Adjusting valves

Post by **airhead** » 13 Nov 2006, 23:42

I tried adjusting my valves a couple of weeks back and it was not a success at all. I took the measurements, then rang to get new shims. I was then asked what size I needed. How do I find this out with the info I have, or is it just guesswork? Cause if it is, this is going to be a ridiculously expensive job cause I have to buy all the shims for each valve. There has to be a better way? Secondly, how do I get the old shims out without the special tool that VW use? And lastly, it says in the manual to rotate the engine so the cam lobes are at the top when measuring. Grand, but how the hell do I rotate by hand a diesel engine with a compression ratio of 23 to 1?? I took to leaving the van in first gear and shoving it whenever I needed to move the engine. This is a pain in the ass though.

(Anyway Ive to get my van back from having all its wires replaced after the fire before I think about this again, but no harm doing the research now)

Thanks.

Post by **airhead** » 14 Nov 2006, 01:59

Sorry, should have specified... Its a 1.6 JX turbodiesel.

Post by **Westy.Club.Joker** » 14 Nov 2006, 13:21

Measure the clearances and note down, remove the shims, work out what thickness of shims you need to make the clearances right, order/beg/steal the correct shims and then fit to buckets. Check clearances again and hope you`ve done it right, or go back to start

Special tool for removal, unless you are handy and can make something to hold the bucket down while you flick the shim out with a magnetic screwdriver.

Post by **airhead** » 14 Nov 2006, 13:47

So do I need a vernier guage to measure the existing shims and just add the extra to that to find out what size I need? How can I get the special tool? And how do I rotate the engine?

Post by **Westy.Club.Joker** » 14 Nov 2006, 13:53

Micrometer is the preferred measuring device, or a digital vernier caliper if you can use it accurately.

Measure the clearance, note it down. remove the shim and measure it. If the clearance is too BIG then add the amount it is too big to the shim thickness and you should arrive at the correct clearance. If the clearance you measured is too SMALL then subtract from the shim thickness, to gain the correct clearance.
Aim to shim it to around the minimum clearance if you can, so it shouldn`t need doing again for quite a while. If the clearances are small then you need to check regularly, if the clearance closes right up then the valve will be held off its seat, which will burn it out.