Diesel Engines Adjusting tappet clearances

California Dreamin Probably the single most 'NEGLECTED' part of a diesel engine service (original 1.6D/1.7D & 1.6TD). Tappet check and adjust (replacing shims on top of the cam followers) was part of every VAG main service but as this involves 'Special Tools' (follower push down tool and shim removing pliers) your 'average' so called specialist VW garage now conveniently side steps this essential part of the service...that obviously doesn't apply to all of course.

Adjusted 'HOT' the clearances are set to: Inlet 0.20mm - 0.30mm & Exhaust 0.40mm - 0.50mm

Inlet: the 0.20 feeler gauge should go in but the 0.30 shouldn't

Exhaust: the 0.40 feeler gauge should go in but the 0.50 shouldn't

In the absence of the correct tools I suppose you could measure the gaps and then remove the camshaft. Once removed you would then need to measure each shim and work out how much smaller/larger it needed to be to get the correct clearance..all rather long winded compared to using the right tools lol.

I guess what I'm trying to emphasize is the importance of carrying out this vital maintenance. At best, incorrect clearances with cause poor running and performance, they also effect fuel consumption. At worst, closed up clearances can burnt out valves.

I've own the tools myself but ironically, I'm a wasserboxer owner lol.