Autotech 10.109.418K Sport 16V Camshaft Set, Mk1, Mk2, Mk3 16V - Manual (Page 4)

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18. ENGINE TIMING
Once cam-to-cam timing is set properly, you can now set the engine timing (cam-to-crank).
Install the valve cover and gasket on the head with its eight bolts (
10 Nm/7.2 ft lb).
Rotate the camshaft timing sprocket until the TDC mark aligns with the mark on the valve
cover (Fig 1). The crankshaft should not have been moved, but you should double check that
the crank is still at TDC. Note that the 16V engine is an "interference engine," meaning that
the valves will hit the tops of the pistons if the engine goes out of time. Therefore, you
cannot rotate the cams beyond the point where the valves hit the top of the piston on any
one cylinder.
Once TDC on both cams and crank are confirmed, place the timing belt on the camshaft
timing sprocket and set the belt tension using the special tool (AST 10.012.86400). Tighten
the belt tension (Fig 5) until you can rotate the belt no more than 45° (this is different
than 8-valve engines). Torque the tensioner nut to spec (
45 Nm/33 ft lb).
19. Install the ignition distributor using the marks you made earlier to locate the body position.
You will still need to set your ignition timing, once the engine is back together, but it should
be close using these marks.
20. Re-assemble all remaining components on the engine in the reverse of removal. The braces
on the back of the intake plenum should be tightened last ( 20 Nm/15 ft lb).
21. Rotate the engine by hand (19mm wrench on the crank bolt) at least two full rotations, and
re-check your timing marks before attempting to start the engine.
22. WAIT AT LEAST 30 MINUTES BEFORE STARTING ENGINE!
The hydraulic lifters will need at least that time to bleed down to normal level. If you start
the engine, and the lifters have not yet bled down, you could possibly damage the engine due
to valve-to-piston interference. When you're ready to start the car, be ready to shut it
down if the engine runs rough. If it does not start or runs rough, DON'T PANIC! Wait 30
minutes more before trying to start it again. The lifters may still be pumped up and are
keeping the valves open. Be patient. Some lifters take longer than others to bleed down.
23. Once the engine is started, run the engine at a high idle (1500-2000 rpm) for 20 minutes
to assure good oil pressure on the new camshafts. Set your ignition timing to factory specs
(adjusting value: 6° BTDC ±1°).
Fig 5
Fig 4-cam to cam timing