DIY 8 valve camshaft swop
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- Jetta2
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DIY 8 valve camshaft swop
This is 1.6Carbsters cam swop.
Parts needed:
1X camshaft of your choice for the swop
Valve cover gasket set
Torque wrench
10mm, 13mm, 17mm and 19mm sockets and ring spanners
5mm Allen key
Wait for the motor to cool down before working on it.
Take off the cambelt cover by loosening the two 10mm nuts on the top and the allen cap screw on the side near the bottom of the cover.....
Make sure you turn the motor to top dead centre on cylinder 1.
Use the crank pulley and the mark on the inside of the cam pulley to make sure. The big crank pulley has a notch in it for using to check this and for the ignition timing mark.
The mark on the inside edge of the cam pulley must sit level with the edge of the cam cover. Some pulleys will have a small dot and others have a groove.
Remove the air intake hose or if it is a carb model take off the air cleaner assembly and remove the choke and throttle cables.
Loosen the cam belt tensioner using a 17mm spanner or socket. Slide the cambelt off the cam pulley.
Next, use a socket extension or water pump pliers or big screwdriver to wedge into one of the holes on the cam pulley. Loosen the 19mm bolt holding the cam pulley on.
This bolt is tightened to 80Nm so it's pretty tight.
Next take off the valve cover by loosening the other 6X 10mm nuts. The other 2 nuts hold the cambelt cover in place.
Take off the plastic cover on top of the camshaft as well.
Loosen the 8 nuts on the cam caps slowly in sequence. Loosen each one a little at a time. The cam will still be pushing some valves open so do it SLOWLY AND IN SEQUENCE. Note that the cam caps are numbered 1,2,3 and 5. Number 1 is on the pulley end.
It will now look like this.....
Next take out the bolt holding the cam pulley in place and the small Woodruf key in the camshaft.
Admire the profile of the new cam. On the right is the old "G" cam, and on the left is the 268/276 split duration cam. Note the shape of the cam lobes.....the new cam has a more pronounced profile. The valves will stay open longer.
Take the new cam, put in the Woodruf key and put the pulley in place. Don't try tighten the bolt up now.
Put the cam onto the head. Double check that the mark on the inside of the pulley is in the same place as before you ripped the old cam out.
Put the cam caps back on but do not tighten anything up now.
1 or 2 of the cam caps will have to be pushed down to put the nuts back on. Next tighten the nuts up slowly and in sequence. Don't torque them up, just slowly turn them in sequence so the cam gets put in place slowly without stressing the cam by too much bending.
When the cam caps are completely in place use the torque wrench with the setting on 20Nm and torque the nuts in the same sequence as used to loosen them.
Refit the cam cover and use the new gasket.
Use the extension/screwdriver/waterpump pliers to wedge in the opposite hole in the cam pulley and tighten the pulley bolt to 80Nm.
Next put the cambelt back on the pulley and set the tension of the belt. In the Haynes manual it says the belt should just be able to be twisted through 90 degrees.
Refit any parts removed. Cambelt cover, cables, etc.
Parts needed:
1X camshaft of your choice for the swop
Valve cover gasket set
Torque wrench
10mm, 13mm, 17mm and 19mm sockets and ring spanners
5mm Allen key
Wait for the motor to cool down before working on it.
Take off the cambelt cover by loosening the two 10mm nuts on the top and the allen cap screw on the side near the bottom of the cover.....
Make sure you turn the motor to top dead centre on cylinder 1.
Use the crank pulley and the mark on the inside of the cam pulley to make sure. The big crank pulley has a notch in it for using to check this and for the ignition timing mark.
The mark on the inside edge of the cam pulley must sit level with the edge of the cam cover. Some pulleys will have a small dot and others have a groove.
Remove the air intake hose or if it is a carb model take off the air cleaner assembly and remove the choke and throttle cables.
Loosen the cam belt tensioner using a 17mm spanner or socket. Slide the cambelt off the cam pulley.
Next, use a socket extension or water pump pliers or big screwdriver to wedge into one of the holes on the cam pulley. Loosen the 19mm bolt holding the cam pulley on.
This bolt is tightened to 80Nm so it's pretty tight.
Next take off the valve cover by loosening the other 6X 10mm nuts. The other 2 nuts hold the cambelt cover in place.
Take off the plastic cover on top of the camshaft as well.
Loosen the 8 nuts on the cam caps slowly in sequence. Loosen each one a little at a time. The cam will still be pushing some valves open so do it SLOWLY AND IN SEQUENCE. Note that the cam caps are numbered 1,2,3 and 5. Number 1 is on the pulley end.
It will now look like this.....
Next take out the bolt holding the cam pulley in place and the small Woodruf key in the camshaft.
