AUTOTECH 10.109.01.109 Installation Instructions Manual

AUTOTECH

Installation Instructions

Part Number: 10.109.01.109

Description: AUTOTECH Sport 270° Hydraulic Camshaft

Note: If the job seems to be beyond your abilities, we recommend that you refer this in-

stallation to a qualified mechanic. Please read through the instructions before starting

your installation to ensure that you have have the tools and understanding of the task.

Procedure for Golf 2 and Jetta 2 models only:

1. Remove the valve cover by removing the eight 10mm valve cover nuts and reinforcing

strips. Remove idle stabilizer and bracket (if your car has one) by removing the 10mm bolts

from the valve cover and manifold, and then taking off the hoses at the throttle body and

intake manifold. Lift off valve cover. Remove the retaining nut on the side of the camshaft

drive belt cover with a 6mm allen wrench and lift off the cover.

2. Move camshaft sprocket to cylinder number one TDC mark by turning crankshaft clock-

wise with a 19mm socket until the dot on the camshaft pulley lines up with the upper edge

of the camshaft drive belt inner cover (fig. 1). Check TDC by removing the distributor cap

and making sure the rotor lines up with the notch on the distributor (fig. 2), and that the

flywheel is at TDC (fig. 3). If these marks do not line up, you will need to continue to rotate

the crankshaft until they do.

3. Loosen belt tensioner with a 15mm open end wrench and slide off the camshaft drive

belt, while keeping the belt tension on the lower sprockets so that they don't move or slip.

If they do, you will probably have to re-align them in a procedure described later. By tying

the belt via a bungee or other cord to the hood or laying the belt towards the rear using a

weight (wrench etc...) to keep the belt tension, you can install the cam without having to re-

align all of the sprockets.

4. Remove bearing caps one and three, in that order. Take note of which end of each cap is

pointing towards you. Caution: The bearing caps are offset, and will break if re-installed

backwards and tightened down. Next, remove the nuts from bearing caps two and five a

little at a time and crosswise so that the spring tension is evenly relieved. Lift cam with

attached sprocket out of the head.

5. Loosen the camshaft sprocket bolt 1/2 to 3/4 turn and tap the sprocket loose using a

soft faced hammer. Remove the bolt completely and remove the sprocket, woodruff key, and

cam seal. Lightly coat the cam seal with oil and place on the new camshaft. Install the

woodruff key and sprocket onto the new camshaft and torque the cam sprocket mounting

bolt to 59 ft/lb.

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6. Apply oil to the bearing surfaces, and a small amount of assembly lube to the lobes of

the new camshaft. Lay the camshaft in the head with the lobes for the number one cylin-

der facing up. Install bearing caps two and five, tightening down gradually and crosswise

until the camshaft is pushed completely into the bearing saddles. Install the remaining

bearing caps and torque all nuts to 15 ft/lb.

7. Check to see if the dot on the inside of the cam sprocket lines up with the upper edge

of the camshaft drive belt inner cover (fig. 1). If not, rotate cam slightly until it does.

8. Re-install the valve cover and reinforcing strips, tightening the nuts to 7 ft/lb.

9. Slide camshaft drive belt over cam sprocket.

10 . Using a special spanner wrench (AST P/N 10.012.86400 or equiv.), tighten the drive

belt by rotating the tension pulley in the direction of the arrow (fig. 4). The belt should feel

tight when twisted 90 degrees with the thumb and forefinger, halfway between the cam-

shaft and intermediate shaft pulleys. Tighten the pulley retaining nut to 33 ft/lb.

11. Caution! Before starting engine, turn crankshaft two complete revolutions and check

belt tension, camshaft alignment, crankshaft alignment, and distributor alignment. If every-

thing checks out, re-install distributor cap, timing belt cover, and idle stabilizer valve if so

equipped.

12 . Start engine and run it at around 2000 RPM for twenty minutes. This is the crucial

break-in period for a new cam. It is important that the cam has good oil pressure at this

time! Once twenty minutes are up, you're ready to run.

Fig. 1

Fig. 2

Fig. 4

Fig. 3