Volkswagen Taro 1989 Instruction manual

VA.G Service.
Workshop Manual
VolkswagenTaro 1989 b
1.8 and 2.2 Itr.
I BOO klet Earburetorengines
I
Edition02.89
ServiceDepartment.TechnicalInformation

E" ,ne
cmLttecsIN4~l l l l l l l l l l l l l I
Booklet 1.8 and 2.2 ftr. Carburetor engines -ion 02.89
When flllng a technical instruct~onsheet, please enter the sheet number after the tltle of the Instruction.
Th~sw~llenable youto see immediately which oftheservice bulletin topics havebeenpubl~shed as tech-
n~calinstruction sheets
.--p
r~epa~rGroup T Workshop Bullet~ns
ENGINE MECHANICAL 1 1
I
I
REMOVE AND FITENGINE Ill
TROUBLESHOOTING . ENGINE TUNE-UP 111
COMPRESSION CHECK CYLINDER HEAD
l!i
+--. l
TIMING CHAIN AND CAMSHAFT CYLINDER BLOCK
--
1 l l
FUEL SYSTEM
C
1 ~ : 4
TROUBLESHOOTING ON-VEHICLE INSPECTION 1
WATER PUMP . THERMOSTAT . RADIATOR
llltl
p-
CARBURETOR . FUEL PUMP
DECELERATION FUEL CUT SYSTEM
1
,- - -
FUEL TANK AND LINE 1
----
COOLING SYSTEM
TROUBLESHOOTING
CHECK AND REPLACEMENT OFENGINE COOLANT
LUBRICATION SYSTEM 111
TROUBLESHOOTING . OIL PRESSURECHECK
,P-------.-- . - -
REPLACEMENT OFENGINE OIL AND OIL FILTER OIL PUMP
1
l
l '+
1
l
IGNITION SYSTEM
l !
TROUBLESHOOTING IGNITION SYSTEM CIRCUIT
1111
l
ON-VEHICLE INSPECTION DISTRIBUTOR 1
1
l
EMISSION CONTROL SYSTEM lil
PVC-. TP-, SD- and AS-System
I
AUXILIARY SYSTEMS
EVAP-, HAI-, CB-
and MP-System ! ,7-1
normal safety ~recautlonsto beobserved when work~ngon motorveh~clesarealso appl~cable
TheWorkshop Manual
IS only Intended for usew~thnthe
VA G Organtsat~on.andpasslng on the th~rdpartles IS not perm~tted
Prnted m German!
1989 VOLKSWAGENAG
(XX7.5016.5(1.:~

ENGINE MECHANICAL
SPECIFICATIONS
TORQUE SPECIFICATIONS
REMOVEAND FIT ENGINE
TROUBLESHOOTING
ENGINETUNE-UP
COMPRESSION CHECK
20
CYLINDER HEAD 22
TIMINGCHAINAND CAMSHAFT 38
CYLINDER BLOCK 52
I FUELSYSTEM 1 I
COOLING SYSTEM
SPECIFICATIONS
TORQUE SPECIFICATIONS
TROUBLESHOOTING
CHECK AND REPLACEMENTOF ENGINECOOLANT
WATER PUMP
THERMOSTAT
117
RADIATOR l18

I INDEX
I LUBRICATION SYSTEM I I
I EMISSION CONTROL SYSTEM I I
SPECIFICATIONS
TORQUE SPECIFICATIONS
TROUBLESHOOTING
OIL PRESSURECHECK
REPLACEMENTOF ENGINEOILAND OIL FILTER
~II PIIMP
120
120
120
121
122
123
I AUXILIARY SYSTEMS
I
COMPONENTLAYOUTAND SCHEMATIC DRAWING
POSITIVECRANKCASEVENTILATION (PCV)SYSTEM
THROTTLE POSITIONER(TP) SYSTEM
SPARK DELAY (SD) SYSTEM
AIR SUCTION(AS) SYSTEM
146
148
151
155
158

