1. Remove the valve cover. It is advisable to replace the valve cover gasket.
2. Turn the engine by the crankshaft pulley bolt using a socket or box wrench so that the protrusions of the cams of the valves being checked are facing up. Do not use the camshaft sprocket to crank the engine, as the toothed belt is stretched excessively.
3. It is recommended to remove the spark plugs before turning the engine.
4. Measure the gap between the tappet shim and the cam using a feeler gauge (pic. D:2). The arrangement of inlet and final valves is shown in fig. D:1.
5. If the result is out of range (see section "Technical data"), remove the adjusting washers from the tappet and replace them with a set of washers of a different thickness. Replace shims in the following sequence:
6. To remove the adjusting washer, you need to press the pusher down. To do this, it is recommended to use a special tool VW (pic. D:4). If there is no such tool, then you can use a C-wrench for round nuts or a curved lever. If you are using a special tool, make sure that the tappets are turned with the slots inward, as shown in fig. D:3. When using a hand tool, make sure that it rests only on the edge of the pusher, and not on the shim. Pry out the washer with a small screwdriver.
7. Install a thicker washer if the clearance is too large, and a thinner one if the clearance is too small. Shims are available in 26 different sizes from 3.00 to 4.25 mm in 0.05 mm intervals. The thickness of the washer is indicated on its underside. If the marking is illegible, measure the washer thickness with a micrometer.
8. Intact shims can be reused. Install the washer with the marking down, towards the pusher.
9. In a similar way adjust backlashes of other valves.
WARNING: After repair of the cylinder head (replacement or grinding of valves, replacement of the camshaft) it is required to carry out the initial setting of valve clearances on a cold engine - in this case, use the values of the clearances given for a cold engine (see section "Technical data"). Check the valve clearances after about 1000 km.
If, after regrinding the valve seats, the gap is too small even with the thinnest washer, replace the valves with shorter ones (see more in section "Cylinder Head - Inspection").
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