Admire the profile of the new cam. On the right is the old "G" cam, and on the left is the 268/276 split duration cam. Note the shape of the cam lobes.....the new cam has a more pronounced profile. The valves will stay open longer.
Take the new cam, put in the Woodruf key and put the pulley in place. Don't try tighten the bolt up now.
Put the cam onto the head. Double check that the mark on the inside of the pulley is in the same place as before you ripped the old cam out.
Put the cam caps back on but do not tighten anything up now.
1 or 2 of the cam caps will have to be pushed down to put the nuts back on. Next tighten the nuts up slowly and in sequence. Don't torque them up, just slowly turn them in sequence so the cam gets put in place slowly without stressing the cam by too much bending.
When the cam caps are completely in place use the torque wrench with the setting on 20Nm and torque the nuts in the same sequence as used to loosen them.
Refit the cam cover and use the new gasket.
Use the extension/screwdriver/waterpump pliers to wedge in the opposite hole in the cam pulley and tighten the pulley bolt to 80Nm.
Next put the cambelt back on the pulley and set the tension of the belt. In the Haynes manual it says the belt should just be able to be twisted through 90 degrees.
Refit any parts removed. Cambelt cover, cables, etc.
Ryan Demoser
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
- Jetta2
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Can I just suggest that you also use the timing mark on the side of the distributor and on the flywheel. This will ensure that you never get it wrong.
The mark on the cam pulley is a line on the inside of the pulley (facing the battery) and at TDC this mark must be level with the bottom of the tappet cover.
The rotor must point to the mark on the side of the distributor (you will need to take the plastic cover under the rotor off to see it).
There are 2 "flat pieces" on the flywheel, but neither one of these is the mark... the mark you are looking for will be in between these 2 "flat pieces". This mark is either a punch mark (small round hole) and / or a v-type line cut into the flywheel and this mark must be in the middle of the inspection hole on the gearbox.
Once all these marks are lined up, put a 19mm socket on the crank pulley bolt and turn the motor by hand at least one complete revolution to make sure the motor will turn freely.
The mark on the cam pulley is a line on the inside of the pulley (facing the battery) and at TDC this mark must be level with the bottom of the tappet cover.
The rotor must point to the mark on the side of the distributor (you will need to take the plastic cover under the rotor off to see it).
There are 2 "flat pieces" on the flywheel, but neither one of these is the mark... the mark you are looking for will be in between these 2 "flat pieces". This mark is either a punch mark (small round hole) and / or a v-type line cut into the flywheel and this mark must be in the middle of the inspection hole on the gearbox.
Once all these marks are lined up, put a 19mm socket on the crank pulley bolt and turn the motor by hand at least one complete revolution to make sure the motor will turn freely.
'20 SEAT Tarraco XC 1.5 TSi
'12 VW Up! 1.0 MPi
Ex:
'06 Golf MKV GTi
'04 Golf MKIV GTi.:R
'99 Citi Golf 2.0i
Patience is the ability to idle your motor when you feel like stripping your gears.
'12 VW Up! 1.0 MPi
Ex:
'06 Golf MKV GTi
'04 Golf MKIV GTi.:R
'99 Citi Golf 2.0i
Patience is the ability to idle your motor when you feel like stripping your gears.
- Jetta2
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- Jetta2
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- Cadet
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Excellent post Jett. Won't attempt myself but at least I'll have an educated look over the mackies' shoulder;)
'00 POLO 1800 (brospeed downpipe, 50mm powerflow, K&N flat)
ex: '95 Honda Ballade 180e (K&N Flat)
'88 Ford Laser 1.6i sport (292 cam & vernier, head-job, Full Brospeed zaust, K&N flat, 79KW ATW - mastercam dyno)
'78 Ford 30s ( Cowley branch with bus pipe)
ex: '95 Honda Ballade 180e (K&N Flat)
'88 Ford Laser 1.6i sport (292 cam & vernier, head-job, Full Brospeed zaust, K&N flat, 79KW ATW - mastercam dyno)
'78 Ford 30s ( Cowley branch with bus pipe)
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just a thought
Couldnt we have a DIY section in the forum? It would be usefull as Im sure there has been a ton of questions about howto do this?
just me 2c
apologies on the hijack
Couldnt we have a DIY section in the forum? It would be usefull as Im sure there has been a ton of questions about howto do this?
just me 2c
apologies on the hijack
Current car: 2005 Velociti 1.6i (Black Magic) Detrumpeted Airbox
Project Car: Silver 2 Door Mk1 http://www.vwclub.co.za/vwforum/viewtopic.php?t=29523
Project Car: Silver 2 Door Mk1 http://www.vwclub.co.za/vwforum/viewtopic.php?t=29523
- EX-DOHCTOR
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That kind of question should really be directed towards the commitee...just a thought
Couldnt we have a DIY section in the forum? It would be usefull as Im sure there has been a ton of questions about howto do this?
just me 2c
2014 - VW Jetta 6 - 1.6 TDi DSG
2000 - VW Golf 3.5 Cabrio - 2.0
1980 - VW MK1 GT - 1.8 Carb - https://www.vwclub.co.za/forum/viewtopi ... 1&t=153861
1971 - Mitsubishi Colt 1100F - https://www.vwclub.co.za/forum/viewtopi ... 1&t=220503
MK1 Build Register: https://www.vwclub.co.za/forum/viewtopi ... 1&t=192835
Instagram: https://www.instagram.com/projectkirschwasser/
Racing is meant for the RACE track - deal with it...
