1. Remove the valve cover. It is advisable to replace the valve cover gasket at the same time.
2. Turn the engine by the crankshaft pulley bolt using a socket or open-end wrench so that the cam lobe projections of the valves being checked are facing upward. Do not use the camshaft sprocket to turn the engine, as this will stretch the timing belt excessively.
3. Before turning the engine, it is recommended to remove the spark plugs.
4. Measure the clearance between the tappet adjusting washer and the cam using a feeler gauge (figure G:2). The location of the inlet and outlet valves is shown in Figure G:1.
5. If the result is outside the acceptable range (see section "Technical data"), remove the adjusting washers from the pushrod and replace them with a set of washers of a different thickness. Replace the adjusting washers in the following sequence:
6. To remove the adjusting washer, you need to press the pusher down. For this, it is recommended to use a special VW tool (figure G:4). If you do not have such a tool, you can use a C-shaped wrench for round nuts or a bent lever. If you use a special tool, make sure that the tappets are turned so that the slots are facing inward, as shown in Figure D:3. If you use a hand tool, make sure that it rests only on the edge of the tappet, and not on the adjusting washer. Press out the washer with a small screwdriver.
7. Install a thicker washer if the clearance is too large, and a thinner washer if the clearance is too small. Adjusting shims are available in 26 different sizes from 3.00 to 4.25 mm in 0.05 mm increments. The thickness of the washer is indicated on its underside. If the marking is illegible, measure the thickness of the washer with a micrometer.
8. Undamaged adjusting washers can be reused. Install the washer with the marking facing down, towards the tappet.
9. Adjust the clearances of other valves in a similar manner.
CAUTION: After repairing the cylinder head (replacement or grinding of valves, replacement of camshaft) it is necessary to perform the initial valve clearance setting on a cold engine - in this case, use the clearance values given for a cold engine (see section "Technical data"). Check the valve clearances after approximately 1000 km of running.
If after regrinding the valve seats the clearance is too small even with the thinnest washer installed, replace the valves with shorter ones (for more details, see the section "Cylinder head - inspection").
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