Not sure on this, I haven't listened to a stage 3 cam. What did Kerma or Colt cams say?

 

Did you replace the lifters when you put the cam in?

 

Did you fine the problem? Was it a valve, injector, lifter or lack or oil pressure?

 

Daniel, have you found the problem?
I have an '05 Passat TDI.
My stage 3 Colt is quiet during normal driving but I do have a nasty tap when I'm accelerating under full throttle. I replaced the chrome lifters with the black ones in Kerma's kit. On cylinder 3 one of the chrome lifters had a small hole worn through, the cam lobe was heavily worn.

 

I'm getting ready to order a Stage 3 cam. Maybe I should hold off. Have you pulled the cover yet Bob?

 

It's my head gasket. There is a small leak that causes the coolant system to over pressurize and puke out of the overflow tank vent.
I didn't have to do any grinding on the head when I installed the cam. The install and flash went well and I do recommend going through with the install.

 

I'll be changing the gasket once I get back from my deployment to Afghanistan.

 

Well that's great. You didn't need to clearance anything? That makes this a no brainer then. I was very hesitant until hearing this.

 

I'm doing a turbo swap and nozzles. GTB2260VK with Firad +80% nozzles. Who did your tune?

 

Charlie Migliore at Kerma TDI

 

Thanks, Be safe

 

I should make it clear that I have an '05 BHW Passat. I didn't bother verifiying the cam clearance with a feeler gauge as I could see the gap clearly, and during rotation by hand.

 

I spoke with Frank @ Franks TDI about getting a Cam. He told me that a Stage 3 Cam in a BHW head would lead to head cracks and gasket problems due to excessive EGT's. Said that they do extensive porting to reduce the problem but in his opinion going that route was a waste of time and money. Maybe your problems are related? Think I'll stick with the Stage 2 Colt.

 

My issues are pre-existing, the Passat has 209,000 miles on it and the previous owner likely got rid of due to the work needing to be done.
I'm glad you got the info from Frank before making the purchase, If I'd known that beforehand I'd have hit him up for a cam vs. Colt.

 

Couple of things:
OP car was run with a lot of coolant in the oil, causing a complete failure of all the engine bearings. That was the knocking sound.

ChrisRoser, what you've been told about stage 3 cam causing cracks in the head is incorrect. High combustion pressures and temperatures can cause that damage, and the cam reduces egt not raises it. Also lowers effective compression by keeping the intake valve open longer. And removing material by "porting" can weaken the head in that critical area if it's not done correctly. When you consider those negative and somewhat drastic comments, consider that the Colt stage 3 cam requires a fresh billet grind. That's because the stage 3 dimensions are impossible to attain form a used camshaft- there is simply not enough material available on the stock camshaft lobes to regrind to colt stage 3 specs. So when you get "info" like that from a competitor without a comparable billet product, perhaps it should be considered in that context.

 

This is what a competitor sent me.

Date: Tue, 14 Apr 2015 15:46:25 +0000
From: frankstdis
To: christopherroser
Subject: Re: PD Cam questions

how strange... you are the second in as many days talking about an Allroad conversion. The other fellow is converting an ALH with BHW pistons, which I may think better in some respects... injectors for one.
We do not feel that the PD motor is appropriate for big builds, as the head has cracking issues. That is not to say we do not increase the horsepower substantially. We have some builds in excess of 200hp. But that power comes with issues.
That being said, we obtained the 200+ hp with our stage II cam and our own design port. No matter what cam, we think that improving the ports, particularly the exhaust ports, is a marked improvement in efficiency and lowered EGT's.
Right now, it's super-busy. I would be interested in working with you and discussing your options another day. I can simply say that going to any Stage III cam is born of ignorance. The lifters are an issue anyway. Taking more steps to marginalize them is, in my opinion, something that should be reserved for full-race vehicles who are interested in dominating a class, but doing so at the cost of the engine.
Frank
Frank's VW TDI's, LLC
1007 Olive St.
Lockwood, MO 65682
Fax or Ph: 417-232-4634

 

After speaking with a few trusted TDI Freaks I went with the Kerma Colt Stg 3 Cam kit. I will be having the head worked by Wild Bill.