Corrado G60 /passat VR6 g54 big brake kit for mk3 cars
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Difficulty 2/5

Disclaimer: Before you attempt a big brake conversion or any brake work on your car, refer to the factory service manual and follow all precautions.  Any and all information presented on this website is superseded by the official service manual and is not a substitute for the services or advice of a certified professional mechanic.

Introduction

This swap is the easiest "plug and play" brake upgrade.  By using a larger rotor and a larger carrier, it moves the brake caliper outward, increasing leverage of the brake caliper.  Please read 1000 answered questions: brake FAQ and busting big brake kit myths to see why you might not want a BB kit. Note: the corrado/vr6 brake calipers are 2mm wider than the TDI g54 brake calipers to accommodate the wider corrado rotor.  The corrado brake pads may not fit with your passat/jetta calipers, or they must be sanded down a little bit to fit.  Since your car probably has high miles by now, it might make more sense to replace the calipers anyways at this point.  Although both the corrado/early VR6 and jetta/passat TDI all use calipers named "g54", they have different part numbers due to rotor width!  You also probably need 15" wheels to clear the brakes.

Parts

Corrado g54 brake calipers VW# 109091 (rebuilt) (can be found in the 1990-91 corrado G60 1.8L engine or 92-94 corrado slc vr6 aaa, 90-91 passat 16v, 92-95 passat vr6 SLC V6 AAA engine)
Corrado G60 g54 brake carriers (can also be found on the above cars)
Corrado G60 11" (280mm x 22mm) brake rotors VW #535-615-301 Note: 4 lug only, the corrado or passat vr6 rotors have a different offset and you cannot use the vr6 rotors!
Corrado G60 brake pads
Brake fluid - DOT 4

Procedure

Simply remove the brake rotor, caliper, and carrier and replace with the new units, that's it!  For more detailed information on how to remove the brake components, refer to: 1000q: a3/b4 front brakes

I do not suggest ever buying used brake components because any failure could result in a serious crash and injury.  Napa and Autozone carry rebuilt calipers in the price range of 32.00 each and a 15.00 core charge.  If you were to buy used calipers, you should at least have them rebuilt, but by the time you pay 50.00 for a set of used calipers, pay the shipping and then buy the rebuild kits at 15.00 per side you are at 90.00 total.   It may be easier to just pay about 95.00 or so and have them already rebuilt from Napa or Autozone.

Pictured below is an 11" rotor with corrado g54 calipers