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 rear 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) 1.9 TDI, VW PASSAT Variant (3B5) 2.5 TDI, VW PASSAT Variant (3B5) 1.9 TDI, VW PASSAT Variant (3B5) 2.0, 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
WD-40 spray
Brake cleaner
Copper grease
Torque wrench
Combination spanner #10
Combination spanner #13
Combination spanner #15
Drive socket # 10
Drive socket # 13
Wheel impact socket #17
Ratchet wrench
Brake hose clip
Water pump pliers
Round-nose pliers
Brake bleeder kit
Crow bar
Wheel chock
Buy tools
Replacement: brake caliper – VW PASSAT Variant (3B5). AUTODOC experts recommend:
  • 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
    Secure the wheels with chocks.
    Step 3
    How to change Brake Calipers on Passat 3b5 1997 - free PDF and video manuals
    Loosen the wheel mounting bolts. Use wheel impact socket #17.
  2. Step 4
    Raise the rear of the car and secure on supports.
    Step 5
    How to replace VW PASSAT Variant (3B5) 1.9 TDI 1998 Brake Calipers - step-by-step manuals and video guides
    Unscrew the wheel bolts.
    AUTODOC recommends:
    Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. VW PASSAT Variant (3B5)
  3. Step 6
    Passat 3b5 1.8 T 1999 Brake Calipers replacement: free workshop manuals
    Remove the wheel.
  4. Step 7
    Changing Brake Calipers on VW PASSAT Variant (3B5) 1.6 2000 by yourself
    Clean the fastener of the parking brake cable. 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.
  5. Step 8
    How to remove VW PASSAT 1.9 TDI Syncro/4motion 2001 Brake Calipers - online easy-to-follow instructions
    Release the parking brake cable. Use water pump pliers. Use round-nose pliers.
  6. Step 9
    How to replace Brake Calipers on VW PASSAT Variant (3B5) 1997: 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 wire brush. Use a brake cleaner.
    Replacement: brake caliper – VW PASSAT Variant (3B5). Tip:
    After applying the spray, wait a few minutes.
  7. Step 10
    How hard is it to do yourself: Brake Calipers replacement on Passat 3b5 1.9 TDI 4motion 1998 - download illustrated guide
    Clamp the brake hose off using a brake hose clamp.
  8. Step 11
    Need to know how to renew Brake Calipers on VW PASSAT 1999? This free workshop manual will help you to do it yourself
    Loosen the brake hose fastening. Use a combination spanner #13.
  9. Step 12
    Changing of Brake Calipers on Passat 3b5 2000 won't be an issue if you follow this illustrated step-by-step guide
    Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.
  10. Step 13
    VW PASSAT 1.9 TDI Brake Calipers replacement: online guides and video tutorials
    Unscrew the brake caliper fastening. Use a combination spanner #13. Use a combination spanner #15. Use a drive socket #13. Use a ratchet wrench.
  11. Step 14
    Replacing Brake Calipers on Passat 3b5 1997 1.9 TDI by yourself
    Remove the brake caliper.
    Replacement: brake caliper – VW PASSAT Variant (3B5). Tip from AUTODOC:
    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.If no new guide pins were supplied in a kit with the new brake calipers, use the old pins. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
  12. Step 15
    PASSAT Variant (3B5) 1.9 TDI Syncro/4motion 1998 Brake Calipers DIY replacement workshop manual
    Remove the brake pads. Use a crowbar.
  13. Step 16
    How to change Brake Calipers on VW PASSAT Variant (3B5) 1999 - tips and tricks
    Install the brake pads.
  14. Step 17
    Step-by-step recommendations for DIY replacement Passat 3b5 2000 1.9 TDI Syncro/4motion Brake Calipers
    Install the brake caliper and fix it. Use a combination spanner #13. Use a combination spanner #15. Use a torque wrench. Tighten it to 35 Nm torque.
  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
    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.
  16. Step 19
    How to change Brake Calipers on Passat 3b5 1997 - free PDF and video manuals
    Install and fix the brake hose into a new caliper. Use a combination spanner #13.
  17. Step 20
    How to replace VW PASSAT Variant (3B5) 1.9 TDI 1998 Brake Calipers - step-by-step manuals and video guides
    Tighten the fastener connecting the brake pipe to the brake caliper. Use a drive socket #13. Use a torque wrench. Tighten it to 40 Nm torque.
  18. Step 21
    Passat 3b5 1.8 T 1999 Brake Calipers replacement: free workshop manuals
    Treat the brake hose. Use a brake cleaner.
    Replacement: brake caliper – VW PASSAT Variant (3B5). Professionals recommend:
    After applying the spray, wait a few minutes.
  19. Step 22
    Changing Brake Calipers on VW PASSAT Variant (3B5) 1.6 2000 by yourself
    Remove the brake hose clamp.
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