How To Change VW Passat 2.8 V6 Timing Belt Service

How To Perform VW Passat Timing Belt Replacement

Wondering how to replace the timing belt on a VW Passat with a 2.8L 30 valve engine? Blauparts is here to help! Below are step-by-step VW Passat timing belt installation instructions and tips. Our hands-on experience has helped us create instructions that are specific to your VW Passat engine. For instructions on how to perform the VW Passat front bumper removal and timing belt service position see our related how-to instructions.

DISCLAIMER: VW Passat timing belt installation is a complex repair procedure and should be performed by experienced automotive technicians, trained in performing proper timing belt installation. 

Blauparts recommends that an Audi VW Factory Trained ASE Certified Technician perform timing belt repair. One who has been trained in specific timing belt procedures for your exact vehicle engine. This is for your safety and to prevent improper installation by untrained and unqualified installers and technicians, leading to possible engine damage. 

Always read the factory service manual safety instructions and guidelines. Always wear safety glasses and other safety items when performing the following repair.

Please Note: Our timing belt tool rental kits are no longer available for rent. All tool rental kits are available for sale in good used condition in our online catalog.

How To Step 1

With the bumper cover removed and the front of the vehicle in the timing belt service position, proceed to remove all decorative engine covers. 

Please Note: (See Related Posts Below) Passat front bumper cover and timing belt service position.

How To Step 2 

READ IMPORTANT SERVICE BULLETIN regarding draining the coolant system (See Related Posts Below).

Drain the remaining coolant from the engine block by removing the drain plug. On a 2.8L VW Passat engine, the drain plug is located at the bottom of the block, just behind the driver side of the sub-frame. The 6mm Allen head fastener will be in a machined recessed area on the engine side of the bell housing. Reinstall this fastener when the cooling system has been thoroughly drained. It's important to note that some choose to just remove the thermostat and water pump and not completely drain the engine block 100%. Pulling out the water pump and thermostat to drain the coolant isn't enough. It's important to completely drain the block by paying close attention to this step.

How To Step 3

Compress the two pressure clips on the secondary air pump pipe. Pull outward and place off to the side.

How To Step 4

Use a 17mm socket wrench to remove the accessory belt by rotating the belt tensioner clockwise.

How To Step 5

Use a 10mm Allen wrench to remove the spring-loaded accessory belt tensioning device.

How To Step 6

Using a 6mm Allen wrench and tool 3212, remove the power steering pump pulley. Please Note: When using tool 3212, spread the arms of the tool apart as far as possible, so as not to bend or break the tool.

How To Step 7

Remove the viscous fan assembly by using special tools 3312 and 3212. Contrary to the typical lefty-loosey theory, this is a reverse thread since the engine spins in a clockwise position. The unit has a left-hand thread, so you must remove it by turning the fastener in a clockwise direction. These may be very tight and require some patience. 

Please Note: When using tool 3212, spread the arms of the tool apart as far as possible, so as not to bend or break tool.

How To Step 8

Remove all 3 timing belt covers. VW Passat timing belt covers are held in place by several clips on the top and bottom of each cover.

How To Step 9

Remove the viscous fan pulley bracket. To remove the fan pulley bracket locate two 6mm Allen head fasteners hidden on the lowest portion of the fan pulley bracket. There will be two additional fasteners that are located and accessed through the pulley. One is a 5mm Allen head fastener located at about 11 o'clock through one of the small holes. The other is a 6mm Allen head fastener located at about 6 o'clock through one of the oval shaped holes. 

Please Note: These fasteners are hard to find and difficult to see and may sometimes seem lost. The viscous span pulley bracket has 2 hidden Allen head fasteners within the pulley. The 5 mm fastener is located at approximately 11 o'clock and the 6mm fastener is located at approximately 6 o'clock.

