DIY 8 valve camshaft swop

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Jetta2
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DIY 8 valve camshaft swop

Postby Jetta2 » Sat Jun 16, 2007 8:44 pm

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.....

Image



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.

Image


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.

Image

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.

Image


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.

Image

It will now look like this.....

Image


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.

Image


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.

Image



Refit any parts removed. Cambelt cover, cables, etc.
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Postby meox » Sat Jun 16, 2007 9:01 pm

You should write a book with DIY's :D

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Postby Jetta2 » Sat Jun 16, 2007 11:24 pm

meox wrote:You should write a book with DIY's :D



Good idea.

Anyone know a good publisher? :lol:
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Postby MacMan » Sat Jun 16, 2007 11:45 pm

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.

Image



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).

Image



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.

Image



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.
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Postby Jetta2 » Sun Jun 17, 2007 12:00 am

:oops: :oops:

Thanks MacMan...... :wink:
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Postby HvK » Sun Jun 17, 2007 9:05 am

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?

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Postby Jetta2 » Sun Jun 17, 2007 11:05 am

I have read that you only have to do that when new cam followers are used.
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Postby trumpy » Sun Jun 17, 2007 3:54 pm

Excellent post Jett. Won't attempt myself but at least I'll have an educated look over the mackies' shoulder;)
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Postby silver2dr » Sun Jun 17, 2007 4:11 pm

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

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Postby EX-DOHCTOR » Sun Jun 17, 2007 6:00 pm

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


That kind of question should really be directed towards the commitee... :wink:
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Postby MacMan » Sun Jun 17, 2007 7:28 pm

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?


:? 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)?

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.
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Postby 1.6carbster » Mon Jun 18, 2007 11:32 am

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!

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Postby 1.6carbster » Mon Jun 18, 2007 11:32 am

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!

Current:
2005 BMW 330i (E90) The Beef
Image
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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Postby Jetta2 » Mon Jun 18, 2007 11:38 am

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!!!

:wink:
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Postby 1.6carbster » Mon Jun 18, 2007 10:36 pm

Thanks Chris.....

That 1.6 Carb really flies. Anyone who doubts that a carb 1600 can haul ass, take a ride in that Mk1!!!


Thanks Ryan,

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!! :D

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Postby Jetta2 » Mon Jun 18, 2007 10:42 pm

I'm sure you'll get at least 88Hp ATW now.

:shock: That's the kinda power the Jetta has.....

Time to put the new head on and the 276 cam :wink:

BTW I'm going to pick the head up from Sarel in the morning.
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Postby bru-tom » Wed Jun 20, 2007 8:34 am

Wow bru!!!!!!!!!!!!!!! another awesome DIY! :oops: :oops: :lol: :lol:

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?? :D

that would be sumthing id buy- " Ryans rock to performance DIY's" :wink:

nice one once again dude :wink:
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Postby Jetta2 » Wed Jun 20, 2007 10:54 am

Thanks Bruce.

Just another contribution to the Club :wink:


'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\
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Postby bru-tom » Wed Jun 20, 2007 11:01 am

what about one for the lads on the vw forum....nah, that wont work really, we have all your DIY's already :oops: :lol: hmmmm.....pity though, it would be cool having a book published with your name on it :twisted:
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Postby slakkie » Fri Jul 13, 2007 12:25 am

Jetta2 wrote:I'm sure you'll get at least 88Hp ATW now.

:shock: That's the kinda power the Jetta has.....

Time to put the new head on and the 276 cam :wink:

BTW I'm going to pick the head up from Sarel in the morning.


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.
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Postby Jetta2 » Fri Jul 13, 2007 6:31 pm

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.
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Postby slakkie » Fri Jul 13, 2007 7:48 pm

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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Postby Jetta2 » Sat Jul 14, 2007 10:16 am

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 :wink:
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Postby cmpelser » Sat Jul 21, 2007 5:51 pm

speaking about workshop manuals, I can`t seem to find anything on a 1.4i citi golf. (including all the mp9 stuff. - error codes- for vag-com etc.)
anyone got books on the mp9 system???

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Question

Postby GSX1800 » Thu Jan 31, 2008 12:49 pm

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 [email protected] 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 [email protected] much appreciated.
Golf III 1800 GSX Fuel Injected
Performance branch n free flow exhaust
BMC Flat Bed Filter

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