Examination
Warm up the engine to operating temperature (coolant temperature above +35°C, the cylinder head should be warm to the touch).
Disconnect the fuel supply hose from the carburetor, close the holes in the hose and the carburetor pipe with plugs. Remove the cylinder head cover.
Turning the crankshaft with a wrench by the toothed pulley mounting bolt, install each camshaft cam in sequence with the back part on the end of the tappet and measure the gap between the back of the cam and the adjusting washer on the valve tappet with a set of feeler gauges.
Warning: It is not recommended to turn the camshaft directly by the pulley mounting bolt, so as not to damage the timing belt.
Adjustment
The first adjustment of valve clearances after repairs should be performed on a cold engine. Adjust the valve clearances if deviations from the permissible values are detected during the check.
Adjusting clearances in the valve drive mechanism. Checking the clearance between the back of the cam and the adjusting washer on the end of the tappet
Clearances in the valve drive mechanism
The clearance between the camshaft cams and the adjusting washers on a warm engine should be 0.25±0.05 mm for the intake valves and 0.45±0.05 mm for the exhaust valves; on a cold engine, 0.20±0.05 and 0.40±0.05 mm, respectively.
Record the clearance values Zi for each valve.
Set the valve of one of the cylinders (No. 2 1, 3, 4 or 2) to the position of maximum clearance between the cam and the adjusting washer, thus loading the tappets of the opposite cylinder (No. 2 4, 2, 1, 3), adjust the clearance.
Using the VW 546 tool, press the inlet and outlet valve tappets into the cylinder head. Rotate the tappet slot perpendicular to the camshaft axis and remove the valve adjusting washer using the special puller 10 208.
Measure the thickness T of the removed washer with a micrometer and calculate the thickness of the new washer using the formula:
Tn=T+Zi-Zn,
where:
Tn - thickness of the new washer;
T — thickness of the removed washer;
Zi - measured gap;
Zn — nominal clearance.
Select a washer of the required thickness and install it on the pusher with the mark facing the pusher.
The original text can be found on the portal (vwmanual)
Remove the VW 546 tool.
Adjust the clearances for the remaining valves in the same manner.
Final adjustment of valve clearances should be made on a warm engine if the initial adjustment was made on a cold engine.
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