2000 - VW Golf 3.5 Cabrio - 2.0
1980 - VW MK1 GT - 1.8 Carb - https://www.vwclub.co.za/forum/viewtopi ... 1&t=153861
1971 - Mitsubishi Colt 1100F - https://www.vwclub.co.za/forum/viewtopi ... 1&t=220503
MK1 Build Register: https://www.vwclub.co.za/forum/viewtopi ... 1&t=192835
Instagram: https://www.instagram.com/projectkirschwasser/
Racing is meant for the RACE track - deal with it...
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The cam caps are the pieces of aluminium that hold the cam in place. Are you not referring to the lifters (the round things under the cam)?HvK wrote:Why didn't you flush out the cam caps? Shouldn't this be done so that the cam and caps settle perfectly with the right amount of oil?
I have never bled the lifters when fitting a new cam and I have never had any problems. I even went from a stock cam to a 276 cam and I didn't touch the lifters. No problems at all.
'20 SEAT Tarraco XC 1.5 TSi
'12 VW Up! 1.0 MPi
Ex:
'06 Golf MKV GTi
'04 Golf MKIV GTi.:R
'99 Citi Golf 2.0i
Patience is the ability to idle your motor when you feel like stripping your gears.
'12 VW Up! 1.0 MPi
Ex:
'06 Golf MKV GTi
'04 Golf MKIV GTi.:R
'99 Citi Golf 2.0i
Patience is the ability to idle your motor when you feel like stripping your gears.
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Awesome DIY post, jetta2!
And should i just add,the new cam ensures that my cabbie kinda hauls ass @ the moment! Thanx again for the work you've done for me Ryan!
If anyone ever needs anything done 2 their cars,give ryan a call! He can help u with interior,exterior and engine mods!
And should i just add,the new cam ensures that my cabbie kinda hauls ass @ the moment! Thanx again for the work you've done for me Ryan!
If anyone ever needs anything done 2 their cars,give ryan a call! He can help u with interior,exterior and engine mods!
Current:
2005 BMW 330i (E90) The Beef
Ex:
1999 Audi A4 1.8T (AEB) the tank
1992 VW Citi 1.8i MP9 R.I.P.
1973 Mini Cooper S sold
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- Colonel
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Awesome DIY post, jetta2!
And should i just add,the new cam ensures that my cabbie kinda hauls ass @ the moment! Thanx again for the work you've done for me Ryan!
If anyone ever needs anything done 2 their cars,give ryan a call! He can help u with interior,exterior and engine mods!
And should i just add,the new cam ensures that my cabbie kinda hauls ass @ the moment! Thanx again for the work you've done for me Ryan!
If anyone ever needs anything done 2 their cars,give ryan a call! He can help u with interior,exterior and engine mods!
Current:
2005 BMW 330i (E90) The Beef
Ex:
1999 Audi A4 1.8T (AEB) the tank
1992 VW Citi 1.8i MP9 R.I.P.
1973 Mini Cooper S sold
- Jetta2
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1.6carbster wrote:Awesome DIY post, jetta2!
And should i just add,the new cam ensures that my cabbie kinda hauls ass @ the moment! Thanx again for the work you've done for me Ryan!
If anyone ever needs anything done 2 their cars,give ryan a call! He can help u with interior,exterior and engine mods!
Thanks Chris.....
That 1.6 Carb really flies. Anyone who doubts that a carb 1600 can haul ass, take a ride in that Mk1!!!
Ryan Demoser
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
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Thanks Ryan,Thanks Chris.....
That 1.6 Carb really flies. Anyone who doubts that a carb 1600 can haul ass, take a ride in that Mk1!!!
I must say, come to think about it.
Std power on a MK1 1.6carb is 62kw on the fly.
Money spent: R+-3500
Power on the fly, with g-cam, 90kw on the fly.
I'm hoping for about 87 or 88hp on the wheels with the new cam!!
Current:
2005 BMW 330i (E90) The Beef
Ex:
1999 Audi A4 1.8T (AEB) the tank
1992 VW Citi 1.8i MP9 R.I.P.
1973 Mini Cooper S sold
- Jetta2
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I'm sure you'll get at least 88Hp ATW now.