IDENTIFICATION INFORMATION
ENGINESERIAL NUMBER
The engineserialnumberisstamped
on the rightslde d the cylinder
block
GENERAL REPAIR INSTRUCTIONS
1
Use fender, seat andfloorcovers to keepthevehicleclcenand
preventdamage.
2.
Duringdisassembly.keeppansinordertoiacilite reassembly.
3 Observethefdlowing:
(a) Beforeperformingelectricalwork, disconnectthe negatlve
(-) cablefromthe batterytermtnal
(b) If8is necessarytodisconnectthe batteryfor inspectionor
repair,alwaysdisconnectthe cablefromthe negative
(-)
termlnalwhlch is groundedtothevehicle body.
(C) TOpreventdamagetothe baneryterminalpost,logsenthe
termmalnutand ralsethe caMe Rralghtupwithouttwisting
or prymg 11
(d) Cleanthe batteryterminal postsandcabieterminaiswnha
shop rag Do not scrape them with
a fileor other abraslve
object
(PI lnsta l tnecable termlnaltothe banery postwnh the nut
loose andt ghtenthe nutaner mtatlatlon Do not use a
nammeltotap the termlnal ontothe post
(Q Besurethe cover fortheposnive (+) terminal is propedy in
place.
4
Check hose'and wiringconnectorstomakesurethattheyare
Secureandcorrect
5 Non-reusablepans
(a) Always replaceconerplnsgaskets. 0-nngs, oil seals,etc.
with newones.
(b) Non-reusablepans are indicatedinthe componentillu-
strations by the
"+' symbol.

6 Precoatedpans
Precoatedpansare boksand nuts, etc thatare coated witha
seal lockadhesive(arrow)at thefactory.
(a) Ifa precoatedpanis retightend, loosened or causedto
move
In any way, itmust berecoatedwilhthespecifiedad-
hes~e.
(b) Recoatingof PrecmtedPans
(1) Cleanoff theoldadhesivefromthe pan'sthreads
(2) Dry witcomprresedair.
(3)
Applythespecifiedseallock adhesivetothe pats
threads
(c) Precoatedpansare indicafedinthe componentillustrations
bythe
'W symbol.
7 When necessaryusea sealeron gasketsto prevent leaks.
B
Carefullyobserveall specificationsfor bolttorques Alwaysuse
atorquewrench
9
Useof specialsewlcetools (SST)and special servicema-
terlals (SSM) may
be reqored,dependingon the natureof the
repalr Be sureto useSST andSSM where sDecliedand follow
the properworkprocedure. Fora llstof SST'S~~ SST catalogue
Alist of SSM can befoundat page IX
l0 When replacingfuses, besurethenewfuse 1s thecorrectampe-
rage DO
NOT exceedthe ratingor use one d alowerrating
11 Care must betakenwhenjackingupandsupponingthevehicle.
Be sure to
liff and supponthevehlcleat the proper locations
(a) Ifthe vehicle 1s to bejackeduponlyat thefronfr end,
be sure to blockthe wheels inorder to ensuresafety.
(b) Aner the vehicle isjackedup,besureto suppon il on
stands It1s extremelvdanoeroustodoanvwork on the
ve-
hicle raised on alackalone, evenfor as&ll jobthat can be
finshedquickly
l2 Observethefollowingprecautionstoavoiddamagingthe pans
(a) Be careful nottodrop electricalcomponents,suchassen-
sorsor relays Iftheyaredroppedon a hardfloor,they
should bereplacedand not reused

