How to carry out replacement: Brake Calipers 1.9 TDI Passat 3b5
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Change Passat 3b5 1.9 TDI Brake Calipers yourself – manuals and video tutorials

How to change front brake caliper on VW PASSAT Variant (3B5) – 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 (3B5) 1.6, VW PASSAT Variant (3B5) 1.8, VW PASSAT Variant (3B5) 1.8 T, VW PASSAT Variant (3B5) 2.3 VR5, VW PASSAT Variant (3B5) 2.8 V6, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 2.8 V6 Syncro/4motion, VW PASSAT Variant (3B5) 1.8 Syncro/4motion, VW PASSAT Variant (3B5) 1.9 TDI Syncro/4motion, VW PASSAT Variant (3B5) 2.3 VR5 Syncro/4motion, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 2.5 TDI, VW PASSAT Variant (3B5) 2.5 TDI Syncro/4motion, VW PASSAT Variant (3B5) 1.9 TDI 4motion, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 2.0, VW PASSAT Variant (3B5) 2.0 4motion, VW PASSAT Variant (3B5) 1.8, VW PASSAT Variant (3B5) 2.8 V6, VW PASSAT Variant (3B5) 2.8 V6 … 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 (3B5) and other VW models
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Tools
Replacement: brake caliper – VW PASSAT Variant (3B5). Tools you need:
Wire brush
Brake cleaner
Copper grease
Combination spanner #10
Combination spanner #11
Drive socket # 10
Drive socket # 11
HEX bit no.H7.
Wheel impact socket #17
Ratchet wrench
Torque wrench
Fluid container
Brake hose clip
Brake bleeder kit
Crow bar
Wheel chock
Buy tools
Replacement: brake caliper – VW PASSAT Variant (3B5). AUTODOC recommends:
  • 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 (3B5). Take the following steps:
  1. Step 1
    Open the bonnet. Unscrew the brake fluid reservoir cap.
    Step 2
    How to change Brake Calipers on Passat 3b5 1997 - free PDF and video manuals
    Secure the wheels with chocks.
  2. Step 3
    How to replace VW PASSAT Variant (3B5) 1.9 TDI 1998 Brake Calipers - step-by-step manuals and video guides
    Loosen the wheel mounting bolts. Use wheel impact socket #17.
  3. Step 4
    Raise the front of the car and secure on supports.
    Step 5
    Passat 3b5 1.8 T 1999 Brake Calipers replacement: free workshop manuals
    Unscrew the wheel bolts.
    Replacement: brake caliper – VW PASSAT Variant (3B5). Tip:
    To avoid injury, hold up the wheel when unscrewing the bolts.
  4. Step 6
    Changing Brake Calipers on VW PASSAT Variant (3B5) 1.6 2000 by yourself
    Remove the wheel.
  5. Step 7
    How to remove VW PASSAT 1.9 TDI Syncro/4motion 2001 Brake Calipers - online easy-to-follow instructions
    Disconnect the ABS sensor electric socket. Disconnect the brake pad wear sensor plug. Use a crowbar.
    Please note!
    Some cars are not equipped with the brake pad wear sensor.
  6. Step 8
    How to replace Brake Calipers on VW PASSAT Variant (3B5) 1997: download PDF manuals and video instructions
    Clamp the brake hose off using a brake hose clamp.
  7. Step 9
    How hard is it to do yourself: Brake Calipers replacement on Passat 3b5 1.9 TDI 4motion 1998 - download illustrated guide
    Put a container for gathering brake fluid beneath.
  8. Step 10
    Need to know how to renew Brake Calipers on VW PASSAT 1999? This free workshop manual will help you to do it yourself
    Clean the brake pipe fastener. Use a wire brush. Use a brake cleaner.
    AUTODOC recommends:
    Replacement: brake caliper – VW PASSAT Variant (3B5). After applying the spray, wait a few minutes.
  9. Step 11
    Changing of Brake Calipers on Passat 3b5 2000 won't be an issue if you follow this illustrated step-by-step guide
    Unscrew the fastener connecting the brake pipe to the brake hose. Use a combination spanner #11.
  10. Step 12
    VW PASSAT 1.9 TDI Brake Calipers replacement: online guides and video tutorials
    Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
  11. Step 13
    Replacing Brake Calipers on Passat 3b5 1997 1.9 TDI by yourself
    Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
  12. Step 14
    PASSAT Variant (3B5) 1.9 TDI Syncro/4motion 1998 Brake Calipers DIY replacement workshop manual
    Detach the brake caliper retaining spring. Use a crowbar.
  13. Step 15
    How to change Brake Calipers on VW PASSAT Variant (3B5) 1999 - tips and tricks
    Remove the brake caliper.
    Replacement: brake caliper – VW PASSAT Variant (3B5). Professionals recommend:
    Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.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. 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.
  14. Step 16
    Remove the brake pads.
    Step 17
    Step-by-step recommendations for DIY replacement Passat 3b5 2000 1.9 TDI Syncro/4motion Brake Calipers
    Clean the brake caliper surface. Use a wire brush. Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  15. Step 18
    DIY replacement of Brake Calipers on VW PASSAT Variant (3B5) 1.8 2001 is not an issue anymore with our step-by-step tutorial
    Unscrew the brake hose fastening bracket from the brake caliper. Use a drive socket #11. Use a ratchet wrench.
  16. Step 19
    How to change Brake Calipers on Passat 3b5 1997 - free PDF and video manuals
    Unscrew the fastener connecting the brake pipe to the brake caliper. Use a combination spanner #11.
  17. Step 20
    How to replace VW PASSAT Variant (3B5) 1.9 TDI 1998 Brake Calipers - step-by-step manuals and video guides
    Treat the brake pipe. Use a brake cleaner.
    Replacement: brake caliper – VW PASSAT Variant (3B5). Tip:
    After applying the spray, wait a few minutes.
  18. Step 21
    Passat 3b5 1.8 T 1999 Brake Calipers replacement: free workshop manuals
    Screw in the fastener connecting the brake pipe to the brake caliper. Use a combination spanner #11.
  19. Step 22
    Changing Brake Calipers on VW PASSAT Variant (3B5) 1.6 2000 by yourself
    Secure the brake hose fastening bracket. Use a drive socket #11. Use a ratchet wrench.
  20. Step 23
    How to remove VW PASSAT 1.9 TDI Syncro/4motion 2001 Brake Calipers - online easy-to-follow instructions
    Install the brake pads.
    Replacement: brake caliper – VW PASSAT Variant (3B5). Tip from AUTODOC experts:
    If going to use the old brake pads, clean them.
  21. Step 24
    How to replace Brake Calipers on VW PASSAT Variant (3B5) 1997: download PDF manuals and video instructions
    Install the brake caliper and fix it. Use HEX No.H7. Use a torque wrench. Tighten it to 25 Nm torque.
  22. Step 25
    How hard is it to do yourself: Brake Calipers replacement on Passat 3b5 1.9 TDI 4motion 1998 - download illustrated guide
    Install the dust boot caps of the brake caliper guide pins.
  23. Step 26
    Need to know how to renew Brake Calipers on VW PASSAT 1999? This free workshop manual will help you to do it yourself
    Treat the brake hose. Use a brake cleaner.
    AUTODOC recommends:
    Replacement: brake caliper – VW PASSAT Variant (3B5). After applying the spray, wait a few minutes.
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