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Discussion Starter #1
I'm starting this now, as I've officially started to collect everything I need for the Timing belt, coolant pump, belt idler, etc, replacements. This will be a step by step so that anyone wanting to follow along the same path, or when it's done have some insights/tips behind the How to Replace VW Passat Timing Belt on 2.8L 30V" Blauparts Timing Belt Installation Guide. Note that I am NOT a mechanic and NOT the most experienced reference on this site by a long shot! That's why I'm making this thread for myself and others like me to get help along the way and to get it done the right way the first time. This will take a while as I am buying the parts piece by piece.

So to start, I've ordered the Timing Belt cam lock bar tool 3391, crankshaft locking pin tool 3242, and pin tool T400011 (all for $23 from eBay!)
99679

The other tools I'll need (most I have) are:
a 12 Pt 24mm (15/16th SAE) shallow socket, which is at Home Depot for under $5. (main crank)
a 17mm socket for accessory belt idler
a 10 mm socket for locking pin/pulley cover/coolant pump
a 10 mm Allen key wrench
an 8 mm Allen key wrench for hydraulic damper/idler pulley
a 6 mm Alen Key wrench
a 5 mm Alen Key wrench
a pulley pin wrench (special tool 3212) - which I plan on making
a flat 32mm wrench (special tool 3312) - which I plan on making
a 2.6-ton pulley puller
50% concentrated G12 coolant
a hose clamp wrench (I use a modified pair of vice grips)
Torque wrench - 5 to 50 lbs
Torque wrench - 50 - 200 lbs

Parts list:
Item Cost CADSub TotalsItemsVW Part No.
$105.00toothed belt078 109 119 J
$115.00relay roller078 109 244 H
$83.00belt tensioner078 109 243 S
$227.00belt tensioning damper078 109 479 E
$1.20bolt for damper: bolt, hex. hd. (combi.)N 102 056 04
$123.00Tensioning lever078 109 487 C
Timing belt total$654.20water pump parts
$1.70O-Ring 60X3,50N 901 368 02
$0.20bolt for thermostat cover: bolt, hex. hd. (combi.)N 908 244 04
$42.51Thermostat078 121 113 G
$49.51Coolant pump with seal078 121 006 X
$1.20bolt for pump: bolt, hex. hd. (combi.)N 090 261 9
Water pump total$95.12
Subtotal$749.32
Tax. 15%$112.40
Total$861.72

I will take any advice on tools or parts! Once I get everything, I'll update this thread. It may be a month! I hope it helps someone.

Stay tuned.
 
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Nice spreadsheet, really shows organization. The parts cost is high, I expect due to dealer parts department pricing. Looking at autohausaz for example, those parts (minus the O-rings and cap screws), total about $275 for the Hepu set, or $220 for the Continental set. with a Mahle thermostat ($13) included.
 

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Discussion Starter #3
Yes, note that none of the items are in kits (where even from VW are listed with a combined discount), and that all of these prices are in Canadian
 

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Sounds like Canadian based internet parts store is in order.
 
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Discussion Starter #5
There is a local parts store, called Car Quest and Napa Auto. If they carry the part refurbished, it’s a great deal. I’ve saved many hundreds on just the starter, alternator, and brakes. But for the online Canadian parts web sites, Rock Auto in the states is often cheaper. For some reason Canadian companies think they can gouge the customers.
 

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just come down to the States and buy it, then when returning thru customs just tell them it is hockey equipment,works every time......
 

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Discussion Starter #8
AND by the way ,did you every get your brakes sorted out?
I am STILL WAITING for the delivery of the ODBII / VAG-COM cable.... it was ordered on May 14... frig I’m pissed at that, but I’ve been busy fixing various other bits. Tracking does show movement, but I’ve never had to wait so long.
 

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Discussion Starter #9
just come down to the States and buy it, then when returning thru customs just tell them it is hockey equipment,works every time......
If the pandemic wasn’t around, this would be a great option. I’ve always done this. I needed a MAS sensor, and at any Canadian store / dealer it was 320 minimum. I jumped across the border at lunchtime to autozone and got it for $80. That was cheap, even considering US exchange and gas cost - oh and I filled up the tank for half the cost as in Canada too. Everyone thinks they can price gouge Canadians; not this one.
 
