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REAR/PARKING BRAKES

WARNING: Before attempting to work on the Passat Rear Brake System, it is essential to have the Diagnostic Software Interface, and a battery charger available (in addition to the usual workshop tools.)

The Passat is equipped with an Electromechanical Park Brake System, which is integrated into the rear brake calipers. It is therefore a requirement of the system that the diagnostic system is used to retract the pistons into the caliper housing.

The battery charger should be connected to the battery prior to starting any procedure on the vehicle using the diagnostic equipment. This will avoid any voltage fluctuation to the ECU and/or other control systems.

This model is fitted with an electromechanical parking brake. 
Rear calipers are fitted with two motors controlling parking brake operation.

Note:

Parking brake adjustment can only be carried out with a diagnostic tool, by following the repositioning procedure.
 

REMOVAL

  • Position vehicle onto lift.
  • Remove rear wheels.
  • Retract the pistons using the diagnostic system and then loosen the caliper slide pins.
  • Remove the calipers and the brake pads.
  • The caliper must be properly cleaned of all brake residue, especially on all moving surfaces.
  • Slide pins must be cleaned and lightly lubricated with a high temperature molybdenum grease.

REPLACEMENT

  • Push the caliper pistons to the full home position.

Note:

Prior to returning the piston into the cylinder, draw out some of the brake fluid from the reservoir. If the reservoir is full, the brake fluid could overflow, causing damage.
  • Fit brake pads to the brake hanger (arrows 1).
  • Make sure that brake pads are properly positioned in their retaining plates (arrows 2).

Note:

If brake pads have an adhesive surface, make sure they do not adhere to the caliper before they reach their correct position.
  • Tighten the brake fluid hose coupling to caliper to a torque of 14 Nm.
  • Secure the brake caliper, tightening the slide pins to a torque of 35 Nm.
  • Check brake fluid level and top up when necessary.

Warning:

After replacing the brake pads, fully depress the brake pedal several times to reposition the pistons in the calipers.

PARK BRAKE RESETTING

  • Using the diagnostic system, reset the park brake motor pistons to their home position.

Note:

Prior to returning the piston into the cylinder, draw out some of the brake fluid from the reservoir. If the reservoir is full, the brake fluid could overflow, causing damage.

 
  • Connect the diagnostic tool to the vehicle and select the parking brake function.
  • Reposition the pistons.

Warning:

Piston repositioning using the diagnostic tool alone is insufficient. Press the piston fully home retracting the linkage by means of its presser (X) (see figure page 3).

BRAKE DISC

REMOVAL

  • Remove the caliper frame by loosening the mounting bolts, to provide access to the brake disc.
  • Loosen the locating screw and remove the discs and brake pads.
  • Clean the caliper of all brake residue, especially on all moving surfaces.

Note:

Do not try to force the brake discs off the wheel hub: in case of resistance use a rust-removing product.

REPLACEMENT

  • Position brake disc onto hub ensuring mating surfaces are clean.
  • Tighten the locating screw to a torque of 4 Nm.
  • Fit brake pads as per brake pad fitment section (page 1).
 

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