User manual AUTOTECH 10.109.01.109

[. . . ] 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 realign all of the sprockets. Remove bearing caps one and three, in that order. [. . . ] intermediate shaft timing should already be close if you put the motor at TDC before beginning your cam install. Rotate crankshaft (by hand using a wrench or socket on the end of the crank) and intermediate shaft until the dot from the intermediate shaft is visible through the "V" in the crankshaft pulley (fig. 1). Caution: Rotate the crankshaft the least amount necessary align the marks. Since the drive belt is not installed, there may be piston to valve interference if you try to rotate the crankshaft too much. Check camshaft timing mark, make sure that the dot on the inside of the cam sprocket is lined up with the camshaft drive belt inner cover (fig 1). Install the camshaft drive belt by sliding it over the sprockets. Start at the crankshaft, then the intermediate shaft, and finally the camshaft. Try to keep the belt as tight as possible between the crankshaft and the intermediate shaft, and between the intermediate shaft and the camshaft sprockets. Using a special spanner wrench (AST P/N 10. 012. 86400 or equiv. ), tighten the drive belt by rotating the tension pulley in the direction of the arrow (fig. The belt should feel tight when twisted 90 degrees with the thumb and forefinger, halfway between the camshaft and intermediate shaft pulleys. Tighten the pulley retaining nut to 33 ft/lb. fig 1 fig 2 32240-E Paseo Adelanto, San Juan Capistrano, CA 92675 Phone 949. 240. 4000 Fax 949. 240. 0450 A U T O T E C H Installation Instructions 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 installation 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. Move camshaft sprocket to cylinder number one TDC mark by turning crankshaft clockwise with a 19mm socket until the dot on the camshaft pulley lines up with the arrow on the drive belt cover (fig. 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. If these marks do not line up, you will need to continue to rotate the crankshaft until they do. 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. [. . . ] Set motor to TDC (see step 2 on instruction sheet). Loosen tension pulley and slide off camshaft drive belt. Align dot between the "O" and the "T" of the camshaft sprocket with the arrow on the drive belt cover (fig. Rotate crankshaft by hand until the TDC mark on the flywheel lines up with the pointer in the bellhousing (fig 2). [. . . ]