COMP Cams 12-205-2 High Energy Camshaft User Manual

1. Introduction

This manual provides comprehensive instructions for the installation, operation, and maintenance of the COMP Cams 12-205-2 High Energy 206/206 Hydraulic Flat Camshaft. This camshaft is designed for Chevrolet Small Block engines, offering a strong torque profile and excellent mileage within an 800-4,800 RPM operating range. Please read this manual thoroughly before proceeding with any installation or operation to ensure proper function and longevity of your engine components.

2. Product Overview

The COMP Cams 12-205-2 camshaft is part of the High Energy series, known for blending efficiency with performance. It is specifically engineered for performance street rebuilds and is compatible with mainly stock components such as rockers, manifolds, heads, compression, torque converters, and gears.

Figure 2.1: The COMP Cams 12-205-2 High Energy Camshaft. This image displays the camshaft, a long cylindrical component with various lobes and bearing surfaces, designed to control valve timing in an internal combustion engine.

Key Features:

• Operating Range: 800-4,800 RPM
• Duration at .050": 206/206
• Lobe Separation Angle: 110 Degrees
• Valve Lift: 0.425/0.425
• Engine Compatibility: Chevrolet GEN 1 Small Blocks (262, 265, 267, 283, 302, 305, 307, 327, 350, 400). Does not fit LT1/LT4 or factory roller Small Blocks built from 1985 and newer.
• Idle Characteristics: Smooth idle
• Performance: Strong torque, excellent mileage, likes high axle ratios.

3. Safety Information

Always prioritize safety when working with automotive components. Failure to follow safety precautions can result in serious injury or damage to the product and vehicle.

• Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Ensure the vehicle is properly supported on jack stands or a lift before working underneath.
• Disconnect the battery before beginning any electrical work.
• Work in a well-ventilated area.
• Keep all tools and parts organized to prevent tripping hazards.
• Refer to your vehicle's service manual for specific torque specifications and procedures.
• This product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always wash hands after handling.

4. Setup and Pre-Installation

Before installing the camshaft, ensure all necessary tools and additional components are available. Proper preparation is crucial for a successful installation.

4.1 Required Tools and Materials:

• Basic hand tools (wrenches, sockets, screwdrivers)
• Torque wrench
• Camshaft installation tool (if applicable)
• Engine assembly lubricant (additional recommended beyond included packet)
• Gasket scraper and new gaskets (timing cover, oil pan, intake manifold)
• Clean rags and degreaser
• New lifters (recommended for new camshaft installation)
• Timing chain and gears (recommended for new camshaft installation)

4.2 Pre-Installation Checks:

1. Inspect the camshaft for any signs of damage, such as nicks, scratches, or bent lobes.
2. Ensure the camshaft journals are clean and free of debris.
3. Verify that the engine block's camshaft bore is clean and clear.
4. Confirm compatibility with your specific Chevrolet Small Block engine model (refer to Section 2).

5. Installation and Break-in Procedure

This section outlines the general steps for camshaft installation and the critical break-in procedure for hydraulic flat tappet camshafts. Always consult a professional mechanic or your vehicle's specific service manual for detailed, step-by-step instructions.

5.1 Installation Steps (General Overview):

1. Remove existing components: Drain fluids, remove radiator, fan, accessory drives, harmonic balancer, timing cover, fuel pump, pushrods, rocker arms, and lifters.
2. Remove old camshaft: Carefully slide out the old camshaft, ensuring not to damage the cam bearings.
3. Lubricate new camshaft: Apply a generous amount of engine assembly lubricant to all camshaft lobes and journals. It is highly recommended to purchase additional assembly lube as the packet included may be small.
4. Install new camshaft: Carefully slide the new COMP Cams camshaft into the engine block, rotating it slightly as needed to clear cam bearings.
5. Install new lifters: Lubricate new lifters with assembly lube and install them into their respective bores.
6. Reassemble engine: Install timing chain and gears, timing cover, harmonic balancer, pushrods, rocker arms, and other removed components. Ensure all fasteners are torqued to manufacturer specifications.
7. Adjust valve lash: For hydraulic flat tappet cams, ensure proper lifter preload according to engine manufacturer specifications.

5.2 Camshaft Break-in Procedure:

The break-in procedure is critical for the longevity of hydraulic flat tappet camshafts and lifters. Failure to properly break in the camshaft can lead to premature wear and failure.

1. Fill engine with break-in oil: Use a high-zinc break-in oil or a conventional oil with a zinc additive.
2. Prime the oil system: Before starting the engine, prime the oil system to ensure oil pressure is present at the lifters.
3. Initial start-up: Start the engine and immediately bring the RPMs up to 2000-2500 RPM. Vary the RPMs between 2000-2500 RPM for the first 20-30 minutes of operation. Do not let the engine idle for extended periods during this time.
4. Monitor engine: Continuously monitor oil pressure, water temperature, and listen for any unusual noises.
5. Cool down: After the initial break-in period, allow the engine to cool completely.
6. Change oil: After the break-in, change the oil and filter to remove any break-in debris.

6. Maintenance

Proper maintenance ensures the continued performance and longevity of your COMP Cams camshaft and engine.

• Oil Changes: Adhere to your vehicle manufacturer's recommended oil change intervals. Use high-quality engine oil with appropriate ZDDP (zinc dialkyldithiophosphate) levels, especially for flat tappet camshafts, to prevent premature wear.
• Valve Lash Inspection: Periodically check and adjust valve lash/lifter preload as per engine specifications to ensure optimal valve train operation.
• Listen for Abnormal Noises: Pay attention to any unusual ticking or clattering noises from the valve train, which could indicate wear or improper adjustment.
• Engine Tune-up: Regular engine tune-ups, including spark plug replacement and ignition timing checks, contribute to overall engine health and camshaft performance.

7. Troubleshooting

This section provides guidance for common issues that may arise after camshaft installation. For complex problems, consult a qualified automotive technician.

8. Specifications

9. Warranty and Support

For warranty information and technical support, please contact Comp Cams directly. It is recommended to retain your proof of purchase for any warranty claims.

• Manufacturer: COMP Cams
• Website: www.compcams.com (Note: This is a placeholder URL, please refer to official Comp Cams documentation for actual contact information.)
• Customer Service: Refer to the manufacturer's website for current contact methods (phone, email, support portal).