That's the kinda power the Jetta has.....
Time to put the new head on and the 276 cam
BTW I'm going to pick the head up from Sarel in the morning.
That's the kinda power the Jetta has.....
Time to put the new head on and the 276 cam
BTW I'm going to pick the head up from Sarel in the morning.
Ryan Demoser
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
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Wow bru!!!!!!!!!!!!!!! another awesome DIY!
yeah, i agree with the other guys, write a book, doesnt have to be a huge ass one, just a small one, with say the top ten big performance diy's??
that would be sumthing id buy- " Ryans rock to performance DIY's"
nice one once again dude
yeah, i agree with the other guys, write a book, doesnt have to be a huge ass one, just a small one, with say the top ten big performance diy's??
that would be sumthing id buy- " Ryans rock to performance DIY's"
nice one once again dude
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'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
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'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
**Meet Nimbus----EURO PROJECT**...SOLD
**My 77' HONDA CB550 Project**
- Jetta2
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Thanks Bruce.
Just another contribution to the Club
've thought about a DIY book, but there are so many modifying books and manuals available I don't think it's worth the hassle.I\
Just another contribution to the Club
've thought about a DIY book, but there are so many modifying books and manuals available I don't think it's worth the hassle.I\
Ryan Demoser
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
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what about one for the lads on the vw forum....nah, that wont work really, we have all your DIY's already hmmmm.....pity though, it would be cool having a book published with your name on it
....../.----------------.\......
..../._____________.\.....
../( )====VW====( )\..
.|\_________________/|.
.|_\_______________/_|.
'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
**Meet Nimbus----EURO PROJECT**...SOLD
**My 77' HONDA CB550 Project**
..../._____________.\.....
../( )====VW====( )\..
.|\_________________/|.
.|_\_______________/_|.
'A Trend is For a Month, Style is Forever...'
**2009 AB-EFF'd citi Rox**
**Meet Nimbus----EURO PROJECT**...SOLD
**My 77' HONDA CB550 Project**
- slakkie
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Jetta2. Give us a quote on swapping DOHC (2 cams) with 2 split duration 268/272 cams on a golf 2. Be generous lol. Also how long does it take.Jetta2 wrote:I'm sure you'll get at least 88Hp ATW now.
That's the kinda power the Jetta has.....
Time to put the new head on and the 276 cam
BTW I'm going to pick the head up from Sarel in the morning.
Now you see me, now you don't
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- Jetta2
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slakkie wrote:Jetta2. Give us a quote on swapping DOHC (2 cams) with 2 split duration 268/272 cams on a golf 2. Be generous lol. Also how long does it take.
I have honestly never done a swop like that so I don't know how long and how much it would be.....Sorry.
Ryan Demoser
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
- slakkie
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ok Jetta2 If I give you the 2 ready cut camshafts. Just to take the old ones out and put the new ones in. Can you do that?
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- Jetta2
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Yup, I can do it but remember I am in Pta and you're in Jhb. It would be much easier for you to do it yourself and get a "Haynes" workshop manual from Motorbooks in Craighall Park
Ryan Demoser
1996 Mk3 Golf VR6
2017 Caddy Maxi Crew Bus 2.0 TDI
2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
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2013 Aprilia RSV4 track toy
2021 Aprilia RS660 road bike
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Question
Hi Guys excellent post I just need to find out
I have a golf III - 1800 GSX Fuel Injected the only
mods I have on the vehicle is a branch n free flow, well
got a flat bed filter in as well but that is not a mod.
I am looking to put in a 276 cam - any idea what the power
gain would ne as I have never dyno the car cos there was no
need to. I am just looking for a little more power to play around with.
Car stock was 82kw @ 5200 rpm
Torque 162nm@3500 rpm
Branch n free flow (not sure how much more this adds)
276 cam = ??????
Please can your'll tell me what I would be expected to push out??
mail me on prashan@kznmcc.co.za much appreciated.
I have a golf III - 1800 GSX Fuel Injected the only
mods I have on the vehicle is a branch n free flow, well
got a flat bed filter in as well but that is not a mod.
I am looking to put in a 276 cam - any idea what the power
gain would ne as I have never dyno the car cos there was no
need to. I am just looking for a little more power to play around with.
Car stock was 82kw @ 5200 rpm
Torque 162nm@3500 rpm
Branch n free flow (not sure how much more this adds)
276 cam = ??????
Please can your'll tell me what I would be expected to push out??
mail me on prashan@kznmcc.co.za much appreciated.
Golf III 1800 GSX Fuel Injected
Performance branch n free flow exhaust
BMC Flat Bed Filter
Performance branch n free flow exhaust
BMC Flat Bed Filter