Girling g60 big brake conversion for the mk3 jetta/passat TDI
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Difficulty: 3/5

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 not a substitute for a certified professional mechanic.  See the TOS Agreement for the full legal disclaimer.

Introduction

This is the largest "plug and play" brake upgrade for the mk3 a3/b4 jetta/passat.  I ranked it 3/5 instead of 2/5 because you must change a few more components than the smaller brake upgrades.  Please read 1000 answered questions: brake FAQ and busting big brake kit myths before you upgrade the brake system.

You should also change the brake master cylinder to compensate for the larger brake caliper's fluid volume.  The reason why it's recommended to replace the brake master cylinder is because the larger brake caliper will result in longer brake pedal travel.  If you experience a brake problem, it can also result in a no-brakes situation.  This is because if one circuit fails in a tandem brake cylinder, brake pedal travel increases before pressure builds up in the good circuit.  Replacing the brake master cylinder with the Audi coupe quattro non-abs brake master cylinder, it keeps brake pedal travel the same.  Also, if you have an old master cylinder, the seals are worn into a certain pattern.  Significantly longer pedal travel will send the seals farther into the piston and can wear it out faster and in some cases, cause a leak.

This brake upgrade uses a larger rotor than stock and a 2 piston caliper for even greater stopping power than the rotor upgrade only discussed in 1000q: corrado G60 brake conversion.  It does bias the brakes more towards the front than with the original brakes.  It might be possible to change the brake bias using the brake proportioning valve but I would leave it alone because most of the valves have rusted and no longer work and because it's best to have a specialist to dial in the correct amount of brake bias.  Too much rear brake is normally worse than too much front brake since this can result in a loss of directional control under braking.  

Comparison between the stock jetta and passat TDI front brakes and the girling g60 brakes.

Picture of the caliper and carrier separated

Parts and tools

Girling g60 brake calipers
Girling g60 brake carriers
Corrado G60 11" (280mm) brake rotors - 4 lug only!
25mm brake master cylinder from a 1990 Audi coupe quattro non-abs
brake pads
brake fluid - DOT 4
custom brake lines

13mm deep socket for the brake master cylinder
11mm flare nut wrench for the hydraulic lines - avoid using an open end socket because they can strip the nuts

NOTE: Minimum 15" alloy wheel for brake clearance, cannot use 15" VW steel wheels
All these parts are required for the girling g60 brake upgrade

Sources for girling g60 brake parts:  The girling g60 can be found from 1989-1991 Audi 200 turbo quattro, 92-94 Audi s4 turbo quattro, 1990-1994 Audi V8, 1992-1994 Audi 100 V6, 1987-1988 Audi 5000 quattro turbo, 1984-1988 Audi 5000 turbo, and 1993-1995 Audi 90 V6.  Piston bore is 60mm. 

Procedure

Remove the brake caliper, carrier, and rotor and replace using the new parts. If you need more details, refer to 1000q: a3/b4 front brakes.

You also should replace the brake master cylinder to keep pedal travel the same.  The stock master cylinder has a diameter of 22mm. The new one should have a diameter of 25mm. This extra capacity is a better fit to push the larger, 2 piston caliper.  Remove the brake fluid reservoir, remove the old master cylinder, and bolt in the new one.  Clean the old reservoir and reinstall.  Afterwards, you must bleed the brakes and clutch to get out any air. 

Note that the new master cylinder may be missing the clip for the reservoir.  Just use some zip ties to hold it on.

The master cylinder is made by ATE, 331511021a, brake master cylinder for 200 turbo/200 turbo quattro.

Picture of left and right calipers and carriers

Picture of installed girling g60 brakes