Important!
This replacement procedure can be used for:
VW PASSAT (3B2) 1.9 TDI, VW PASSAT Variant (3B5) 1.9 TDI

The steps may slightly vary depending on the car design.
Required tools:
Required tools:
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
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 3b5 1996 - free PDF and video manuals
    Step 1
    Open the bonnet.Unscrew the brake fluid reservoir cap.
  2. How to replace VW PASSAT Variant (3B5) 1.9 TDI 1997 Brake Calipers - step-by-step manuals and video guides
    Step 2
    Secure the wheels with chocks.
  3. Passat 3b5 1.8 T 1998 Brake Calipers replacement: free workshop manuals
    Step 3
    Loosen the wheel mounting bolts.Use wheel impact socket #17.
  4. Changing Brake Calipers on VW PASSAT Variant (3B5) 1.6 1999 by yourself
    Step 4
    Raise the front of the car and secure on supports.
  5. How to remove VW PASSAT 1.9 TDI Syncro/4motion 2000 Brake Calipers - online easy-to-follow instructions
    Step 5
    Unscrew the wheel bolts.
    AUTODOC recommends:
    To avoid injury, hold up the wheel when unscrewing the bolts.
  6. How to replace Brake Calipers on VW PASSAT Variant (3B5) 2001: download PDF manuals and video instructions
    Step 6
    Remove the wheel.
  7. How hard is it to do yourself: Brake Calipers replacement on Passat 3b5 1.9 TDI 4motion 1996 - download illustrated guide
    Step 7
    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.
  8. Need to know how to renew Brake Calipers on VW PASSAT ? This free workshop manual will help you to do it yourself
    Step 8
    Clamp the brake hose off using a brake hose clamp.
  9. Changing of Brake Calipers on Passat 3b5 1998 won't be an issue if you follow this illustrated step-by-step guide
    Step 9
    Put a container for gathering brake fluid beneath.
  10. VW PASSAT 1.9 TDI Brake Calipers replacement: online guides and video tutorials
    Step 10
    Clean the brake pipe fastener.Use a wire brush.Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  11. Replacing Brake Calipers on Passat 3b5 2000 1.9 TDI by yourself
    Step 11
    Unscrew the fastener connecting the brake pipe to the brake hose. Use a combination spanner #11.
  12. PASSAT Variant (3B5) 1.9 TDI Syncro/4motion 2001 Brake Calipers DIY replacement workshop manual
    Step 12
    Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
  13. How to change Brake Calipers on VW PASSAT Variant (3B5) 1996 - tips and tricks
    Step 13
    Unscrew the brake caliper fastening.Use HEX No.H7.Use a ratchet wrench.
  14. Step-by-step recommendations for DIY replacement Passat 3b5 1997 1.9 TDI Syncro/4motion Brake Calipers
    Step 14
    Detach the brake caliper retaining spring.Use a crowbar.
  15. DIY replacement of Brake Calipers on VW PASSAT Variant (3B5) 1.8 1998 is not an issue anymore with our step-by-step tutorial
    Step 15
    Remove the brake caliper.
    AUTODOC recommends:
    Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.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.
  16. How to change Brake Calipers on Passat 3b5 1996 - free PDF and video manuals
    Step 16
    Remove the brake pads.
    Step 17
    Clean the brake caliper surface.Use a wire brush.Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  17. How to replace VW PASSAT Variant (3B5) 1.9 TDI 1997 Brake Calipers - step-by-step manuals and video guides
    Step 18
    Unscrew the brake hose fastening bracket from the brake caliper.Use a drive socket #11.Use a ratchet wrench.
  18. Passat 3b5 1.8 T 1998 Brake Calipers replacement: free workshop manuals
    Step 19
    Unscrew the fastener connecting the brake pipe to the brake caliper. Use a combination spanner #11.
  19. Changing Brake Calipers on VW PASSAT Variant (3B5) 1.6 1999 by yourself
    Step 20
    Treat the brake pipe. Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  20. How to remove VW PASSAT 1.9 TDI Syncro/4motion 2000 Brake Calipers - online easy-to-follow instructions
    Step 21
    Screw in the fastener connecting the brake pipe to the brake caliper.Use a combination spanner #11.
  21. How to replace Brake Calipers on VW PASSAT Variant (3B5) 2001: download PDF manuals and video instructions
    Step 22
    Secure the brake hose fastening bracket.Use a drive socket #11.Use a ratchet wrench.
  22. How hard is it to do yourself: Brake Calipers replacement on Passat 3b5 1.9 TDI 4motion 1996 - download illustrated guide
    Step 23
    Install the brake pads.