How To Step 10

Rotate the engine by the crankshaft with a 12 point 24mm socket wrench in a clockwise direction to align all timing marks. To accomplish this you will be lining up two engine timing marks. One will be your crankshaft timing mark and the other will be the camshaft timing mark. To align the crankshaft timing mark there will be a machined line in the crankshaft vibration damper that will coincide with an arrow mark on the lower most timing belt cover. Simultaneously, the two largest holes on each diamond shaped camshaft washer should be pointed directly inward. 

Please Note: Be sure to take your time. Make sure to properly align the timing marks and insert the pin (see next step) before you take anything else apart. You do not want the crankshaft to move.

How To Step 11

The crankshaft locking plug can be a plastic cap or a metal threaded Allen plug. Using a 6mm Allen wrench, remove the crankshaft locking plug cap. This plug is located under the driver side engine motor mount bracket. To access this plug, you will need to bend the motor mount harness bracket off to the side. 

When you remove the plug, be careful to not lose it's companion o-ring seal. If you are assured that the engine timing marks are aligned, thread crankshaft locking pin tool 3242 in place and lightly tighten with a 10mm wrench. With a 12 point 24mm socket wrench, double check that the crankshaft will not move by lightly trying to turn the crankshaft. 

Please Note: Be sure to complete this step and install crankshaft locking pin tool 3242 before you take anything more apart. This tool helps to achieve 100% proper engine timing. You do not want the crankshaft to move. Although inserting this tool at this point may seem like more work, it's really less work in the long run.

How To Step 12

Use a 6mm Allen wrench to remove the vibration damper/serpentine belt pulley from the end of the crankshaft. 

Please Note: Take your time. You can easily strip or round out the pulley Allen fasteners, making it difficult to get off. Before vibration damper removal, clean out the 6mm Allen heads with a pick. Lightly tapping in the 6mm Allen bit may also be helpful.

How To Step 13

Use a 10mm socket wrench to remove bolts holding the pulley cover into place.

How To Step 14

Tool 3391 can be a single or three piece tool. Use cam lock bar tool 3391 to loosen the tapered camshaft pulleys from each camshaft. Loosen camshaft fasteners until they can be hand loosened. The tapered camshaft pulleys must be loosened to properly set the engine timing during reassembly.

IMPORTANT TIMING BELT CAMSHAFT PULLEY NOTE: The camshafts do not have key ways.

They are tapered camshafts and are held in place by the conical shape of the camshaft and pulley being tightly pressed together when tightened. 

For camshaft timing reference, the two largest holes on each diamond shaped camshaft washer should be pointed directly inward. When the diamond shaped washers are removed there will be a large flat spot on the cone of the camshafts. This is also a timing reference. These flat spots always point inward. 

Always make sure the diamond-shaped washers mate properly to the camshaft when being installed! If by chance the camshafts move manually turn them back into place. During reassembly the tapered camshaft pulleys must be loosened to properly set engine timing and timing belt tension. If the timing belt tension is set without the tapered camshaft pulleys being loosened and reset, proper engine timing and timing belt tension will not be attained. Again, if the camshaft sprockets are not loosened and reset, this can cause belt misalignment, as well as, binding of the timing belt causing premature timing belt and related timing belt component wear.

How To Step 15

By hand loosen the cam pulley bolts about 3-4 full turns. This will allow an air gap between the fastener washer and the diamond shaped washer.

How To Step 16

Remove cam lock bar tool 3391.

How To Step 17

Use puller T40001 to slowly and evenly apply tension to the tapered camshaft pulleys until they pop loose. 

Please Note: Be sure to do this in a slow and even manner, so as to avoid warping your cam pulley and damaging the tool.

How To Step 18

READ IMPORTANT SERVICE BULLETIN regarding hydraulic tenioner damper before proceeding (See Related Posts Below). 

Using an 8mm Allen wrench, VERY SLOWLY AND EVENLY turn the hydraulic damper/idler pulley CLOCKWISE to compress the hydraulic damper. This will loosen tension of the old timing belt. 

Align and insert pin tool T400011 into the hole near the top of the hydraulic damper to keep the damper retracted and the belt loose. 

