Volkswagen Passat 2011 Instruction manual

Workshop Manual
Passat 2011 ➤
Passat Variant 2011 ➤
Brake systems
Edition 02.2014
Service
Service Department. Technical Information

List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E8030ED9A

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Allocation of PR number - brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Checking vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Checking parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Vehicle diagnosis, testing and information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 ABS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Removing and installing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Removing and installing speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4 Removing and installing speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5 Removing and installing ESP sensor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.6 Removing and installing steering angle sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.7 Removing and installing brake servo vacuum sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1 Overview of fitting locations - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2 Removing and installing control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3 Removing and installing parking brake motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3 Connecting brake pedal to brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.5 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1 Front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
Contents i

1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2 Rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.1 Assembly overview - rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.2 Removing and installing rear brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.2 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.3 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.4 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.1 Assembly overview - vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.2 Assembly overview - electric vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.3 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.4 Removing and installing brake servo pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.5 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.1 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.2 Pre-bleeding hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.3 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.4 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.5 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
ii Contents

00 – Technical data
1 Identification
(VRL006456; Edition 02.2014)
⇒ “1.1 Allocation of PR number - brakes”, page 1
1.1 Allocation of PR number - brakes
The type of brake system installed in the vehicle is indicated
among other things by the corresponding PR number on the ve‐
hicle data sticker.
The vehicle data sticker can be found in the spare wheel well and
in the service booklet.
♦ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
♦ The following table explains the PR numbers. These are im‐
portant for the brake caliper/brake disc and brake pads.
1.1.1 Front brakes
Engine PR No. Front brakes
1.4l - 90 kW FSI 1ZM FN3 (16”)
1.4l 110 kW EcoFuel
1.4l - 118 kW TSI
1.6l -77 kW TDI
1.8l - 118 kW FSI
2.0l - 155 kW FSI
2.0l - 100, 103 kW TDI
2.0 l - 125; 130 kW TDI
3.6l - 220 kW 1LA C60 (17”)
Country-specific brake for Japan:
Engine PR No. Front brakes
2.0l - 147 kW 1ZG FN3 (16”)
1.1.2 Rear brakes
Engine PR No. Rear brakes
1.4l - 90 kW FSI 1KW CII 38 (16")
1.4l 110 kW EcoFuel
1.4l - 118 kW TSI
1.6l -77 kW TDI
1.8l - 118 kW
2.0l - 155 kW FSI
2.0l - 100, 103 kW TDI
2.0 l - 125; 130 kW TDI
3.6l - 220 kW 2EA CII 41 (17")
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
1. Identification 1

2 Technical data
⇒ “2.1 Technical data for brakes”, page 2
2.1 Technical data for brakes
⇒ “2.1.1 Brake master cylinder and brake servo”, page 2
⇒ “2.1.2 Front brakes”, page 2
⇒ “2.1.3 Rear brakes”, page 3
2.1.1 Brake master cylinder and brake servo
Brake master cylinder
(low-output engine) ∅ in mm 22.22
Brake master cylinder
(high-output engine) ∅ in mm 23.81
Brake servo (LHD) ∅ in inches 11
Brake servo (RHD) ∅ in inches 7 / 8
2.1.2 Front brakes
Front brakes FN 3:
Item PR No. 1ZM / 1ZG
1 Brake caliper FN3 (16”)
2 Brake pad,
thickness mm 14
Brake pad, wear
limit without
backplate
mm 2
3 Brake disc ∅ in
mm 312
Brake disc,
thickness mm 25
Brake disc,
wear limit mm 22
4 Brake caliper
piston ∅ in mm 54
Front brakes C60:
Item PR No. 1LA / 1LB
1 Brake caliper C60 (17”)
2 Brake pad,
thickness mm 13
Brake pad, wear
limit without
backplate
mm 2
3 Brake disc ∅ in
mm 340
Brake disc,
thickness mm 30
Brake disc,
wear limit mm 27
4Brake caliper
piston ∅ in mm 60
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
2 Rep. gr.00 - Technical data

2.1.3 Rear brakes
Rear brakes CII 38:
Item PR No. 1KW
1 Brake caliper CII 38 (16")
2 Brake pad,
thickness mm 11
Brake pad, wear
limit without
backplate
mm 2
3 Brake disc ∅ in
mm 286
Brake disc,
thickness mm 12
Brake disc,
wear limit mm 10
4 Brake caliper
piston ∅ in mm 38
Rear brakes CII 41:
Item PR No. 2EA
1 Brake caliper CII 41 (17")
2 Brake pad,
thickness mm 11
Brake pad, wear
limit without
backplate
mm 2
3 Brake disc ∅ in
mm 310
Brake disc,
thickness mm 22
Brake disc,
wear limit mm 20
4 Brake caliper
piston ∅ in mm 41
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
2. Technical data 3