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Discussion Starter #10 (Edited)
So far, I've read many posts and viewed many videos on the V6 timing belt, and accumulated the following (see the paid column):

PaidItem Cost CADSub TotalsItemsVW Part No.
92$105.00toothed belt, but the one I got was the Gates blue High-Performance belt... because... it had 'high performance' in the name... Well, I hope it's actually blue because it says it might end up black anyway... (😥 I want blue)078109119J
54$115.00relay roller078 109 244 H
44$83.00belt tensioner078 109 243 S
29$227.00belt tensioning damper078 109 479 E
$1.20bolt for damper: bolt, hex. hd. (combi.)N 102 056 04
68$123.00Tensioning lever078 109 487 C
$285Timing belt total$654.20water pump parts
$1.70O-RingN 901 368 02
$0.20bolt for thermostat cover: bolt, hex. hd. (combi.)N 908 244 04
43$68 (price increase)Thermostat & o-ring 60X3,50078 121 113 G
50$49.51Coolant pump with seal078 121 006 X
$1.20bolt for pump: bolt, hex. hd. (combi.)N 090 261 9
$93Water pump total$120
Subtotal$749.32
Tax. 15%$112.40
380Total$861.72
 

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are YOU absolutely sure you do not work for Ernst and Young ? seriously (and there will be mixed conjecture on the prices) this is totally outstanding . Regardless of monies this provides a checklist of purchased parts needed and previous post of tools. O.K. go get a 1.8 and rebuild for us. Never fails I scribble down something and always end up omitting something,kudos.
 

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toothed belt, but the one I got was the Gates blue High-Performance belt... because... it had 'high performance' in the name... Well, I hope it's actually blue because it says it might end up black anyway... (😥 I want blue)

It's blue.
… and just because it is blue, it'll add another 50hp.
 
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Serpentine belt?

While changing out the timing belt, that would be a good time to swap out that cheesy plastic thermostat housing.
Changed all of my V6's over to this aluminum housing. Around $100 (US) if I recall correctly.

100854
 

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Discussion Starter #14
Serpentine belt?

While changing out the timing belt, that would be a good time to swap out that cheesy plastic thermostat housing.
Changed all of my V6's over to this aluminum housing. Around $100 (US) if I recall correctly.

View attachment 100854
Do you know where I can source such a version?
 

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Do you know where I can source such a version?
Here you go.

Thermostat Housing

Don't worry about that note that says it only fits up to some model VIN# - split in 2001.
I've installed that aluminum housing on both AHA and ATQ version V6's with no issues.
Matter of fact I've done it to all my V6's which include:
1998 AHA
2001 ATQ
2003 ATQ
2004 ATQ

FCP Euro used to sell them, but obviously not anymore as I can't find it on their website.
 

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Discussion Starter #16
Great! I found another but it was almost $50 more. Thanks!
 

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They often list them on AudiZine classifieds for about $75.

It's blue.
… and just because it is blue, it'll add another 50hp.
I found the Race belt tended to make a slight squeaking noise at idle, not loud, but enough to notice. My son did not seem to care, but I replaced it last year due to mileage.
 

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Discussion Starter #18
They often list them on AudiZine classifieds for about $75.


I found the Race belt tended to make a slight squeaking noise at idle, not loud, but enough to notice. My son did not seem to care, but I replaced it last year due to mileage.
Well, I’m going for the 50 hp boost, so it’s ALL MORE AWESOMER... it did come and it was...
100858
blue!!
 

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They often list them on AudiZine classifieds for about $75.


I found the Race belt tended to make a slight squeaking noise at idle, not loud, but enough to notice. My son did not seem to care, but I replaced it last year due to mileage.
Same here!
Mine was actually so loud I tore off the whole front end just to replace it with a Genuine VW/Audi belt.
Matter of fact I posted about this very topic back in 2015.
 

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Discussion Starter #20
Would it be better to use a three or two jaw gear puller for the timing pulleys? Wouldn't three distribute the pressure better?

Two seems like it would stress the pulley?
100863
 
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