Please Note: Failure to compress the hydraulic tensioner damper in a very slow manner can result in the incorrect transfer of fluid within the hydraulic tensioner damper causing it to lose its ability to tension the timing belt.

How To Step 19

Remove the old timing belt and components.

How To Step 20

READ IMPORTANT SERVICE BULLETIN regarding cooling system before proceeding (See Related Posts Below).

Remove old water pump. The water pump is held in place by 10mm bolts. Thoroughly clean the gasket mating surfaces of all old material so it is squeaky clean! Also see our related posts below regarding properly cleaning the water pump seal area.

How To Step 21

If installing a new thermostat, remove thermostat housing and old thermostat along with o-ring located just below the passenger side cylinder head. Be prepared to use a catch pan for a small amount of fluid left within the manifold even after draining the cooling system. 

Some thermostats may be difficult to remove. Over time dissimilar material can establish a solid bond. A tap with the handle end of a small hammer may be needed. Thoroughly clean out the recessed area where the new thermostat mates to the block to ensure a quality seal. 

On your model vehicle there are two types of thermostat housings. One is a aluminum housing which is held in place with two 10mm fasteners and the second is plastic which has a hidden fastener on the bottom side of the housing. In some cases both 5mm Allen type fasteners and 10mm bolts could have been used. If needed, remove two coolant hoses.

Also see our related posts below regarding properly cleaning the thermostat seal area.

How To Step 22

Install your new water pump and gasket. Make sure the gasket does not fold over, causing improper sealing. Begin by evenly hand tightening the water pumps bolts in the order pictured. Then torque 10mm bolts to 7 ft lbs. in the order pictured. This ensures that the composite gasket is compressed evenly for a proper seal. Wait 10-15 minutes after torquing the water pump bolts to 7 ft lbs. Then, re-torque the water pump bolts again to 7 ft. lbs. This ensures that the composite gasket is compressed and properly set. Lastly, tighten the 2 timing belt backing cover to water pump mounting nuts to 7 ft lbs.

Please Note: Gasket sealing agents should NOT be used. Sealing agents vary in composition and intended usage and may affect the composite gasket's long term ability to perform its sealing function. See our related posts below regarding properly cleaning the water pump sealing area area.

How To Step 23

Thoroughly clean the thermostat o-ring mating surface of all old material so it is squeaky clean! Install the new thermostat with the thermostat spring support bar in a level and/or horizontal position as pictured. Then install the new o-ring as pictured. Install the thermostat housing over your new thermostat and torque the mounting bolts to 7 ft lbs.

Please Note: Gasket sealing agents should NOT be used. Sealing agents vary in composition and intended usage and may affect the o-ring's long term ability to perform it's sealing function.

How To Step 24

READ IMPORTANT SERVICE BULLETIN regarding crankshaft timing gear pulley before proceeding (See Related Posts Below).

If your crank seal is not leaking, you may choose not to change it, and skip steps 24-27, pertaining to the VW Passat crank seal replacement.

When performing steps 24-27 and changing the crank seal, it is recommended to purchase a new Crankshaft Timing Pulley Kit.

With crankshaft locking pin tool 3242 still in place, use a 3/4" breaker bar with 12 point 24mm socket to remove the main crankshaft bolt, then remove the toothed pulley.

How To Replace VW Passat Timing Belt Step 24

How To Step 25

Please Note: If you're moving forward with crank seal replacement because you've determined that the crank seal is leaking, be sure to pay close attention to this step! 

Use tool 3203 to remove the lower crank seal. 

Inspect crankshaft for a possible groove where the old seal engaged the crankshaft. If the crankshaft is grooved, recess the seal a few millimeters deeper, so that it rides on a new mating surface. Be careful not to scar the crankshaft. This can cause irreversible damage to the crank, resulting in an unsealable crankshaft and subsequent oil leaks. 

