[Vwdiesel] mkII diesel valve adjustment

[LBaird119 at aol.com]

In a message dated 11/27/2011 2:41:23 P.M. Pacific Standard Time,  
vegbenz300 at gmail.com writes:

Also, I  guess that I need to go in to the valve cover, remove the pucks,
get their  tolerances, do the math to figure out what pucks are needed, then
put it  back together till I can order the pucks needed.  Is there a  
simpler
way?  Does anyone know of a good online tutorial on the  process?




There's a couple ways to do it.  You pretty much need the  spring compressor
tool (kind of a "J" shaped tool.  There's gas and diesel so you need  the 
correct 
one.  I've done it with a pair of large screwdrivers but don't know  how.  
Couldn't 
the last time I tried!
  There are puck pliers that work well most of the time.  You can  also use 
compressed air to blow them out of the tappet, or needle nosed pliers,  
small 
screwdriver, etc.
  Now to the pucks.  You have two options.  Get a  kit/collection of pucks 
so that 
you can swap as you go or pull each one, clean, read or mic the thickness,  
write 
it down.  Then measure your clearance, subtract the correct clearance  
(.010" IN, 
.018" EX, while hot) and then calculate the correct shims, see how many  
will 
swap around from the other cylinders, then order what you're short.   IIRC, 
.002" =
.05mm or, one shim thickness.  If it's off by more than .1mm, you'll  
probably still 
end up off by one thickness.  Never seems to fail when doing it by  
calculation.  At 
least you're allowed + .05mm when adjusting and + .1mm when  "checking."
  Check each cylinder when both lobes are equally "up" which is one  
forward/up and 
one back/up.
    Loren