3 Brake test
⇒ “3.1 General information”, page 4
⇒ “3.2 Checking vehicles with front-wheel drive”, page 4
⇒ “3.3 Checking vehicles with four-wheel drive”, page 4
3.1 General information
♦ The drive is provided by the roller dynamometer.
♦ For the test ensure for vehicles with a manual gearbox that the
gear lever is in neutral, and for vehicles with an automatic
gearbox that the selector lever is in »N«.
♦ For the test, observe the specifications provided by the man‐
ufacturer of the roller dynamometer.
Note
The brake regulation systems do not function when ignition is off.
3.2 Checking vehicles with front-wheel drive
The brake test must be performed on a single-axle roller dyna‐
mometer.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
3.3 Checking vehicles with four-wheel drive
with Haldex coupling
⇒ “3.3.1 On a regulated roller dynamometer with contra-rotating
rollers for four-wheel drive vehicles”, page 4
⇒ “3.3.2 Without roller dynamometer for four-wheel drive vehi‐
cles”, page 5
3.3.1 On a regulated roller dynamometer with
contra-rotating rollers for four-wheel
drive vehicles
The brake test must be performed on a regulated single-axle roller
dynamometer with contra-rotating rollers for four-wheel drive ve‐
hicles.
“Contra-rotating” means that the dynamometer rollers are driven
forwards on one side and backwards on the other side.
“Regulated” means that the speed of the brake test stand rollers
is so controlled so that there is no difference in speed during the
brake test.
This prevents the transfer of a force through the stationary wheels
(not on the set of rollers) via the propshaft to the rotating wheels
on the rollers.
The forward rotating wheel is measured during the test, which
means two brake tests per axle must be performed.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
4 Rep. gr.00 - Technical data

3.3.2 Without roller dynamometer for four-
wheel drive vehicles
If no test rig is available for four-wheel drive vehicles, the brake
test can also be carried out on a standard single-axle roller dy‐
namometer as follows:
– Drive vehicle forwards onto the rollers.
– Switch engine off and wait for 2 seconds.
– Carry out front brake test.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.
– Drive vehicle forwards until rear wheels are positioned on roll‐
ers.
– Switch engine off and wait for 2 seconds.
– Carry out rear brake test.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.
3.4 Checking parking brake
Electromechanical parking brake
⇒ “3.4.1 Checking parking brake, vehicles with front-wheel drive”,
page 5
⇒ “3.4.2 Checking parking brake, vehicles with all-wheel drive”,
page 6
3.4.1 Checking parking brake, vehicles with
front-wheel drive
Activate »TÜV mode«:
• Seat belt is fitted
• Rear axle on single-axle roller dynamometer
• Ignition remains switched on
• Auto-hold is switched off
• Front wheels must be stationary
• Rear wheels must rotate at constant speed between 2.5 and
9 km/h for at least 5 seconds.
Entering »TÜV mode« is indicated by the yellow electric parking
brake and handbrake fault warning lamp - K214- lighting up.
Note
In »TÜV mode«, the electromechanical parking brake does not
close fully when the button is first pressed.
The tension is increased gradually by actuating the electrome‐
chanical parking brake button - E538- four times in succession.
Actuating the electromechanical parking brake button - E538- a
fifth time releases the electromechanical parking brake.
End »TÜV mode«:
• Front wheels, speed over 0 km/h
• Rear wheels, speed lower than 2.5 km/h or over 9 km/h
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
3. Brake test 5

• Ignition off.
3.4.2 Checking parking brake, vehicles with
all-wheel drive
Activate »TÜV mode«:
• Seat belt is fitted
• Rear axle on single-axle roller dynamometer
• Engine is switched off and ignition is switched on
• Auto-hold is switched off
• Front wheels must be stationary
• Rear wheels must rotate at constant speed between 2.5 and
9 km/h for at least 5 seconds.
Entering »TÜV mode« is indicated by the yellow electric parking
brake and handbrake fault warning lamp - K214- lighting up.
Note
In »TÜV mode«, the electromechanical parking brake does not
close fully when the button is first pressed.
The tension is increased gradually by actuating the electrome‐
chanical parking brake button - E538- four times in succession.
Actuating the electromechanical parking brake button - E538- a
fifth time releases the electromechanical parking brake.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.
End »TÜV mode«:
• Front wheels, speed over 0 km/h
• Rear wheels, speed lower than 2.5 km/h or over 9 km/h
• Ignition off.
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
6 Rep. gr.00 - Technical data

