UPDATE: Got the Passat back together and running. worked late last night to do everything but the final torque steps on the head. One of the exhaust manifold to turbo bolts kept galling up threads, so I had to take the manifold back off, and chase threads into the turbo exhaust inlet. Installing the timing belt with the *NEW AND IMPROVED* tensioner was tough. The belt was just long enough to fit. Had to get the last two head bolts, and some Mobil 1 this morning to finish the job.
The engine sounded like a pea thrasher until the tappets pumped up. I let it idle fast for 5 minutes or so with plain water in the cooling system to flush any gasket funk away, and to observer the belt, tensioner, and pulleys for problems. after getting up to temp, the valve noise went away
.
D&F'ed the cooling system, changed the oil and filter, put the covers, and accessory belts back on, and drove home
This was the most expensive timing belt job I have done to date.
