Brake system of car Volkswagen Passat B6

General information about the braking system
The speed of the Passat, depending on the modification, reaches 190–240 km/h. The weight of the car creates an additional load on the brakes. When installing modern powerful...

Electronic brake system components
The brake system of the Passat includes a whole complex of electronic devices. The car is equipped with an anti-lock braking system (ABS), which prevents the wheels from locking...

Brake system components
Pressure regulator The pressure regulator limits the output pressure to the rear brakes after the pressure has reached the maximum value in the master cylinder. The regulator is...

Technical characteristics of brakes
Master Cylinder and Brake Booster Front brakes Fig. 6.1. Front brakes FN 3 Fig. 6.2. Front brakes FNR-G Rear brakes Fig. 6.3. Rear brakes CII 38 Fig. 6.4. Rear brakes CII 41

Pressure leak test
To carry out the check it is necessary that the brake system, its functionality and tightness (hydraulic unit, brake hoses, brake lines and brake calipers) should be fine. Unscrew...

Checking the brake fluid level
Note: The brake fluid level depends on the degree of wear of the brake pads. Caution: Do not mix brake fluid with fluids containing mineral oil (oil, gasoline, cleaning agents)....

Replacing brake fluid
Replace the brake fluid in the brake system and clutch unit. Fig. 6.6. Brake system expansion tank cap Unscrew cap 1 of the brake system expansion tank (Fig. 6.6). Fig. 6.7....

Visual inspection of the brake system for leaks and damage
Check the following parts and components for leaks and damage: master brake cylinder; brake booster (with ABS: hydraulic unit); brake force regulator and brake calipers. Check...

Checking the thickness of the front and rear brake pads
Front brake pads To most accurately determine the remaining thickness of the brake pads, remove the front left wheel. Remove wheel bolt caps if necessary. Mark the position of the...

Removal and installation brake pads
Removal Mark the brake pads if they are to be reused. They must be installed back in their original positions, otherwise uneven distribution of braking forces between the wheels...

Removal and installation the electromechanical parking brake control unit
The electromechanical parking brake control unit and the ESP sensor are installed in the same housing under the center console. After replacing the electromechanical parking brake...

Removal and installation the parking brake drive
Removal Note: After turning off the ignition, wait at least 30 seconds before disconnecting the plug connection. Fig. 6.19. Parking brake actuator plug Disconnect plug 1 from the...

Disconnecting the brake pedal from the brake booster
Fig. 6.23. Pressing the brake pedal: 2 – pressure rod; 3 – locking tabs First press the brake pedal towards the brake booster and secure (Fig. 6.23). Using the release tool, pull...

Connecting the brake pedal to the brake booster
Fig. 6.24. Fixing the ball head Hold the ball head of the push rod in front of the fastener and press the brake pedal towards the brake booster until the ball head engages with an...

Removal and installation the piston for the FN 3 brake caliper
Fig. 6.25. Brake caliper components: 1 – cap; 2 – bleed nipple, 10 Nm; 3 – caps; 4 – guide bolt, 30 Nm; 5 – support sleeve; 6 – brake caliper; 7 – bracket holder; 8 – retaining...

Removal and installation the brake caliper piston
Removal Rotate the axle in the direction of the arrow using a T45 socket wrench. Fig. 6.34. Pushing out the piston using a T45 socket wrench The lock nut will push the piston out...

Removal and installation the brake light switch F
Removal Disconnect the battery. Remove the air intake sleeve, air filter housing (in vehicles with diesel engines and some petrol engines) and battery. In vehicles with a 6-cyl....

Removal and installation the master brake cylinder
Removal Disconnect the battery. Remove the air intake sleeve, air filter housing (in vehicles with diesel engines and some petrol engines) and battery. In vehicles with a 6-cyl....

Removal and installation the brake booster
Removal Disconnect the battery. Remove the air intake sleeve, air filter housing (in vehicles with diesel engines and some petrol engines) and battery. In vehicles with a 6-cyl....

Repair of brake pipes
The VAS 6056 tube flaring device can be used to flare brake pipes with an external diameter of 5 mm without damaging the coating. This means that individual parts of the brake...

General information about the anti-lock braking system
The brake system with ABS is dual-circuit and diagonal. The brake system is reinforced by a vacuum booster. Vehicles with ABS do not have a mechanical brake force regulator....

Removal and installation the speed sensor on the front axle
Fig. 6.60. ABS components on the front axle: 1 – ABS speed sensor; 2 – Allen bolt, 8 Nm; 3 – Wheel bearing/wheel hub assembly; 4 – drive shaft Removal Raise the car. Fig. 6.61....

Removal and installation the speed sensor on the rear axle
Fig. 6.62. ABS components on the rear axle: 1 – ABS speed sensor; 2 – Allen bolt, 8 Nm; 3 – wheel bearing/wheel hub assembly Removal Raise the car. Fig. 6.63. Plug connection of...

Removal and installation the speed sensor on the rear axle (all-wheel drive)
Fig. 6.64. ABS components on the rear axle (all wheel drive): 1 – ABS speed sensor; 2 – Allen bolt, 8 Nm; 3 – journal and hub assembly Removal Raise the car. Fig. 6.65. Plug...

Removal and installation the low pressure sensor in the brake booster
Removal In vehicles with a 6-cyl. petrol engine, the battery is located in the luggage compartment; accordingly, only the air filter housing needs to be removed. Remove the...

Possible malfunctions, their causes and methods of elimination
Possible causes of malfunction Method of elimination Brake warning light is on Brake fluid leak Fix the leak or add fluid The parking brake switch is closed to "ground" Repair the...

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