Manual

AUTOTECH
Part Number: 10.109.01.109
Description: AUTOTECH Sport 270° Hydraulic Camshaft
Note: If the job seems to be beyond your abilities, we recommend that you refer this instal-
lation to a qualified mechanic. Please read through the instructions before starting your
installation to ensure that you have have the tools and understanding of the task.
Procedure for Golf 3 and Jetta 3 models only:
1. Remove upper drive belt cover by unsnapping the bands fastening it to the head.
2. Move camshaft sprocket to cylinder number one TDC mark by turning crankshaft clock-
wise with a 19mm socket until the dot on the camshaft pulley lines up with the arrow on
the drive belt cover (fig. 1). Check TDC by removing the distributor cap and making sure
the rotor lines up with the notch on the distributor (fig. 2), and that the flywheel is at TDC
(fig. 3). If these marks do not line up, you will need to continue to rotate the crankshaft
until they do.
3. Remove upper intake manifold. Remove all connected vacuum hoses, electrical connections
(i.e. throttle body, etc...), and throttle cable from the upper manifold. Remove the five socket
head bolts (located near the fuel rail) and remove the manifold. Note: It is a good idea to
either tape over, or place clean rags in the lower intake manifold to prevent foreign objects
from falling in.
4. Loosen belt tensioner with a 15mm open end wrench and slide off the camshaft drive
belt, while keeping the belt tension on the lower sprockets so that they don't move or slip. If
they do, you will probably have to re-align them in a procedure described later. By tying the
belt via a bungee or other cord to the hood or laying the belt towards the rear using a
weight (wrench etc...) to keep the belt tension, you can install the cam without having to re-
align all of the sprockets.
5. Remove valve cover by removing the eight 10mm nuts and reinforcing strips.
6. Remove bearing caps one, three and five, noting which end of each cap is pointing to-
wards you. Caution: The bearing caps are offset, and will break if re-installed backwards
and tightened down. Next, remove the nuts from bearing caps two and four a little at a
time and crosswise so that the spring tension is evenly relieved. Lift cam with attached
sprocket out of the head.
7. Loosen the camshaft sprocket bolt 1/2 to 3/4 turn and tap the sprocket loose using a
soft faced hammer. Remove the bolt completely and remove the sprocket, woodruff key, and
cam seal. Lightly coat the cam seal with oil and place on the new camshaft. Install the
woodruff key and sprocket onto the new camshaft and torque the cam sprocket mounting
bolt to 59 ft/lb.
Installation Instructions
Phone [phone] Fax [phone]-E Paseo Adelanto, San Juan Capistrano, CA 92675