    AUTODOC recommends:
    If going to use the old brake pads, clean them.
  23. Need to know how to renew Brake Calipers on VW PASSAT ? This free workshop manual will help you to do it yourself
    Step 24
    Install the brake caliper and fix it.Use HEX No.H7.Use a torque wrench.Tighten it to 35 Nm torque.
  24. Changing of Brake Calipers on Passat 3b5 1998 won't be an issue if you follow this illustrated step-by-step guide
    Step 25
    Install the dust boot caps of the brake caliper guide pins.
  25. VW PASSAT 1.9 TDI Brake Calipers replacement: online guides and video tutorials
    Step 26
    Treat the brake hose.Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  26. Replacing Brake Calipers on Passat 3b5 2000 1.9 TDI by yourself
    Step 27
    Screw in the fastener connecting the brake pipe to the brake hose. Use a combination spanner #11.
  27. PASSAT Variant (3B5) 1.9 TDI Syncro/4motion 2001 Brake Calipers DIY replacement workshop manual
    Step 28
    Remove the brake hose clamp.
  28. How to change Brake Calipers on VW PASSAT Variant (3B5) 1996 - tips and tricks
    Step 29
    Connect the ABS sensor electric socket.Connect the brake pad wear sensor plug.
  29. Step-by-step recommendations for DIY replacement Passat 3b5 1997 1.9 TDI Syncro/4motion Brake Calipers
    Step 30
    Install the brake caliper retaining spring.
  30. DIY replacement of Brake Calipers on VW PASSAT Variant (3B5) 1.8 1998 is not an issue anymore with our step-by-step tutorial
    Step 31
    Secure the brake bleeder kit.
  31. How to change Brake Calipers on Passat 3b5 1996 - free PDF and video manuals
    Step 32
    Undo the brake bleeder screw.Use a combination spanner #10.
  32. How to replace VW PASSAT Variant (3B5) 1.9 TDI 1997 Brake Calipers - step-by-step manuals and video guides
    Step 33
    Connect the brake bleeder kit to the brake bleeder screw.
  33. Passat 3b5 1.8 T 1998 Brake Calipers replacement: free workshop manuals
    Step 34
    Bleed the brake caliper system.Without starting the engine, press the brake pedal several times until you feel significant resistance.
  34. Changing Brake Calipers on VW PASSAT Variant (3B5) 1.6 1999 by yourself
    Step 35
    Tighten the brake bleeder screw.Use a combination spanner #10.
  35. How to remove VW PASSAT 1.9 TDI Syncro/4motion 2000 Brake Calipers - online easy-to-follow instructions
    Step 36
    Disconnect the brake bleeder kit.
  36. How to replace Brake Calipers on VW PASSAT Variant (3B5) 2001: download PDF manuals and video instructions
    Step 37
    Tighten the brake caliper bleed screw. Use a drive socket #10.Use a torque wrench.Tighten it to 25 Nm torque.
  37. How hard is it to do yourself: Brake Calipers replacement on Passat 3b5 1.9 TDI 4motion 1996 - download illustrated guide
    Step 38
    Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
  38. Need to know how to renew Brake Calipers on VW PASSAT ? This free workshop manual will help you to do it yourself
    Step 39
    Clean the brake disk surface.Use a brake cleaner.
    AUTODOC recommends:
    After applying the spray, wait a few minutes.
  39. Changing of Brake Calipers on Passat 3b5 1998 won't be an issue if you follow this illustrated step-by-step guide
    Step 40
    Install the wheel.
    AUTODOC recommends:
    To avoid injury, hold up the wheel when screwing in the fastening bolts.
  40. VW PASSAT 1.9 TDI Brake Calipers replacement: online guides and video tutorials
    Step 41
    Screw in the wheel bolts.Use wheel impact socket #17.
  41. Replacing Brake Calipers on Passat 3b5 2000 1.9 TDI by yourself
    Step 42
    Lower the car and working in a cross order, tighten the wheel bolts.Use a torque wrench.Tighten it to 120 Nm torque.
  42. PASSAT Variant (3B5) 1.9 TDI Syncro/4motion 2001 Brake Calipers DIY replacement workshop manual
    Step 43
    Remove the jacks and chocks.
    AUTODOC recommends:
    Check the brake fluid level in the expansion tank and refill if necessary.
  43. How to change Brake Calipers on VW PASSAT Variant (3B5) 1996 - tips and tricks
    Step 44
    Tighten the brake fluid reservoir cap. Close the hood.
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