Autotech 10.109.418K User Manual

AUTOTECH

Installation Instructions

Part Number: 10.109.418K
Description: Autotech 16V Sport Camshaft Set

Notes:

Ground on Autotech’s own, custom manufactured, chill-hardened billets, our new Sport
16V camshafts achieve power levels higher than the benchmark Schrick 260°, yet pro­vide far better low-end torque and drivability. Without question, they are the best
street-legal* performance cams for your 16V.
* Exempt under C.A.R.B. Executive Order D-375-4. All timing settings and tune-up speci­fications are the same as original.

1) For a trouble-free installation, it is important to understand that there are two
separate timing procedures that must be addressed when installing this
(or any VW 16V) cam set:
First, there is cam-to-cam timing, which is set by the position of the chain connecting
both cams.
Second, there is engine timing, set by the position of the timing belt connecting the
crankshaft to the exhaust camshaft.
These timing procedures should be viewed as two, independent operations. Once seen
this way, the installation is quite simple, and will go smoothly, even if it's your first time
doing this sort of thing.

2) We strongly recommend changing the timing belt when it has seen 50,000 miles of
use. If you're not sure how many miles your 16V's belt has, CHANGE IT! A new belt is
cheap insurance against costly engine damage caused by a broken belt.

1

Procedure:

1. Remove the camshaft drive belt cover on the front (
side bolts (

2. Rotate the crankshaft clockwise with a 19mm wrench until the No. 1 cylinder is at TDC (Top
Dead Center), indicated by the marks on the camshaft sprocket and valve cover (see Fig 1)

10 Nm/87 in. lb).

Fig 1

Phone [phone] Fax [phone]-E Paseo Adelanto, San Juan Capistrano, CA 92675

6 Nm/53 in. lb.) and

2. (cont)
Note: because the timing mark on the vibration damper and the "0" on the flywheel can
indicate TDC for either cylinder No 1 or No 4, don't use these marks for double-checking
here. Use the mark on the camshaft only.

3. Pull all four spark plug wires off the plugs. Keep the wires attached to the distributor cap,
and remove the cap from the distributor.

4. Remove the upper intake manifold plenum. To do this, first remove the two rear support
braces (

20 Nm/15 ft lb)., all vacuum hoses, electrical connections, the throttle cable, and
the intake boot from the throttle body. Then, using a 13mm wrench, remove the 5 nuts
that hold the upper plenum to the lower (

20 Nm/15 ft lb). Slide the upper plenum off of

the lower half.

5. Cover the lower manifold to prevent any dirt or objects from falling into the engine.

6. Loosen the belt tensioner using a 15mm wrench. Slide the timing belt off of the cam
sprocket.

7. Using a scribe or indelible pen, mark the position of the ignition distributor body relative to
the cylinderhead. This will aid in re-installation and closer initial timing settings. Remove the
two bolts that retain the ignition distributor to the head. Remove the distributor and set
aside.

8. Remove the two center and six outer valve cover bolts. Remove the valve cover. If the rubber
gasket has gotten hard or brittle, replace it. Otherwise, set the gasket aside for re-use.

9. With the engine still at TDC, use a clean rag to wipe the oil off of the two chainwheels and
the top portion of the timing chain. Using a "paint pen" or marker, mark the position of the
chain and chainwheels relative to one another (two places). This will aid in the proper timing
of the new cams later (arrows, Fig 2).

2

Fig 2

10. Removing the cam bearing caps - Use an 11mm wrench to:

• remove bearing caps 5 and 7 (each cap is marked) from the INTAKE camshaft.

• Next, remove the end cap on the INTAKE cam closest to the chainwheel.

• Remove caps 1 and 3 on the EXHAUST cam, then remove the two end caps as well.

• Now gradually and evenly loosen the nuts on the remaining caps a little at a time, so the
tension in the valve springs and cam chain are released evenly.

NOTE THE DIRECTION AND NUMERICAL SEQUENCE OF THE BEARING CAPS ON THE ENGINE!
IF THESE CAPS ARE INSTALLED INCORRECTLY, IT CAN PREVENT THE CAMSHAFTS FROM
TURNING AND WILL CAUSE UNREPAIRABLE CAMSHAFT AND BEARING WEAR!

11. Lift the camshafts from the head TOGETHER, then remove the drive chain. Make sure you
have marked the chain and chainwheels, as in Figure 2, before separating them!

(cont)

Phone [phone] Fax [phone]-E Paseo Adelanto, San Juan Capistrano, CA 92675