Installed together in one housing. Removing and installing, refer to «ELECTROMECHANICAL PARKING BRAKE CONTROL MODULE»(ref-460525-S13852481692012032900000) .
  8. Seal
  9. Right Parking Brake Motor -V283- Component location: On right rear brake caliper. Removing and installing, refer to «PARKING BRAKE MOTOR»(ref-460525-S12997907682012032900000) .
  10. Bolt 12 Nm
  11. Left Parking Brake Motor -V282- Component location: On left rear brake caliper. Removing and installing, refer to «PARKING BRAKE MOTOR»(ref-460525-S12997907682012032900000) .

BRAKE PEDAL ASSEMBLY OVERVIEW

WARNINGThe path of the brake pedal must not be shortened via extra floor mats.

Before installing, lubricate all mounting points with grease, part no. G 000 602.

Scheme 71

Scheme 71
Scheme 71
  1. Mounting Bracket
  2. Nut Self-locking 25 Nm
  3. Nut Self-locking 25 Nm
  4. Brake Pedal Clip brake pedal to push rod for brake booster. Refer to «Connecting»(ref-460525-S10196467642012032900000) .
  5. Cover
  6. Ball Socket
  7. Wheel Hub Support For the ball head on the brake booster push rod.
  8. Bolt
  9. Bushing
  10. Pivot Pin

More articles — Mechanical Components