With a soft cotton rag, thoroughly clean crank seal contact area. Lubricate lip of new seal with clean motor oil.

Then with tool 3203, gently tap new seal into place.

How To Step 26

Reinstall crankshaft toothed belt pulley and tighten to torque spec. Torque spec for this fastener is 148 ft lb. + ½ turn.

How To Step 27

Remove the camshaft bolts and pulleys. Be sure to keep track of which pulleys belong with which side. Using a 10mm socket wrench, remove both rear timing belt backing covers.

How To Step 28

Remove old camshaft seals one at a time using tool 3240BL. With a soft cotton rag, thoroughly clean cam seal contact area. 

NOTE: Inspect camshaft for a possible groove where the old seal engaged the camshaft. If the camshaft is grooved, recess the seal a few millimeters deeper, so that it rides on a new mating surface. Be careful not to scar the camshaft. This can cause irreversible damage to the cam, resulting in an unsealable camshaft and subsequent oil leaks. 

Lubricate lip of new seal with clean motor oil. Then with tool 3241/1, gently tap new seals for each camshaft.

How To Step 29

Reinstall timing belt backing covers with blue thread locker and torque 10mm bolts to 7 ft lbs.

How To Step 30

Reinstall the camshaft toothed pulleys back onto each appropriate camshaft. Install the bolts to retain the pulleys, but leave them finger tight for now. Make sure the diamond shaped washers are inserted properly onto each end of the camshafts with the largest holes pointing inward.

Important Reminder: The camshafts do not have key ways.

They are tapered camshafts and are held in place by the conical shape of the camshaft and pulley being tightly pressed together when tightened. 

For camshaft timing reference, the two largest holes on each diamond shaped camshaft washer should be pointed directly inward. When the diamond shaped washers are removed there will be a large flat spot on the cone of the camshafts. This is also a timing reference. These flat spots always point inward.

Always make sure the diamond shaped washers mate properly to the camshaft when being installed! If by chance the camshafts move, manually turn them back into place.

How To Step 31

READ IMPORTANT SERVICE BULLETIN regarding hydraulic tenioner damper before proceeding (See Related Posts Below). 

Install the new hydraulic damper and torque 10mm bolts to 7 ft lbs. 

WARNING! Do not remove hydraulic tensioner damper pin tool T400011 at this time.

 

How To Step 32

Install new tensioner lever and torque 12mm bolt to 18 ft lbs. 

IMPORTANT NOTE: Make sure the stacking of washers and the liner are correct during installation. Lightly coat the liner with grease. Warning! Failure to install components in the proper stacking order will cause binding and premature timing belt failure.

 

How To Step 33

Install new timing belt tensioner and torque 6mm Allen head bolt to 18 ft lbs. 

IMPORTANT NOTE: Make sure the stacking of washers and the liner are correct during installation. Lightly coat the liner with grease. Be sure to double check that the tensioner pin (A) makes proper contact with tensioner lever (B). Ensure that it isn't binding against the oil pump casting housing. Warning! Failure to install components in the proper stacking order will cause binding and premature timing belt failure.

How To Step 34

Again, by hand, rotate and test to make sure the tensioner lever and tensioner move freely. Any binding is caused by incorrect installation of the tensioner liner or lever. If needed, go back to step 31 and double check your work.

How To Step 35

Install timing belt idler and torque 17 mm bolt to 33 ft lbs. It is very important to always note the stack of washers and liners supplied with the tensioner components. If the washers or liners are not used correctly, this can cause misalignments to the timing belt, resulting in damage to the tensioners, timing belt, or engine. After the tensioner components have been installed, always double check for ease of movement, making sure they all rotate properly with no binding.

IMPORTANT NOTE: After all the timing belt tensioners, idlers and pulleys have been installed it is very important to always note the stack of washers and liners supplied with the timing belt tensioner and idler components. If the washers or liners are not used correctly, this can cause misalignments to the timing belt, resulting in damage to the tensioners, timing belt, or engine. After the tensioner components have been installed, always double check for ease of movement, making sure they all rotate properly with no binding.

