Clutch Fluid: Service and Repair

Brake and Clutch System, Changing Brake Fluid

CAUTION!
• Brake fluid is poisonous.

CAUTION!
• Brake fluid must never come into contact with fluids containing mineral oils (oil, gas, cleaning solutions). Oils containing minerals damage seals and sleeves on brake systems.

• Do not let brake fluid come into contact with paint.

• Brake fluid is hygroscopic, which means that it absorbs moisture from the air. Always store brake fluid in air-tight containers.

• Wash off brake fluid spillage using plenty of water.

• Observe waste disposal regulations!

• Use a "new" special brake fluid with this vehicle. This can only be recognized by the replacement part number Brake fluid VW 501 14 (B 000 750).

• Use the new brake fluid only, the previous brake fluid with replacement part number B 000 700 A must "Not" be filled into the Passat.

Special tools, testers and auxiliary items required

• Brake filler and bleeder unit (VAS 5234)





• Brake pedal depressor (V.A.G 1869/2)





• Brake Bleeder Tool (VAS 5519)

- Unscrew brake fluid reservoir cap - 1 -.





- Extract as much brake fluid as possible using intake hose Brake charger/bleeding unit (VAS 5234).





• The strainer in the brake fluid reservoir must not be removed.

CAUTION!
Extracted brake fluid must not be re-used!

- Screw adapter - 1 - onto brake fluid reservoir.





Observe operating instructions for (VAS 5234)!

- Install brake pedal depressor (V.A.G 1869/2) between driver's seat and brake pedal and apply tension.

- Connect charger hose of brake charger/bleeder unit (VAS 5234) to adapter.

• Use a suitable bleed hose. It must seat tightly on bleed screw so that no air can enter brake system.

- Connect collector bottle bleeder hose - 1 - to left front bleeder screw, open bleed screw and allow the corresponding quantity to flow out (see table). Close the bleeder screw, torque, refer to=> Suspension, Wheels, Steering 44 Removal and Installation.





Repeat work procedure on right side of vehicle at front.

- Unscrew both wheels at rear axle in order to reach the bleed screws.

- Pull cover caps off brake caliper bleeder screws

- Connect collector bottle bleeder hose - 1 - to left rear bleeder screw.





- Open bleeder screw and let the corresponding amount of brake fluid (see table) flow out. Close the bleeder screw, torque refer to => Suspension, Wheels, Steering 47 Removal and Installation.

Repeat work procedure on right side of vehicle at rear.

For vehicles with manual transmission

- Place bleeder hose on clutch slave cylinder bleeder valve.

- Open valve and allow about 100 ml of brake fluid to flow out.

- Close valve and press clutch pedal rapidly 10 to 15 times in succession.

- Open valve again and allow about 50 ml of brake fluid to flow out.

- Close valve, remove bleeder hose and press clutch pedal several times.

- Install air filter box in reverse sequence.

Sequence and Brake Fluid Capacity Table





Total amount: approximately 1.15 Liters

- Place cover caps on bleeder screws.

- Move filler lever on brake charger/bleeder unit (VAS 5234) to position "B" (see operating instructions).

- Take filler hose off adapter.

- Unscrew adapter from brake fluid reservoir.

- Check brake fluid level and top off if necessary.

- Screw in cap - 1 - for brake fluid reservoir.





- Remove brake pedal depressor.

- Check pedal pressure and brake pedal free play. Free play: Max. 1/3 of pedal travel