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Valve Clearances 200/300 TDi

Valve Clearances 200/300 TDi

Tools needed:
  • 1/2 inch ratchet
  • 1/2 inch breaker bar
  • 1/2 inch ring spanner
  • 8mm socket
  • 13mm socket
  • 27mm socket
  • 32mm viscous fan spanner
  • Flat blade screw driver.
To do this job you will need to remove the top radiator hose (you will lose a little coolant), also you will need to remove the hose from the intercooler to the inlet manifold. Next you will be able to remove the radiator cowl, plus the viscous fan (remembering that it will come off clockwise), you will need to use the 32mm viscous fan spanner to remove the fan. Now you will have access to crankshaft pulley bolt.

Next,you will need to remove the valve (rocker) cover.

A new gasket may be required,manufacturers recommend that the rubber gasket that is fitted can be reused to a maximun of 5 times,also new securing bolt washers may need to be replaced

To remove the valve cover you will need to use a 13mm socket and a suitable ratchet, but first you will need to take the breather filter off the rocker cover, you will need to use an 8mm socket and ratchet to do this, also remove the breather hose from the valve cover. Once removed you can proceed with taking off the valve cover by undoing the 3, 13mm bolts.

Now you are ready to check and adjust(if needed) the valve clearances. Using the 27mm socket and a breaker bar,turn the crankshaft pully clockwise (making sure that the gearbox is in neutral) until No 8 valve is fully open (spring fully compressed). With a feeler gauge set to 0.20mm,you can now check valve No 1. To do this you pass the feeler gauge between the valve stem,and the contact face of the rocker arm,the feeler should not be too tight,nor to loose between the arm and the valve stem.

If the clearance is not as specified use the 1/2 inch ring spanner and slacken off the adjuster locknut and turn the rocker arm adjuster clockwise (with the flat bladed screw driver) to reduce the clearance or turn the adjuster anticlockwise to increase the clearance. Once the clearance is set, lock the rocker arm adjuster with the locknut..

Repeat the process with all the valves following the table below.

Remember that the valves are numbered 1-8.

1 at the front of the engine, and 8 closest to the bulk head.

Valve fully open...................Valve clearance to be checked
No 8 ........................................................No 1
No 6 ........................................................No 3
No 4 ........................................................No 5
No 7 ........................................................No 2
No 1 ........................................................No 8
No 3 ........................................................No 6
No 5 ........................................................No 4
No 2 ........................................................No 7

When all the valve clearances have been checked,you can now refit the valve cover,gasket,reattach the breather hose and breather filter. Refit the radiator cowl and the top radiator hose along with the intercooler hose,making sure to tighten up the clips tight.

The last thing you need to do is refit the fan, again remembering that its left handed thread, ie refit it anticlockwise.
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Pete H
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