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Valve Adjustment

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• READ THE MANUAL FIRST!

• You will need a FLAT surface to complete this repair for your safety.

• READ ALL OF  THIS PROCEDURE SEVERAL TIMES SO THAT YOU UNDERSTAND IT.  DO NOT PERFORM THE PROCEDURE OUT OF ORDER.  THIS WILL RESULT IN DEATH OR SERIOUS INJURY.

• Read our Safety page too.

We have available for download the complete procedure on our DOWNLOADS page

This procedure is different from the one listed in the Bentley Manual

TOOLS NEEDED:

1. 13 mm combination wrench

2. 21mm box end wrench

3. Flat head screwdriver 1/4 head

4. Flat head screwdriver 3/8 head

5. "go no-go" feeler gauge, SAE or Metric

6. 4 or more PAPER towels

7. 2 cork valve covers (or reusable rubber gaskets, as long as they do not leak, but do not forget to to clean them.)

8. NO SILICON SEALER!!!!! , ANYWHERE!

*DO NOT USE CLOTH TOWELS ANYWHERE DURING THIS PROCEDURE*

Procedure for Adjustment

1. ATTENTION: Valve adjustment is reverse of engine firing.  Firing order 1,4,3,2; Valve adjust 1,2,3,4. 

2. Engine must be COLD!

3. Align the distributor rotor to #1 TDC (Top Dead Center). The marker to line up with is where the two case halves come together.

4. Jack up or leave on the ground. (we usually take off the wheel)

5. Drop the "flip bail" down with a 21mm box end wrench. Do not use a screwdriver on the valve cover, as you can puncture it.

6. Now you should be looking at the rocker arm assembly, the 13mm locking nuts and the adjusting set screws for #1 and #2 intake and exhaust valves.  #1 is on the passenger side closest to the front of the VW.

7. Now look up the proper clearance in the Bentley manual for the valves. (They must be Cold)

8. Loosen the lock nuts on Cylinder #1.

9. Now you need the "Go-No go" feeler gauges.  

10. Slip the screwdriver through the hole of the box end of the 13mm wrench.  Hold the set screw in its adjusted position while you turn the lock nut to a tightened position.

11. Put the narrow end of the feeler gauge between the valve stem and the adjusting screw.  Turn the set screw until the gauge drags when you move it, but will not slip the rest of the gauge through.

12. Turn the crank pulley counter clockwise to Bottom Dead Center (BDC).

13. Now you are lined up for cylinder #2 which is on the passenger side closest to the rear bumper. #3 is on the Driver's side toward the front of the VW and #4 is located on the Driver's side closest to the rear bumper.

14. Repeat steps 8 through 11 for each cylinder.

15. Wet both sides of the cork gaskets with a thin layer of oil on both sides.

16. Place gasket inside the valve cover and place it up against the head.  

17. With slight pressure, push up until it stops.   

18. Use the 21mm box end wrench to pry up the flip bail into position of the recesses of the valve cover.

19. If you have it on a jack, lower the VW using the Lowering procedure.

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