Colt Cams Stage 3 Chilled-Cast Camshaft (ALH)

What it is
This is Colt Cams' Stage 3 camshaft for the VW 1.9L ALH TDI, chilled-cast construction, not billet. On the ALH platform, Colt doesn't offer a billet cam at any stage, chilled-cast is the material for both Stage 2 and Stage 3. Billet construction is exclusive to Colt's PD-engine cams (BEW/BRM/BHW). This is a higher-lift step up from the ALH Stage 2 cam. KermaTDI is the exclusive U.S. distributor.

What "chilled cast" means
During casting, the iron is poured and cooled rapidly, forming a hardened carbide matrix on the cam lobe surface. This gives strong scuff resistance and is the industry-standard material for quality OHC performance cams, it is not the same as a cheap generic aftermarket cam, which often can't handle the specific stresses of a VW TDI valvetrain despite looking similar.

Not a regrind
Colt Cams are manufactured new from fresh steel blanks, not reground from used factory cores. A regrind can restore lift by removing material evenly around a worn lobe (grinding off the same amount lost to wear, say 0.020", restores the effective lift, with the preload difference absorbed by the hydraulic lifters or reset in a solid-lifter valvetrain), but it can't achieve the lobe geometry of a fresh grind, and it's still working from a potentially fatigued base cam.

Warranty
5-year / unlimited-mile warranty when the cam is ordered together with lifters.

Install note: this cam requires lifter bore clearance work
Because this is a higher-lift profile than stock or Stage 2, installing it requires grinding minor clearance into the lifter bores. Steps, condensed from KermaTDI's install notes:

1. Remove the original camshaft and hydraulic lifter cups. Clean out residual oil with brake cleaner and a shop vac so metal shavings from grinding don't stick to the head.
2. With the lifter cups out, set the new cam into the head to check clearance (don't install bearing caps yet).
3. Mark the head where grinding is needed. The marker ink disappearing tells you when to stop.
4. Grind with a die grinder and carbide bit (a 6" bit works well), running the shop vac close to the grinding point to catch shavings as you go. A second set of hands helps here.
5. Once clearance is right, flush the area again with brake cleaner while vacuuming, paying special attention to the inside of the hydraulic lifter cups, that's the critical spot where leftover shavings cause problems.
6. Install the new cam and lifter cups once the head is fully clean.

A full lifter bore check and grinding procedure PDF is available separately for reference during install.

Break-in procedure
Apply cam lube to all lobes, lifter faces, distributor gears, and oil pump gears. Oil all bearing journals and lifter barrels. Rotate the engine by hand before first start, checking clearances and timing. Run the engine at 1,800-2,000 RPM for 18-20 minutes after startup. Since most modern oils have reduced anti-scuffing additives for flat-tappet break-in, KermaTDI supplies a zinc additive with every Colt Cam, use it before first startup.

Options at checkout

• Lifters, add-on
• Timing belt kit, add-on
• Camshaft seal, included at no charge

Fitment
1998-2003 VW Golf, Jetta, Jetta Wagon, and New Beetle, ALH engine.

Common questions

Is this a billet cam? No, both ALH Stage 2 and Stage 3 are chilled-cast. Colt's billet construction is exclusive to their PD-engine (BEW/BRM/BHW) camshafts.

How is Stage 3 different from Colt's Stage 2 ALH cam? Stage 3 has a higher lift profile, and installing it requires grinding minor clearance into the lifter bores, which Stage 2 doesn't need.

Do I need to do any machine work to install this cam? Yes, minor lifter bore clearance grinding is required due to the higher lift profile. KermaTDI provides a documented procedure and reference PDF for this.

Does the warranty apply if I buy just the cam? No, the 5-year/unlimited-mile warranty requires ordering lifters along with the cam.

Is this a reground factory cam? No, it's manufactured new from fresh steel blanks, not reground from a worn factory core.