45 – Anti-lock brake system
1 General information
The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Vehicles with ABS are not fitted with a mechanical brake pressure
regulator. Specially matched software in the control unit regulates
the brake force distribution on the rear axle.
Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains functional
even without ABS. A change in braking behaviour is to be reck‐
oned with. After the ABS warning lamp comes on, the rear wheels
may lock prematurely during braking.
ABS layout in left-hand drive vehicle:
1 - Hydraulic unit and control unit
2 - Brake servo
The control unit and hydraulic are combined in a single compo‐
nent. Separation is not possible. Hydraulic pump must not be
separated from hydraulic unit either.
ABS layout in right-hand drive vehicle
1 - Brake servo and brake master cylinder
2 - ABS hydraulic unit - N55- and ABS control unit - J104-
The control unit and hydraulic are combined in a single compo‐
nent. Separation is not possible. Hydraulic pump must not be
separated from hydraulic unit either.
1.1 Repair instructions for repair work on
ABS
♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the fault as well as the control unit code
using “Guided Fault Finding”.
“Guided fault finding” is carried out with the ⇒ Vehicle diagnostic
tester.
♦ Disconnect battery earth strap with ignition switched off.
♦ Before carrying out welding work with an electric welding unit,
note ⇒ General Information; Body Repairs, General Body Re‐
pairs .
♦ When working with brake fluid, observe the valid, relevant
safety precautions and notes ⇒ page 132 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding unit - VAS
5234- ⇒ page 134 .
♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
1. General information 7

♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ After separating the control unit/hydraulic unit, use the trans‐
port protection for the contact pins.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. (Use sealing plugs from repair kit
1 H0 698 311 A).
♦ Only use lint-free cloths.
♦ Only unpack replacement parts immediately prior to fitting.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ During painting operations, the electronic control unit can be
exposed to a maximum temperature of 95 °C for only a short
period, and to a maximum of 85 °C for longer periods (approx.
2 hours). Ensure that no brake fluid enters connectors.
1.2 Vehicle diagnosis, testing and informa‐
tion system
Connecting -Fahrzeugdiagnosetester- and selecting functions
Special tools and workshop equipment required
♦ Vehicle diagnostic, testing and information system - VAS
5051-
♦ Diagnostic cable -VAS 5051/1- or -VAS 5051/3-
WARNING
♦ During a road test, you must always secure testing and
measuring equipment on the back seat.
♦ These devices may be operated only by a passenger while
the vehicle is in motion.
– Connect connector of diagnosis cable -VAS 5051/1- or -
VAS 5051/3- to diagnostic connection.
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
8 Rep. gr.45 - Anti-lock brake system

– Switch on tester -arrow-.
The tester is ready for operation when the selector buttons for the
operating modes appear on the screen.
– Switch on ignition.
– Touch Guided Fault Finding on screen.
– Select one after another:
♦ Brand
♦ Type
♦ Model year
♦ Body version
♦ Engine code
– Confirm data entered.
Wait until tester has interrogated all control units in vehicle.
– Press GoTo and select function “Function/component selec‐
tion”.
– Select “Running gear” on display.
– Select “Brake systems” on display.
– Select “01 Self-diagnosis capable system …” shown on dis‐
play.
Either:
– Select “Anti-lock brake system …” shown on display.
or:
– Select “Electromechanical parking brake” on display.
– Select “Function” shown on display.
Now all possible functions from the anti-lock brake system instal‐
led in the vehicle will be displayed.
– Select desired function on display.
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
1. General information 9

2 Overview of fitting locations
⇒ “2.1 ABS/ESP”, page 10
2.1 ABS/ESP
⇒ “2.1.1 ABS/ESP, LHD”, page 10
⇒ “2.1.2 ABS/ESP, RHD”, page 12
2.1.1 ABS/ESP, LHD
1 - ABS control unit - J104-
❑Location: on the hy‐
draulic unit on right in
engine compartment.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
❑ Must not be separated
from ABS hydraulic unit
- N55-
❑ Removing and installing
⇒ page 17 .
2 - ABS hydraulic unit - N55-
❑Location: on right in en‐
gine compartment.
The hydraulic unit consists of
the components:
❑ Brake pressure sender -
G201-
❑ ABS hydraulic pump -
V64-
❑ Valve block (contains in‐
let and outlet valves).
❑ ABS hydraulic pump -
V64- and valve block
must not be separated
from one another.
❑ Must not be separated
from ABS control unit -
J104-
❑ Removing and installing
⇒ page 17 .
3 - Brake pad warning lamp - K32-
❑Location: in dash panel insert.
4 - ABS warning lamp - K47-
❑ Location: in dash panel insert.
5 - ESP and TCS warning lamp - K155-
❑ Location: in dash panel insert.
6 - Brake system warning lamp - K118-
❑ Location: in dash panel insert.
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
10 Rep. gr.45 - Anti-lock brake system