How To Step 36

Install the new timing belt. 

Follow the following order closely! Don't force the belt. Slide it on without resistance to the gears and pulleys. 

This is done by positioning the new VW Passat timing belt over the (1) lower crank pulley and beginning to work upwards. Simultaneously place it around the (2) tensioners. Then around the (3) driver side cam pulley. Around the (4) water pump pulley. Lastly, around the (5) passenger side cam pulley. Make sure that the timing belt is routed evenly around all pulleys and tensioners.

IMPORTANT NOTE: Some have put the new timing belt on in the incorrect order or sequence and have caused excessive tightness and binding, resulting in the use of tools to force the timing belt onto pulleys. Using improper procedures often damages some of the belt teeth, mars the side of the belt, or causes unseen stress to the internal belt cords. This damage can lead to the new timing belt riding crooked on the pulleys and/or premature timing belt failure.

How To Step 37

Install cam lock bar tool 3391 to hold both camshafts in place. Tool 3391 can be a single or three piece tool.

How To Step 38

READ IMPORTANT SERVICE BULLETIN regarding hydraulic tenioner damper before proceeding (See Related Posts Below).

With an 8mm Allen wrench, apply clockwise tension to the belt tensioner to allow the lock pin T400011 to be removed from the hydraulic damper.

Caution: The hydraulic damper is under pressure and must be compressed slowly. Failure to compress the hydraulic tensioner damper in a very slow manner can result in the incorrect transfer of fluid within the hydraulic tensioner damper, causing it to lose its ability to tension the timing belt. Do not scratch or scar the shaft of the hydraulic damper as this can damage the hydraulic damper. Failure to compress the hydraulic damper slowly can cause irreversible damage to the hydraulic damper.

How To Step 39

With an 8mm Allen wrench preload the tensioner in a counterclockwise direction to around 7 ft lbs. This will allow the hydraulic damper to extend out and subsequently apply the correct tension to the new belt.

How To Step 40

With cam lock bar tool 3391 still in place, torque 16mm bolts retaining the cam pulleys to 41 ft lb.

Please Note: Some choose to skip the use of the camshaft locking bar tool #3391 and estimate general cam timing. This results in incorrect cam timing. Upon reassembly and timing belt service completion, the check engine light could appear and a lack of performance is often noticed. This happens when the timing is off several degrees. Be sure to use special tool 3391, in order to achieve 100% proper cam to crankshaft timing.



IMPORTANT REMINDER: The camshafts do not have key ways.

They are tapered camshafts and are held in place by the conical shape of the camshaft and pulley being tightly pressed together when tightened. For camshaft timing reference, the two largest holes on each diamond shaped camshaft washer should be pointed directly inward. When the diamond shaped washers are removed there will be a large flat spot on the cone of the camshafts. This is also a timing reference. These flat spots always point inward. Always make sure the diamond shaped washers mate properly to the camshaft when being installed! If by chance the camshafts move, manually turn them back into place.

 

How To Step 41

Remove both the crankshaft and the camshaft locking tools 3391 and 3242. Then rotate the engine a full two revolutions by hand to assure that there is no interference. Double check that the appropriate crankshaft and camshaft timing marks line up perfectly.

How To Step 42

Reinstall the crank lock plug with o-ring and torque 10mm bolt to 7 ft lb.

How To Step 43

Reinstall lower most timing belt pulley cover and torque 10mm bolts to 7 ft lbs. with blue thread locker.

How To Step 44

Reinstall crankshaft vibration dampener/serpentine pulley and torque 6mm Allen bolts to 18 ft lb.

How To Step 45

Reinstall viscous fan bracket and fan. Remember the left-hand thread involved with the fan.

Please Note: Be sure to install the fan bracket over the top of the lower most timing belt cover tab area. If the fan bracket is installed with the lower most timing belt cover in front of the fan bracket it will rub the crankshaft vibration damper. Rubbing noises may be heard after incorrect installation.

