How to carry out replacement: Brake Calipers 2.0 TDI Passat B6 Variant
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Change Passat B6 Variant 2.0 TDI Brake Calipers yourself – manuals and video tutorials

How to change front brake caliper on VW Passat Variant (3C5) – replacement guide

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When to replace the Brake Calipers on your VW PASSAT
Recommended replacement interval for the part category Brake caliper : 100000 km
Important!
This replacement procedure can be used for:
VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 1.6 FSI, VW Passat Variant (3C5) 2.0 FSI, VW Passat Variant (3C5) 1.9 TDI, VW Passat Variant (3C5) 2.0 TDI 16V, VW Passat Variant (3C5) 1.6, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 2.0 TFSI, VW Passat Variant (3C5) 3.2 FSI 4motion, VW Passat Variant (3C5) 2.0 TDI 16V 4motion, VW Passat Variant (3C5) 2.0 FSI 4motion, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 2.0 TDI 4motion, VW Passat Variant (3C5) 3.6 R36 4motion, VW Passat Variant (3C5) 1.4 TSI, VW Passat Variant (3C5) 1.8 TSI, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 1.4 TSI EcoFuel, VW Passat Variant (3C5) 2.0 TDI, VW Passat Variant (3C5) 2.0 BlueTDI, VW Passat Variant (3C5) 1.6 TDI, VW Passat Variant (3C5) 2.0 TDI 4motion, VW Passat Variant (3C5) 1.8 TSI … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Brake Calipers for Passat Variant (3C5) and other VW models
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Tools
Replacement: brake caliper – VW PASSAT Variant (3C5). List of the tools you'll need:
Torque wrench
Wire brush
HEX bit No.H7
Drive socket # 11
Ratchet wrench
Brake cleaner
Copper grease
Flat screwdriver
Fluid container
Anti-squeal paste
Wheel impact socket #17
Wheel chock
Brake hose clip
Crow bar
Buy tools
Replacement: brake caliper – VW PASSAT Variant (3C5). Tip from AUTODOC:
  • The replacement procedure is identical for the left and right brake calipers on the same axle.
  • All work should be done with the engine stopped.
Replacement: brake caliper – VW PASSAT Variant (3C5). Recommended sequence of steps:
  1. Step 1
    Open the bonnet.
    Step 2
    Unscrew the brake fluid reservoir cap.
    Step 3
    How to change Brake Calipers on Passat B6 Variant 2005 - free PDF and video manuals
    Secure the wheels with chocks.
  2. Step 4
    How to replace VW Passat Variant (3C5) 2.0 TDI 2006 Brake Calipers - step-by-step manuals and video guides
    Loosen the wheel mounting bolts. Use wheel impact socket #17.
  3. Step 5
    Raise the front of the car and secure on supports.
    Step 6
    Passat B6 Variant 2.0 TDI 16V 2007 Brake Calipers replacement: free workshop manuals
    Unscrew the wheel bolts.
    Replacement: brake caliper – VW PASSAT Variant (3C5). AUTODOC recommends:
    To avoid injury, hold up the wheel when unscrewing the bolts.
  4. Step 7
    Changing Brake Calipers on VW Passat Variant (3C5) 2.0 FSI 2008 by yourself
    Remove the wheel.
  5. Step 8
    Disconnect the ABS sensor electric socket. Disconnect the brake pad wear sensor plug. Remove the ABS sensor connector. Remove the connector of the brake pad wear sensor.
    Please note!
    Some cars are not equipped with the brake pad wear sensor.
    Step 9
    How to remove VW PASSAT 2.0 TDI 4motion 2009 Brake Calipers - online easy-to-follow instructions
    Put a container for gathering brake fluid beneath.
  6. Step 10
    How to replace Brake Calipers on VW Passat Variant (3C5) 2010: download PDF manuals and video instructions
    Clean the area where the brake hose is connected to the caliper, and the guide pins area. Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  7. Step 11.1
    How hard is it to do yourself: Brake Calipers replacement on Passat B6 Variant 1.4 TSI EcoFuel 2011 - download illustrated guide
    Clamp the brake hose off using a brake hose clamp.
    Step 11.2
    Need to know how to renew Brake Calipers on VW PASSAT 2005? This free workshop manual will help you to do it yourself
    Unscrew the brake hose from the brake caliper. Use a drive socket #11. Use a ratchet wrench. Move the brake hose aside. Tie the brake hose to the car body with a hook or a piece of wire.
  8. Step 12
    Changing of Brake Calipers on Passat B6 Variant 2006 won't be an issue if you follow this illustrated step-by-step guide
    Remove the dust boot caps of the brake caliper guide pins.
  9. Step 13
    VW PASSAT 2.0 TDI Brake Calipers replacement: online guides and video tutorials
    Spread the brake pads. Use a crowbar.
  10. Step 14
    Replacing Brake Calipers on Passat B6 Variant 2008 2.0 TDI by yourself
    Using a simple screwdriver, remove the brake caliper spring clip.
  11. Step 15
    Passat Variant (3C5) 2.0 TDI 4motion 2009 Brake Calipers DIY replacement workshop manual
    Unscrew the brake caliper fastening. Use HEX No.H7.
  12. Step 16
    How to change Brake Calipers on VW Passat Variant (3C5) 2010 - tips and tricks
    Remove the brake caliper.
    Replacement: brake caliper – VW PASSAT Variant (3C5). Professionals recommend:
    When replacing the brake caliper, it is recommended to check the brake hose for damages and, if necessary, to replace it with a new one. If going to use the old brake pads, clean them.When replacing a brake caliper it is recommended to replace brake pads, check the state of the brake discs and replace them with new ones if necessary.
  13. Step 17
    Step-by-step recommendations for DIY replacement Passat B6 Variant 2011 2.0 TDI 4motion Brake Calipers
    Clean the brake caliper bracket from dirt and dust. Use a wire brush. Treat the brake caliper bracket. Use a brake cleaner.
    AUTODOC recommends:
    Replacement: brake caliper – VW PASSAT Variant (3C5). After applying the spray, wait a few minutes.
  14. Step 18
    Remove the guide pins from the brake caliper.
    Step 19
    Clean old grease and rust stains, if there are any, from the caliper guide pins and guide pin boots. Use a brake cleaner.
    Replacement: brake caliper – VW PASSAT Variant (3C5). Tip:
    After applying the spray, wait a few minutes.
    Step 20
    Lubricate guide pins with special brake grease.
    Replacement: brake caliper – VW PASSAT Variant (3C5). AUTODOC experts recommend:
    If no new guide pins were supplied in a kit with the new brake calipers, use the old pins.
    Step 21
    DIY replacement of Brake Calipers on VW Passat Variant (3C5) 1.9 TDI 2005 is not an issue anymore with our step-by-step tutorial
    Treat the contact surfaces between the brake pads and the brake caliper bracket. Use anti-squeal paste.
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