YP, YZ, EP and OT, DS, DZ engines until July 1985
Warm up the engine (coolant temperature 35°C, cylinder head warm).
Remove cylinder head cover.
Turn the crankshaft and with it the camshaft using a socket spark plug wrench thrown over the crankshaft pulley fastening nut or by driving the car with IV gear engaged.
Warning. Do not turn the camshaft by the pulley mounting bolt, as the atom can damage the toothed belt.
Turn the camshaft, sequentially bringing out a pair of cams of the same cylinder with the backs of their heads above the ends of the pushers, i.e. when both the intake and exhaust valves of the same cylinder are closed (for example, with the valves of the 4th cylinder fully open, the valve clearances of the 1st cylinder should be measured). Measurements should be made with a set of probes with particular care, observing the order of operation of the cylinders (1-3-4-2).
Clearances in the valve drive mechanism
The gap between the camshaft cams and shims on a warm engine should be 0.25±0.05 mm for intake valves and 0.45±0.05 mm for exhaust valves, on a cold engine, respectively: 0.20±0.05 and 0.40±0.05 mm.
If the clearances are not out of range, it is not necessary to replace the valve shims.
To adjust the thermal gaps in the valve drive, proceed as follows:
- install, as indicated above, the cams of the desired cylinder with the back of the head on the ends of the pushers;
- turn the pushers with a slot perpendicular to the axis of the camshaft;
- turn the engine crankshaft ¼ turn back so that you can install the VW 546 tool and push the pushrods into the cylinder head;
- lift shim 1 with puller 10 208 (see photo) and extract it;
- select an adjusting washer of the required thickness from the kit to ensure normal clearance and install the washer with the marked surface to the end of the pusher. Spare parts are supplied with shims 3.00-4.25 mm thick with an interval of every 0.05 mm;
Note. Used shims are allowed for further operation if they do not have mechanical defects. It is recommended to store the shims in the special container 10-212.
- sequentially turning the camshaft, as indicated above, adjust the clearances of the remaining valves, observing the order of operation of the cylinders.
Check and, if necessary, finally adjust the clearances in the valve drive on a warm engine.
DT, DS, DZ engines since July 1985
Since July 1985, hydraulic tappets have been used in the valve drive mechanism of DT, OS, DZ engines, which provide automatic compensation of valve clearances.
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