Autotech 10.109.418K Sport 16V Camshaft Set, Mk1, Mk2, Mk3 16V - Manual (Page 3)

Phone 949.240.4000 Fax 949.240.0450 32240-E Paseo Adelanto, San Juan Capistrano, CA 92675
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12. Now use a 17mm wrench to remove the bolt that holds the timing belt sprocket to the
exhaust cam ( 65 Nm/48 ft lb). We recommend holding the cam in a vise using soft jaws
to do this easily. Gently tap the sprocket to remove from the camshaft. Be careful not to
damage the keyway integral on the sprocket!
13. Removing the chainwheels for transfer to the new cams.
BEFORE REMOVING, NOTE WHICH WAY THE CHAINWHEELS ARE FACING. THEY MUST BE
PLACED THE SAME WAY ON THE NEW CAMS, OR YOU WILL NOT BE ABLE TO PROPERLY
TIME THEM! The chainwheels have a front and back, distinguished by the chamfer or radius
of the wheel's face near the center hole (Fig 3)
The chainwheels must be locally heated to be removed or installed. It is best to have them
pressed on or off the cams using a hydraulic press with steady force after heating. If this
is not possible, you will have to heat, then gently drive the chainwheels off or on with a soft
faced mallet. This is best accomplished by driving the cam off of or onto the chainwheel,
while supporting the chainwheel on at least two places over an open vise. Make sure to keep
the woodruff keys for re-use.
Install the chainwheels on the new cams facing the same direction as on the originals.
14. Once the chainwheels are installed on the new cams, apply a small amount of cam lube or
oil to the inside of a new camshaft oil seal (OE no 068.103.085A) and place it on the exhaust
cam. On a table or flat surface, place the drive chain onto the new cams, and make sure the
marks you made (in Step 9) on the chainwheels and chain align. Now place the cams in the
head TOGETHER, making sure that the chain does not skip or move a tooth while doing so.
15. Install bearing caps 2, 4, 6, and 8, tightening them down gradually and evenly. Make sure the
caps are on the correct journals and that the caps' beveled corners face the intake
(forward) side of the engine. Now install caps 1, 3, 5, and 7 in the same manner. Lastly, put
the four end caps on. Double check to make sure ALL caps are facing the right direction
and are in the proper position! Finally, torque the nuts (
15 Nm/11 ft. lb.).
16. Place the timing belt sprocket on the exhaust cam and bolt it on (
65 Nm/48 ft lb).
17. CAM-TO-CAM TIMING
Rotate the timing belt sprocket to check the cam-to-cam timing as shown in figure 4.
Remember that cam-to-cam timing and engine timing are to be treated as separate
procedures. It is in reality, quite simple to get cam-to-cam wrong! Pay close attention that
the dots are truly in-line with the edge of the head when they face each other.
Cam-to-cam timing must be perfect or serious engine damage could occur!
Fig 3
outer
chamfer
inner
radius