Author Topic: HOW-TO Swap camshaft on a 2.0 8v engine (most 8v engines will be similar)  (Read 38189 times)

Offline Khare

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Right, here it goes.
How to change the camshaft on a 2l 8v mk3. The mk2 gti engines will be the same.

You will need a new new valve cover gasket and cam pulley seal. Cost me about £14 for both from GSF

First off you need to disconnect the earth from the battery.

Remove the air intake pipe and the oil breather hose.

Then, remove the top half of the cam belt cover.

Turn the engine over by hand using a socket and a ratchet. Line up the punched dot on the outer surface of the cam pulley with the front of the cylinder head, then with tip-ex mark up the pulley to the cam belt (I used permanent marker)



Then, you need to remove the nuts holding the valve cover on. There are 8 of these.

Remove the two brackets supporting the throttle body to the cam cover, these are held on by 4 large bolts. Finally, remove the earth bracket on the gearbox side of the cylinder head, it is held on by one nut.

Lift the cam cover out, along with the splash guard.

You should see this.




Now is very important: Timing.

Loosen up the cam belt tensioner.

Remove the cam belt from the cam pulley, have someone holding it tight against the intermediate shaft pulley so it doesnt jump a tooth or two.

Using a bungee cord, hold the cam belt tight towards the bonnet, like so (stolen from danny_p's website)


Now....Using a breaker bar or something hard and long, stick it in through the cam pulley to jam it and loosen up the cam pulley bolt. It's a big heavy bolt that can be a pain to remove, mine came out relatively easy however.

Using the sequence that the Haynes manual recommends, undo all 4 cam bearing caps, these are held by 2 bolts each, like so...



Diagram shows for a 16v, but shows the sequence for each of the cams, do the same on your 8v. Loosen them up slowly and progressively.

once all the bearing caps are off lift the cam out.

Remove the cam pulley bolt, and CAREFULLY separate the pulley from the camshaft, DO NOT LOSE THE WOODRUFF KEY.

Now you need to lay your old cam next to your new one, and show the new one some love.



See the difference between them, high lift cam on the bottom.



Now, you need to do them the reversal of everything.

The new cam pulley seal in first.

Put the woodruff key in the new cam, along with the cam pulley.

Put the cam back in...this part was tricky, because you will have to force it down a bit to compress some of the valves.

Using the same order to undo the cam bearing caps do them up. They should be done to a specified torque using a torque wrench. I didn't have one available, so I did them up to the same tightness they were, which is a tightness my mother could have done up to, so not too tight.



Now, timing belt back on...Spin the camshaft until the punched dot in the pulley is at the same position as it was at first, in line with the front of the cylinder head. Then, slip the belt back into the pulley, and tense it up to the correct tightness, should be twisted 90 degrees between the cam pulley and intermediate pulley. Spin the engine by hand do ensure the valves don't hit the pistons. Spin it over a few times to make sure!

Get the new gasket out and lay it on.

Place splash guard how it was, and put the cam cover back on.

Do up the 8 bolts, the 4 bolts holding the throttle body brackets and the 1 bolt holding the earth point to the cover! or else you're ECU will blow.

-ve earth lead back onto the battery...

Once its all back on, clean up your mess and pray it works!



Might take a few cranks to get going, mine took about twice as long to start up.

When it did, that lumpy idle was glorious. Bonnet down, and took it for a gentle ride. Go up the revs very slowly, listening out for any abnormal noises, don't floor it straight away, do a few miles half throttle or less.

after a few miles, after both water and oil are up to running temp, enjoy your new power!!!!

Remember to check your oil level after the work is done, you might need to top up ever so slightly.

Remember not to over tighten your cam bearing caps, it will increase wear on the camshaft.

I am not responsible if you're engine blows up or if you c0ck up! This is just a rough guide without 1 million pictures, jsut afew pictures of the progress.

ENJOY  :smiley:

Khare
« Last Edit: 03 July 2012, 10:06 by Khare »

Offline Adam

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Nice :afro:

Is it worth it though? Make much of a diff?

Down Hill From Here.

Offline Khare

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Deffo have made a difference.




I'm stopping for petrol more often  :laugh:



Also feels like it doesn't tail off the power at 5500rpm like it used to, now hits the limiter still pulling.
Also sounds ALOT meatier and better and louder  :cool:

Below about 2700rpm it has lost torque, but as soon as the magic RPM hits it just pulls like a work donkey! Effectively, I have VTEC  :grin:

Offline LazyLunatic

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great write up khare! good work! :afro:

Offline Ben Lessani

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20Nm for bearing caps.

Remember to put a spot of clean oil on the new cam bearing faces and run some across the new gasket contact faces too.

Always mark up the intermediate pulley and crank before starting.

... and clean the cam thoroughly after putting it on the grass :laugh:

Offline AudiA8Quattro

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20Nm for bearing caps.

Remember to put a spot of clean oil on the new cam bearing faces and run some across the new gasket contact faces too.

Always mark up the intermediate pulley and crank before starting.

... and clean the cam thoroughly after putting it on the grass :laugh:

You beat me to it, that's exactly what i was going to say  :laugh:
FOR DIY GUIDES GO TO <br>www.volkswagenaudi.co.uk<br/>BRAKES, SUSPENSION, CV JOINTS

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20Nm for bearing caps.

Remember to put a spot of clean oil on the new cam bearing faces and run some across the new gasket contact faces too.

Always mark up the intermediate pulley and crank before starting.

... and clean the cam thoroughly after putting it on the grass :laugh:

You beat me to it, that's exactly what i was going to say  :laugh:


did you use tissues or a sock to clean up after giving it some love?

Offline Khare

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sock mate, sock  :grin:

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Offline darcy

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you make it seam like anyone could do it, i have a 1.8gl so if i got a high lift cam i could change it myself...or with the help of a friend?
or do you really need to have done it before?

but good write up btw.