Hydraulic Tappet Replacement

[keynsham1]

On a 1.9DG engine is it possible to replace tappets with the engine installed by removing the rockers and pushrod, cutting and removing the pushrod tube, and pulling out the tappet? This does assume the availability of collapsible pushrod tubes of course, which I have heard of but never seen!

[kevtherev]

Yes, the procedure is covered in the wiki also

[itchyfeet]

https://www.vwheritage.com/shop/AC10941 ... -set-of-8/" onclick="window.open(this.href);return false;
https://www.brickwerks.co.uk/hydraulic- ... l-all.html" onclick="window.open(this.href);return false; ( out of stock atm but email them because this is a good price)

If yours are noisy then check you have the correct 1540 mineral oil, then do a reset of the preload first.
New tappets may be appealing but they may accelerate your already worn ( made of cheese) cam.

Preload is 2 turns of the tappet adjusters, when the adjusted cylinder is at tdc on compression ( rotor arm will point to the spark plug lead of that cylinder)
Once you have done it you will have to wait a few hours for the tappets to bleed down before you can start the engine.

People will tell you 1 turn or 1.5 turns is ok but I have just done this and 1 turn was noisy.

The procedure is fairly easy and explained in Haynes, I did it in half and hour on Tuesday evening but I have done it before.


rotor pointing at no1 cylinder spark plug lead and marks at TDC ( your distributor may not be in the same position look at your leads)

loosen adjusteres and then from just touching 2 turns and lock off ( a washer will do if you don't have a stubby screwdriver)


Next turn the crank clockwise 1/2 turn ( paint a mark on the inside of the pulley to make life easy) the rotor arm turns anti clockwise then adjust no 4 ,another 1/2 turn the no3 then, 1/2 turn and no2



You will need new rocker gaskets.

[123-jn]

Use SCAT BIG MOUTH telecopic pushrod tubes, £62.00 per set and they are good. The seals that come with them now are good silicone ones so you won't need to buy extras like you used to. AS you fit them twist the tubes into the seals either end it helps to seal them well. Also use a bit of silicone grease around the seals. (heritage do them and cool air used to)