The 2002 Volkswagen Passat was equipped with a 2.8-liter V-6, a 1.8-liter turbocharged four-cylinder, or a 4.0-liter W-8 engine, depending on the sub-model.7. Install brand-new brake pads onto the caliper bracket. Install the rear brake caliper onto the brake meeting. Install and tighten the caliper bolts to 26 foot-pounds with a torque wrench and socket.
1. Elevate the hood on the Passat. Observe the brake fluid alike in the reservoir. Remove brake fluid with a turkey baster or bottle siphon, until the fluid is approximately 1/2 inch below the "Comprehensive" location. Install the reservoir lid and tighten it.
2. Loosen the rear turn lug bolts with a tire iron, however cook not remove them. Up thrust the rear of the Passat with a jack. Domicile jack stands below the rear axle beam, approximately 6-inches incoming from the rear wheels. Remove the rear lug bolts, then remove the rear wheels from the machine.
3. Sit in the vehicle and constitute confident the parking brake shaft inside the van is in the resting or off position. Method absent of the vehicle and position yourself under the rear of the Passat. Cover a screwdriver between the two arms on the parking brake assembly, on the rear of the caliper. Dominion the meeting all the more while removing the hex bolt from the rear of the parking brake meeting with a ratchet and socket. Pull the parking brake lever attached to the cable autonomous from the parking brake assembly with the screwdriver.
4. Remove the caliper bolts from the rear of the caliper with a ratchet and socket, while holding the caliper slide pins all the more with an open-end wrench. Remove the caliper from the brake meeting with a insufficient pry bar whether needed. Hang the caliper from the rear coil spring with a metal clothes hanger or hook. Complete not let the caliper hang freely by the rubber hose it is attached to.
5. Remove the enfeebled brake pads from the caliper bracket by participation. Scrutinize the anti-rattle clips at the top and backside of the caliper bracket, and interchange them provided they are hunched or damaged. Scrutinize the rear brake rotor for cracks, pitting or rust. Degree the rotor thickness with a tape degree. whether the rotor is damaged or is less than 3/8 inches thick, alternate the brake rotor at this hour.
6. Retract the caliper piston into the caliper oppose, using a 3/8-inch manage ratchet, extent and caliper-rotating factor. Turn the piston clockwise while applying incoming power on the piston. Advance turning until the piston is completely retracted into the caliper. Remove the caliper captain pins from the rear of the caliper. Thoroughly grease the pins with caliper grease, then subsume them back into the caliper. Transform the inconsiderable rubber boots on the rear of the caliper at this chronology, whether they are dry rotted or torn.
The 2002 Passat was available in front-wheel impel or all-wheel coerce. The 2002 Passat had rear drum brakes on the example base, on the other hand had the possibility of a four-wheel disc-brake course. The rear calipers on the 2002 Passat hold rotating pistons that have need a different baggage, available at most Car parts stores.
InstructionsInstall the brake cable meeting back onto the rear parking brake meeting. Install and tighten the brake cable fan with a ratchet and socket, while holding the parking brake meeting much with a screwdriver. You may enjoy to loosen the fan on the adjuster arm below the cable arm, to fit the cable arm back into abode. Tighten both fixtures with a ratchet and socket.
8. Repeat steps 3 down 7 to full-dress the rear brake pad replacement on the moment side of the Passat. Fill the brake fluid reservoir provided necessary, until the fluid level is near the "Full" mark. The fluid level may be on an angle due to the incline of the car. Use the middle of the reservoir fluid level as your guide for how full the reservoir is. Install and tighten the reservoir cap.
9. Gently seat yourself in the driver's seat of the Passat. Pump the brake pedal slowly about 40 times. This will seat the caliper pistons against the new brake pads. If the pedal does not stiffen after five or six pumps, stop pumping and bleed the rear brakes. Exit the Passat when you have completed pumping the brakes and have a solid brake pedal.
10. Install the rear wheels onto the Passat. Insert a guide pin or punch awl through one of the lug bolt holes to align the holes on the hub with those on the wheel. Insert all of the lug bolts and begin threading them by hand, to ensure proper threading. Tighten the lug bolts snug with your tire iron. Raise the Passat off of the jack stands, then remove the stands and lower the car to the ground. Apply 90 foot-pounds with a torque wrench and socket. Double check the brake fluid reservoir with the car lowered onto level ground.