Important!
This replacement procedure can be used for:
VW PASSAT (3B3) 1.8 T 20V, VW PASSAT Variant (3B6) 1.8 T 20V

The steps may slightly vary depending on the car design.

How to replace a front brake caliper on VW PASSAT B5+ TUTORIAL | AUTODOC

Required tools:
Required tools:
Wire brush
Brake cleaner
Copper grease
Flare nut spanner #11
Drive socket # 10
HEX bit no.H7.
Wheel impact socket #17
Ratchet wrench
Torque wrench
Flat Screwdriver
Wheel chock
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.
Carry out replacement in the following order:
  1. How to change Brake Calipers on Passat 3B6 2000 - free PDF and video manuals
    Step 1
    Open the bonnet.Unscrew the brake fluid reservoir cap.
  2. How to replace VW PASSAT Variant (3B6) 1.9 TDI 2001 Brake Calipers - step-by-step manuals and video guides
    Step 2
    Secure the wheels with chocks.
  3. Passat 3B6 1.8 T 20V 2002 Brake Calipers replacement: free workshop manuals
    Step 3
    Loosen the wheel mounting bolts.Use wheel impact socket #17.
    Step 4
    Raise the front of the car and secure on supports.
  4. Changing Brake Calipers on VW PASSAT Variant (3B6) 2.0 2003 by yourself
    Step 5
    Unscrew the wheel bolts.
    AUTODOC recommends:
    To avoid injury, hold up the wheel when unscrewing the bolts.
  5. How to remove VW PASSAT 1.6 2004 Brake Calipers - online easy-to-follow instructions
    Step 6
    Remove the wheel.
  6. How to replace Brake Calipers on VW PASSAT Variant (3B6) 2005: download PDF manuals and video instructions
    Step 7
    Detach the brake caliper retaining spring.Use a flat screwdriver.
  7. How hard is it to do yourself: Brake Calipers replacement on Passat 3B6 2.0 TDI 2000 - download illustrated guide
    Step 8
    Remove the dust boot caps of the brake caliper guide pins. Use a flat screwdriver.
  8. Need to know how to renew Brake Calipers on VW PASSAT ? This free workshop manual will help you to do it yourself
    Step 9
    Disconnect the ABS sensor electric socket.Use a flat screwdriver.
  9. Changing of Brake Calipers on Passat 3B6 2002 won't be an issue if you follow this illustrated step-by-step guide
    Step 10
    Disconnect the brake pad wear sensor plug.Use a flat screwdriver.
    Please note!
    Some cars are not equipped with the brake pad wear sensor.
  10. VW PASSAT 1.9 TDI Brake Calipers replacement: online guides and video tutorials
    Step 11
    Unscrew the brake hose fastening bracket from the brake caliperUse a drive socket #10.Use a ratchet wrench.
  11. Replacing Brake Calipers on Passat 3B6 2004 1.9 TDI by yourself
    Step 12
    Unscrew the fastener connecting the brake pipe to the brake caliper. Use a flare nut spanner #11.
    AUTODOC recommends:
    Immediately plug the brake line open end to prevent fluid leakage and ingress of dirt into the hydraulic system.
  12. PASSAT Variant (3B6) 1.6 2005 Brake Calipers DIY replacement workshop manual
    Step 13
    Spread the brake pads.Use a flat screwdriver.
    Step 14
    Unscrew the brake caliper fastening.Use HEX No.H7.Use a ratchet wrench.
  13. How to change Brake Calipers on VW PASSAT Variant (3B6) 2000 - tips and tricks
    Step 15
    Remove the brake caliper.
    AUTODOC recommends:
    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-by-step recommendations for DIY replacement Passat 3B6 2001 1.6 Brake Calipers
    Step 16
    Remove the brake pads.
  15. DIY replacement of Brake Calipers on VW PASSAT Variant (3B6) 1.9 TDI 4motion 2002 is not an issue anymore with our step-by-step tutorial
    Step 17
    Remove the guide pins from the brake caliper.
  16. How to change Brake Calipers on Passat 3B6 2000 - free PDF and video manuals
    Step 18
    Screw in the guide pins.
    AUTODOC recommends:
    If no new guide pins were supplied in a kit with the new brake calipers, use the old pins.
