Volkswagen Workshop Service and Repair Manuals

(not with hydraulic valve clearance compensation)

Note:

• ◆ The valve clearance should be checked and adjusted with the engine warm (coolant temperature above 35 °C, cylinder head hand-warm).
• ◆ The valve clearance is adjusted by using shims of different thickness (3.0...4.25 mm).

When repairs have been carried out on the cylinder head, the valve clearance is set with engine cold.

Note:

• ◆ If repairs have been carried out on the cylinder head for example valves renewed and ground in, camshaft renewed, the valve clearance must be checked and adjusted after approx. 1000 km with the engine warm.
• ◆ The thickness of the shims is etched on the underside. When installing the shims, ensure that the etching is downwards towards the bucket tappet. Used shims can be installed again provided that they are not mechanically damaged.
• ◆ The shims should be kept in the sorting plate with the designation 10-212.

Work sequence

• ‒ Turn the crankshaft until the pair of cams of the cylinder to be adjusted point upwards at similar angles.

• ‒ → Check valve clearance.

•      A -     Exhaust valve
•      E -     Inlet valve

• If tolerance is exceeded, try to achieve mean value when performing adjustment.

Adjusting valve clearance

• ‒ Before inserting depressing tool, turn the bucket tappets such that recesses face inwards on the intake manifold end.

Engines ä 07.82

• ‒ → Press down bucket tappet with VW 546.

Engines 08.82 ä

08.82 ä the distance between inlet and exhaust valve was increased to 39.5 mm (previously 38.5 mm). For this reason, use is to be made of the depressing tool with the designation 2078 (previously only 5 cyl. engine).

• ‒ → Press down bucket tappet with 2078.
• ‒ Lift out shim with pliers.
• ‒ Insert the required shims (lettering downwards).