The Volkswagen 2.0 Aba Engine, renowned for its reliability and fuel efficiency, often leaves drivers desiring more power. One effective way to unlock its hidden potential is through camshaft upgrades. This guide provides a detailed walkthrough of installing a new camshaft, along with essential accompanying components like valve seals, lifters, and springs, specifically for the 2.0 ABA engine.
Prerequisites:
Before embarking on this project, familiarize yourself with the timing belt replacement procedure. This guide does not cover timing belt replacement, which is crucial for proper engine timing. Additionally, a basic understanding of camshaft functionality and valve train components is recommended. Resources for both topics are linked below:
- Timing Belt Replacement: http://faculty.ccp.edu/faculty/dreed/Campingart/jettatech/t-belt/index.htm
- Camshaft Basics: http://auto.howstuffworks.com/camshaft.htm
- Alternative Valve Seal Replacement Guide: http://www.boompa.com/guide/valve-stem-seal-replacement/112 (Mirror: http://www.digitaldownpour.com/blog/maintenance)
- 2.0 ABA Engine Camshaft Profiles: http://forums.vwvortex.com/zerothread?id=3467526
Why Upgrade Your 2.0 ABA Camshaft?
The 2.0 ABA engine, while dependable, can benefit from improved airflow. A performance camshaft, by altering valve lift, duration, and timing, enhances engine breathing and power output. However, a camshaft upgrade is most effective when combined with a larger intake and exhaust system. Installing a camshaft without these supporting modifications will limit potential gains.
Choosing the Right Camshaft:
Camshaft selection depends on your driving style and performance goals. Consider whether your car is a daily driver or a track car, and factor in future engine modifications like forced induction or head porting. Research various camshaft profiles and their respective power bands to find the best fit for your needs. This guide details the installation of an Autotech 260 camshaft, a mild cam known for good idle quality and a broad power band.
Project Duration:
This installation typically takes around 4-6 hours, depending on your experience and whether you’re replacing additional components.
Essential Considerations Before You Begin:
- Oil Change: Perform an oil change before starting this upgrade. Running a new camshaft with old oil is detrimental.
- Timing Marks: Familiarize yourself with the stock timing marks if you’re unfamiliar with them. Precise timing is crucial for proper engine operation.
- Cooling System: This upgrade does not require opening the cooling system. However, if your timing belt is due for replacement, address the water pump simultaneously.
- Adjustable Cam Sprockets: These are generally recommended for larger camshafts and modified cylinder heads. For mild cam upgrades on stock engines, they’re usually not necessary.
Cost Breakdown:
- Camshaft: $100
- Valve Springs: $90
- Lifters: $90
- Seals, Gaskets, Belt: $50
- Specialized Tools (if needed): $120
- Chemicals/Lubricants: $30
- Total: $480 (Add a performance chip for approximately $100 more)
Important Terminology:
- Tappet, Bucket, Lifter, Cam Follower: These terms all refer to the same component.
- Spring Hat, Spring Retainer, Spring Top: These terms also refer to the same component.
Why Replace More Than Just the Camshaft?
- Timing Belt: Always replace the timing belt when performing this upgrade. Reusing an old timing belt is risky and not recommended.
- Lifters: Replace lifters with a new camshaft as they wear together and develop a specific wear pattern during break-in.
- Seals: Replace any accessible seals, including the cam seal, valve cover gasket, and valve seals, while you have access to them.
- Cleanliness: Maintain a clean work environment to prevent debris from entering the engine.
1996 and Later 2.0 ABA Engines (OBDII):
OBDII 2.0 ABA engines have single-rate valve springs. Upgrading to dual-rate or HD springs requires new spring seats (not covered in this guide). OBDII engines also use different lifters and require the older dual-rate style springs found in the OBDI design.
Step-by-Step Installation Procedure:
(Steps 1-12 involve removing the intake manifold, timing belt covers, spark plugs, valve cover, camshaft, and lifters. Detailed instructions with images are available in the original article.)
Step 13: Remove the camshaft sprocket bolt from the old camshaft.
Step 14 (Skip to Step 22 if not replacing valve springs): Use a compression tester with the air valve removed, screwed into the spark plug hole of cylinder #1, to pressurize the cylinder and prevent valves from falling into the engine.
(Steps 15-21 detail removing and replacing valve springs and seals, using a valve spring compressor tool. These steps are illustrated with images in the original article.)
Step 22: Install new lifters with ample assembly lube.
Step 23: Install the new camshaft with the lobes for cylinder #1 pointing up.
Step 24: Install a new camshaft seal with lubricant. Set the crankshaft and distributor back to TDC (Top Dead Center).
(Steps 25-30 cover installing the camshaft caps, sprocket, timing belt, and reassembling the engine. Detailed instructions with images are available in the original article. The final step involves a critical break-in procedure for the new camshaft.)
Conclusion:
Upgrading the camshaft in your 2.0 ABA engine can significantly improve performance. By following this comprehensive guide and taking necessary precautions, you can successfully complete this project and enjoy the increased power and responsiveness of your revitalized engine. Remember to consult a qualified mechanic if you encounter any difficulties during the installation process.