7 - Brake light switch - F-
❑ Location: on brake master cylinder.
❑ Removing and installing ⇒ page 86 .
8 - TCS and ESP button - E256-
❑ Location: in centre console
9 - ESP sensor unit - G419- and control unit for electromechanical parking brake - J540-
❑ Location: under centre console.
❑ Combined lateral acceleration sender - G200- , yaw rate sender - G202- and longitudinal acceleration
sender - G251- .
❑ Installed in one housing together with control unit for electromechanical parking brake - J540-
❑ Removing and installing ⇒ page 32 .
10 - Diagnostic connection
❑ Location: Driver footwell cover.
11 - Steering angle sender - G85-
❑ Location: on steering column between steering wheel and steering column switch
❑ Removing and installing ⇒ page 33 .
12 - Wheel bearing housing
13 - Front right/left speed sensor -G45- / -G47-
❑ Removing and installing ⇒ page 28 .
14 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
15 - Rear right/left speed sensor -G44- / -G46-
❑ Removing and installing (front-wheel drive) ⇒ page 29
❑ Removing and installing (four-wheel drive) ⇒ page 31
16 - Wheel bearing housing
Figure for front-wheel drive
17 - Wheel hub with wheel bearing
Figure for front-wheel drive
❑ ABS sensor ring is installed in wheel bearing.
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
2. Overview of fitting locations 11

2.1.2 ABS/ESP, RHD
1 - ABS control unit - J104-
❑Location: on hydraulic
unit, on left in engine
compartment.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
❑ Must not be separated
from ABS hydraulic unit
- N55-
❑ Removing and installing
⇒ page 22 .
2 - ABS hydraulic unit - N55-
❑Location: on left in en‐
gine compartment
The hydraulic unit consists of
the components:
❑ Brake pressure sender -
G201-
❑ ABS hydraulic pump -
V64-
❑ Valve block (contains in‐
let and outlet valves).
❑ ABS hydraulic pump -
V64- and valve block
must not be separated
from one another.
❑ Must not be separated
from ABS control unit -
J104-
❑ Removing and installing
⇒ page 22 .
3 - Brake pad warning lamp - K32-
❑Location: in dash panel insert.
4 - ABS warning lamp - K47-
❑ Location: in dash panel insert.
5 - ESP and TCS warning lamp - K155-
❑ Location: in dash panel insert.
6 - Brake system warning lamp - K118-
❑ Location: in dash panel insert.
7 - Diagnostic connection
❑ Location: Driver footwell cover.
8 - ESP sensor unit - G419- and control unit for electromechanical parking brake - J540-
❑ Location: under centre console.
❑ Combined lateral acceleration sender - G200- , yaw rate sender - G202- and longitudinal acceleration
sender - G251- .
❑ Installed in one housing together with control unit for electromechanical parking brake - J540-
❑ Removing and installing ⇒ page 32 .
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
12 Rep. gr.45 - Anti-lock brake system

9 - Steering rack with steering angle sender - G85-
❑Additionally a steering angle sensor - G85- is installed on the steering column ⇒ Item 11 (page 11) .
❑Fault diagnosis ⇒ Vehicle diagnostic tester
❑ Removing and installing steering angle sensor - G85- between steering wheel and steering column switch
⇒ page 33
10 - Front right/left speed sensor -G45- / -G47-
❑Removing and installing ⇒ page 28 .
11 - Wheel hub with wheel bearing
❑ABS sensor ring is installed in wheel bearing.
12 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
13 - Rear right/left speed sensor -G44- / -G46-
❑ Removing and installing (front-wheel drive) ⇒ page 29
❑Removing and installing (four-wheel drive) ⇒ page 31
14 - Brake light switch - F-
❑Location: on brake master cylinder.
❑ Removing and installing ⇒ page 87 .
15 - TCS and ESP button - E256-
❑Location: in centre console
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
2. Overview of fitting locations 13