Torque specs are as follows: (3) 6mm Allen head fasteners - 17 ft lb. (1) 5mm Allen head fasteners - 7 ft lb. Fan clutch unit - 27 ft lb.

How To Step 46

Reinstall both the upper and lower radiator hoses.

How To Step 47

Reinstall all timing belt covers. Ensure that there is no rubbing on any of the timing belt components.

How To Step 48

Using a 6mm Allen wrench and tool 3212, reinstall the power steering pump pulley and torque 6mm Allens to 18 ft lbs.

How To Step 49

Reinstall serpentine tensioner and torque 10mm Allen to 41 ft lbs. Make sure pin on the tensioner lines up properly with engine block.

 

How To Step 50

Install serpentine belt. Make sure the belt is set properly in all ribs on pulleys. See STEP 4 for help with belt direction.

How To Step 51

Reinstall plastic breather hose pipe on front side of engine.

How To Step 52

Locate any components removed, not specifically addressed in this guideline, and reinstall. Review each step found in this set of guidelines to ensure that each component has been addressed properly and has been refastened to specification.

How To Step 53

Loosen the clamp on the coolant hose that runs up to the heater core. Pull the hose back until the small bleeder hole located near the end of the hose is no longer sealed.

Please Note: Some ignore burping the cooling system. This can result in air pockets and cavitation, as well as, incorrect coolant quantities within the cooling system. This causes overheating, blown head gaskets, warped cylinder heads, heater core failure, and other engine damage. Don't ignore these steps!

READ IMPORTANT SERVICE BULLETIN regarding filling the coolant system (See Related Posts Below).

How To Step 54

Mix together 50% concentrated G12 / G13 coolant and 50% deionized water. Slowly fill the coolant expansion tank until it flows from the bleeder hole in the above pictured heater core hose. In some cases it is best to unscrew the expansion tank mounting fasteners and lift upward to allow gravity to better help the cooling system to be burped. When this is completed you can refasten the expansion tank.

PLEASE READ IMPORTANT SERVICE BULLETIN REGARDING MIXING CONCENTRATED COOLANT ANTIFREEZE ONLY WITH DEIANIZED WATER. IF DEIANIZED WATER IS NOT AVAILABLE DISTILLED WATER CAN BE USED.

How To Step 55

Push heater hose back into place and re-affix clamp.

How To Step 56

Locate coolant bleeder screw on crossover pipe, just under coolant expansion tank. Loosen screw. You may have to move coolant expansion tank off to the side. On some models you will not have to locate this bleeder screw as there is a coolant hose that will allow the system to be burped directly into the coolant expansion tank.

How To Step 57

Continue to add coolant until it flows from the above bleeder, then tighten bleeder screw.

How To Step 58

Locate and loosen an additional bleeder screw on the front coolant pipe, next to the driver side head.

How To Step 59

Once again, add coolant until it flows from the above bleeder and then tighten bleeder screw.

How To Step 60

Top off coolant level to the max mark of the expansion tank and install the expansion tank cap.

How To Step 61

Set heater controls to the maximum heat position.

How To Step 62

Start engine and let run at idle for 10 to 15 minutes.

How To Step 63

Elevate engine RPM between 2000-4000 RPM at a gradual rate for approximately 10-15 minutes. You might have to turn off the engine and allow the engine to cool for 20-30 minutes and then repeat step 51 to allow proper burping/removal of air in cooling system.

How To Step 64

Allow engine to idle, until the lower coolant hose on the radiator is hot. This is an indication that the thermostat has opened, and the cooling system has been burped properly. Also check to make sure that warm air is coming out of the interior air vents. This is also an indication that the cooling system has been burped and is flowing properly.

How To Step 65

Turn off engine.

How To Step 66

When the engine has cooled, recheck the coolant level. As needed, add properly mixed 50% concentrated G12 / G13 coolant and 50% deionized water.

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