  17. How to replace VW PASSAT Variant (3B6) 1.9 TDI 2001 Brake Calipers - step-by-step manuals and video guides
    Step 19
    Install the brake pads.
    AUTODOC recommends:
    If going to use the old brake pads, clean them.Use a wire brush.
  18. Passat 3B6 1.8 T 20V 2002 Brake Calipers replacement: free workshop manuals
    Step 20
    Install the brake caliper and fix it.Use HEX No.H7.Use a torque wrench.Tighten it to 35 Nm torque.
  19. Changing Brake Calipers on VW PASSAT Variant (3B6) 2.0 2003 by yourself
    Step 21
    Install the dust boot caps of the brake caliper guide pins.
  20. How to remove VW PASSAT 1.6 2004 Brake Calipers - online easy-to-follow instructions
    Step 22
    Treat the brake pipe. Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  21. How to replace Brake Calipers on VW PASSAT Variant (3B6) 2005: download PDF manuals and video instructions
    Step 23
    Screw in the fastener connecting the brake pipe to the brake caliper.Use a flare nut spanner #11.
  22. How hard is it to do yourself: Brake Calipers replacement on Passat 3B6 2.0 TDI 2000 - download illustrated guide
    Step 24
    Secure the brake hose fastening bracketUse a drive socket #10.Use a ratchet wrench.
  23. Need to know how to renew Brake Calipers on VW PASSAT ? This free workshop manual will help you to do it yourself
    Step 25
    Connect the ABS sensor electric socket.
  24. Changing of Brake Calipers on Passat 3B6 2002 won't be an issue if you follow this illustrated step-by-step guide
    Step 26
    Connect the brake pad wear sensor plug.
  25. VW PASSAT 1.9 TDI Brake Calipers replacement: online guides and video tutorials
    Step 27
    Undo the brake bleeder screw.Use a flare nut spanner #11.
  26. Replacing Brake Calipers on Passat 3B6 2004 1.9 TDI by yourself
    Step 28
    Bleed the brake caliper system.Without starting the engine, press the brake pedal several times until you feel significant resistance.
  27. PASSAT Variant (3B6) 1.6 2005 Brake Calipers DIY replacement workshop manual
    Step 29
    Tighten the brake bleeder screw.Use a flare nut spanner #11.
    Step 30
    Tighten the brake caliper bleed screw. Use a flare nut spanner #11.Use a torque wrench.Tighten it to 25 Nm torque.
  28. How to change Brake Calipers on VW PASSAT Variant (3B6) 2000 - tips and tricks
    Step 31
    Install the brake caliper retaining spring. Use a flat screwdriver.
  29. Step-by-step recommendations for DIY replacement Passat 3B6 2001 1.6 Brake Calipers
    Step 32
    Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
  30. DIY replacement of Brake Calipers on VW PASSAT Variant (3B6) 1.9 TDI 4motion 2002 is not an issue anymore with our step-by-step tutorial
    Step 33
    Clean the brake disk surface.Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  31. How to change Brake Calipers on Passat 3B6 2000 - free PDF and video manuals
    Step 34
    Install the wheel.
    AUTODOC recommends:
    To avoid injury, hold up the wheel when screwing in the fastening bolts.
  32. How to replace VW PASSAT Variant (3B6) 1.9 TDI 2001 Brake Calipers - step-by-step manuals and video guides
    Step 35
    Screw in the wheel bolts.Use wheel impact socket #17.
  33. Passat 3B6 1.8 T 20V 2002 Brake Calipers replacement: free workshop manuals
    Step 36
    Lower the car and working in a cross order, tighten the wheel bolts.Use a torque wrench.Tighten it to 120 Nm torque.
  34. Changing Brake Calipers on VW PASSAT Variant (3B6) 2.0 2003 by yourself
    Step 37
    Remove the jacks and chocks.
    AUTODOC recommends:
    Check the brake fluid level in the expansion tank and refill if necessary.
  35. How to remove VW PASSAT 1.6 2004 Brake Calipers - online easy-to-follow instructions
    Step 38
    Tighten the brake fluid reservoir cap. Close the hood.
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