3 Control unit and hydraulic unit
⇒ “3.1 Assembly overview”, page 14
⇒ “3.2 Removing and installing control unit and hydraulic unit”,
page 17
⇒ “3.3 Connecting brake lines to hydraulic unit”, page 25
3.1 Assembly overview
⇒ “3.1.1 Assembly overview - control unit and hydraulic unit,
LHD”, page 14
⇒ “3.1.2 Assembly overview - control unit and hydraulic unit,
RHD”, page 16
3.1.1 Assembly overview - control unit and hydraulic unit, LHD
1 - ABS control unit - J104-
The control unit and hydraulic
unit cannot be separated.
❑ Removing and installing
⇒ page 17 .
2 - ABS hydraulic unit - N55-
The control unit and hydraulic
unit cannot be separated.
❑ Removing and installing
⇒ page 17 .
3 - Brake line
❑To front right brake cali‐
per
❑ Identification: ∅ 5.25
mm and flare nut with
thread M 10 x 1
❑ Marked on hydraulic
unit with “VR”
4 - Brake line
❑ To rear left brake caliper
❑ Identification: ∅
5.25 mm and union nut
with short thread M12 x
1.
❑ Marked on hydraulic
unit with “HL”
5 - Brake line
❑ To rear right brake cali‐
per
❑ Identification: ∅ 5.25
mm and flare nut with
thread M 10 x 1
❑ Marked on hydraulic unit with “HR”
6 - Brake line
❑ To front left brake caliper.
❑ Identification: ∅ 5.25 mm and union nut with short thread M12 x 1.
❑ Marked on hydraulic unit with “VL”
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
14 Rep. gr.45 - Anti-lock brake system

7 - Brake line
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
❑ Identification: ∅ 6 mm and union nut with long thread M12 x 1
❑ Marked on hydraulic unit with “HZ1”
8 - Brake line
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
❑ Identification: ∅ 6 mm and union nut with long thread M12 x 1
❑ Marked on hydraulic unit with “HZ2”
9 - Heat shield
Allocation ⇒ Electronic Parts Catalogue (ETKA) .
10 - Torx socket head bolt, 12 Nm
11 - Brake servo
❑ A vacuum sender is fitted in vehicles with HBS ⇒ page 33 .
❑ Removing and installing ⇒ page 102 .
12 - Bracket
13 - Hexagon nut, 20 Nm
14 - Rubber damper
15 - Torx socket head bolt, 10 Nm
16 - Bracket
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
3. Control unit and hydraulic unit 15

3.1.2 Assembly overview - control unit and hydraulic unit, RHD
1 - Brake line
❑To rear right brake cali‐
per
❑ Identification: ∅ 5.25
mm and flare nut with
thread M 10 x 1
❑ Marking on ABS hy‐
draulic unit - N55- “HR”
2 - Brake line
❑ To rear left brake caliper
❑ Identification: ∅
5.25 mm and union nut
with short thread M12 x
1.
❑ Marking on ABS hy‐
draulic unit - N55- “HL”
3 - Brake line
❑ To front right brake cali‐
per
❑ Identification: ∅ 5.25
mm and flare nut with
thread M 10 x 1
❑ Marking on ABS hy‐
draulic unit - N55- “VR”
4 - Brake line
❑ To front left brake cali‐
per.
❑ Identification: ∅
5.25 mm and union nut
with short thread M12 x
1.
❑ Marking on ABS hy‐
draulic unit - N55- “VL”
5 - Brake line
❑ From primary piston circuit of brake master cylinder to ABS hydraulic unit - N55- .
❑ Identification: ∅ 6.5 mm and union nut with long thread M12 x 1
❑ Marking on ABS hydraulic unit - N55- “HZ1”
6 - Brake line
❑ Brake master cylinder/secondary piston circuit to ABS hydraulic unit - N55- .
❑ Identification: ∅ 6.5 mm and union nut with long thread M12 x 1
❑ Marking on ABS hydraulic unit - N55- “HZ2”
7 - ABS hydraulic unit - N55- with ABS control unit - J104-
ABS control unit - J104- and ABS hydraulic unit - N55- cannot be separated.
❑ Removing and installing ⇒ page 22 .
8 - Bracket
9 - Bolt, 8 Nm
10 - Rubber damper
❑When installing, ensure that rubber dampers are not pressed out of bracket.
Passat 2011 ➤ , Passat Variant 2011 ➤
Brake systems - Edition 02.2014
16 Rep. gr.45 - Anti-lock brake system