Another Jetta BRM Camshaft (Failure)

[FLIGHT316]

Soooo.... I have 97,600 miles on my '06 Special edition Jetta TDI and decided to check the cam for wear before I put it in the shop to change the timing belt. Figured that I didn't want to start on the the timing belt change only to discover that I would have to order a camshaft. To my dismay, but not much surprise, I have found several lobes badly worn. The worst being #1 and #8 valves. The engine runs fine except fr a slight shutter at idle (I assume to to the valves not opening all the way). I purchased the car with 60k on the odometer and the previous owner and I both ran Valvoline VV966, synpower 5-40W meeting VW specifications, always changed at or before VW recommended oil change intervals. Just though I would let all you other PD guys out there know that this cam issue seems more prevalent than is generally though. My opinion (for what it's worth) is that the '05 - '06 VWs are just starting to hit the mileage necessary to start seeing external signs of cam failure (i.e. engine shutter, knocking, etc.). The cam issue seems quite widespread to me, not just a few mis-manufactured cams. I included a couple of pictures of my #1 and #8 cam lobes for everyone's viewing pleasure. Not the greatest pics, but you can definitely see the chamfer on the lobe disappear due to wear. I will try to post more when I actually replace the cam and timing belt.

I am thinking about ordering the cam kit from boraparts.com. From what I've read they seem like a good supplier. I also was contemplating a performance cam, not necessarily for the performance aspect, but more to get as far away from the OEM cam design as I can. Any suggestions?? would be appreciated. Thanks in advance!

[chittychittybangbang]

Some people have used BEW engine cams instead. It has slightly less duration which means less pressure on the tip. They have not reported any loss in mpg or power but yes, it gives slightly less power. Colt does cam regrinds for performance.

And Franko6 has a nice theory about increasing oiling to the cams and using a slightly lower torque on the rocker bolt caps. He can drill out your cam caps and modify the bearings to increase oiling to the bearings and lobes.

It's quite annoying but I still like the car. And I also rent the special camshaft and timing belt tools, send a PM if interested.

[FLIGHT316]

Thanks. I have the timing belt tools, and I think that I am just going to remove the cam and sprocket assembly and separate the two when it's out of the vehicle.
I talked to Aaron at Boraparts on Monday and I am going with the BEW cam with new lifters,bearings, etc. Thanks for the reply.

[chittychittybangbang]

No problem, however, the cam bolt is tightened to around 79 ft-lbs and you don't want to use your new timing belt to counterhold that thing. That is the purpose of the cam pulley counterhold tool. I had a universal holder and it wouldn't fit around the hub.

[FLIGHT316]

Ok, wanted to post an update. Changed the timing belt and associated pulleys, water pump, camshaft (BEW in place of BRM), bearings, bolts, and lifters. Ran it for about 100 miles and noted a lot of copper flecks in the oil. Made me concerned that something was going wrong with the bearings, so I pulled the bearing caps and come to find out all five bearings were wearing extremely fast into the copper layer. I have changed bearings on other engines with no issues, so this has me perplexed. I used the manufacturers tightening procedure for the cam, made sure that there was no debris or oil on the back side of the bearings before I installed them, and used camshaft assembly lube on the cam lobes as well as the bearing surfaces. I used a micrometer to check the new camshaft bearing surface for proper diameter (compared to the old cam) and the new bearings are the same thickness as the old ones (though not anymore since they worn down). All bearings are worn about the same except for #5 which is not worn very much. The cam lobes and lifters broke in well, and look great I have attached a couple of photos of the bearings for review.

Can anyone shed any light on this issue? It would be greatly appreciated.


Bearing Cap #3. You can see where it wore into the copper.




Bearings in the head. All bearings are worn, the #5 bearing is worn, but not badly as can be seen in the photo below.

[chittychittybangbang]

...wow, something is wrong there...that is really bad wear on the bearings. I would guess low oil pressure but that doesn't seem likely.

[FLIGHT316]

Yes, I can't think of what would cause this. Seems that if there was oil starvation that the cam lobes would have suffered during break-in as well, but they all look great. Looking for some insight into why this might have happened. If anyone has suggestions I would be eager to listen.

[tbailey4]

I just went through the procedure at 85k. I did the Frank06 mod, he has a bearing kit and lots of knowledge. I went with a Colt cam (from billet steel) stage II from Kerma. I believe that this is a reground BEW cam. I also went with the black lifters from Kerma. I used Franko6 break-in procedure. I am convinced that all BRMs will experience cam bearing failure eventually and usually at 70-90k. Good luck

[FLIGHT316]

Originally Posted by tbailey4

I just went through the procedure at 85k. I did the Frank06 mod, he has a bearing kit and lots of knowledge. I went with a Colt cam (from billet steel) stage II from Kerma. I believe that this is a reground BEW cam. I also went with the black lifters from Kerma. I used Franko6 break-in procedure. I am convinced that all BRMs will experience cam bearing failure eventually and usually at 70-90k. Good luck

Did you use any special procedure to install the bearings? I've never seen this happen before.

[Buffer]

Just chiming in here. I tooam having to replace camshaft and timing belt.

125,000miles and having it done privately.

Mainly because last two times car has been to the dealer, I've specifically asked them to change belt and check cam.

Everytime they have said there's nothing wrong with it.

#1 posistion was so badly worn, it was basically square.

Hoping no serious damage was done driving car like this.

Sounds like a Massey Ferguson right now and puffing smoke like a river barge.