(b) When separatingelectrical connectors,pullonthe con-
nector
Rsdf (2).notthewires
(1)
(c) Whendisconnectingvacuum hoses, pullontheendof th~
hose (4). notthe middle (3).
(d) When steamcleaning
an engine. protectthe distributor.
coil,air filter, andcarburetorfromwater
(e) Never useanimpactwrenchto removeor installtempera-
turesw~tchesortemperature sensors
(fl When checklngcontinuityat thewire connector, insenthe
tester probecarefullyto preventterminals from bending.
(g) When usinga vacuumgauge, nwer forcethehoseonto
a
connectorthat istoo large Useastepdown adaptor m-
stead Oncethe hose has beenstretched,Rmay leak
13 Tag hosesbefore
disconnecting them:
(a) When
disconnecting vacuum hoses, usetags to identity
howtheyshould bereconnected
(1) VTV for TP. whiieside
(2)
VN for TP, black slde
(b) Aner completing
a job, doublecheck thatthevacuumhoses
are properlyconnected Alabelunder the hoodshowsthe
proper layout.
REMOVE AND FIT ENGINE
intheworkshopthe enginecanberemovedwithanoverheadcrane.When replacingtheengine tightenthe boltsse
curingtheenglne mountings. observingthetorquevalueslisted inthe tableon pageVII. Thetorduevaluesforthe
boltsbetweenengineanddrive linearelistedinthesector on ''ClutchandGear Bof' Noother specialproceedures
need to be obsewed Forthat reason,nospecial
instructions forremovingandfming theenglneare included.

STANDARD BOLT TORQUE SPECIFICATIONS
HOW TO DETERMINE BOLT STRENGTH
Class
Hexagon
head bolt head No
5-
Hexagon
1 6 Nom 4. 1
wlwasher
hexagonbolt
Hexagon
head
ball
Hexagon Welded bob
wlwasher
hexagonbolt
Hexagon
head bOiT
1 r): a, . 1
Class

SPEClnEDTORQUE FOR STANDARDBOLTS
Class
4T
Diameter
mm
Pitch
mm
l
125
125
125
15
1 5
Hexagon head bdl
Nm
HexagonRange bolt
Nm

SSM (SPECIAL SERVICE MATERIALS)

ENGINE MECHANICAL
SPECIFICATIONS
Inginetune-up Drivebelt
Dellection New belt
Used belt
Tension(Reference) New belt
Usedbelt
Enginecoolantcapacily(withHeater)
2Y
4Y
Engineoilcapacty
Dramand refill
withour Oilfllterchange Two-wheel dr~e
Four-wheeldnve
wlth Oilfilterchange Two-wheeldnve
Four-wheeldrwe
Dryfill Two-wheeldrlve
Four-wheeldrive
Baltery specific gravity
High-tensioncordreststanceLlmn
Spaw plug
Type Convent~onaltippedtype
ND
Air gap Conventionalt~ppedtype
igniliontiming(wlthVacuum advanceOFF)
4Y
2Y
Firmgorder
ldlespeed wlthour PowerSteerlng
with PowerSteer~ng
ldleminure speed wilhour PowerSteering
with PowerSteer~ng
Fastldlespeed
ldleCO concentration
ThronlePosnionersettingspeed
l 25 - l 27
(whenfullychargedat 20%)
25
kn percord
4 "BTDC @ idle
8 "BTDC @ idle
1-3-4-2
700
rpm
800 mm
750 rpm
850 rpm
2 E90 rpm
1.5 *OS%
1 200 mm

SPECIFICATION(CONT'D)
lntake
man~fold
vacuum
Compression
oressure
Cvlinderhead
Valve
guide
bush
Valve
Valve sprmg
Rockerarm
and shaft
Push rod
Chmand
sprocket
at idlesDeed
at 250 rpm Standard
Limil
Differenceof pressurebetweeneachcylinder
Warpage Cylinderblock side Limit
Manifoldslde Llm~t
Valve Seat Refacmgangle Intake
Exhaust
Contactlngangle
Contactlngwldth
Standard
Oversize
0 05
Valve overalllength Standard
Limlt
Valveface angle
Stemd~ameter
Sternoilclearance Standard
Llmit
Margln
thickness Standard
Limit
Free length
lnstaliedtensionat 40 6 mm
Squareness
lntake
Exhaust
lntake
Exhaust
Intake
Exhaust
lntake
Exhaust
lntake
Exhaust
Intake
Exhaust
lntake
Exhaust
Limit
Rockerarm lnsided~ameter
Rockershaft diameter
Rockerarm to shaft oil clearance Standard
L~mn
Circle runout Limil
Chain slackat 98
N
Chalnelongation
Crankshaftsprocketwear
Camshaft sprocketwear
Limii
Llmil
Ltmii
LlmR
400 mmQuicksilver (Hg)
90
bar
l0bar
0 15 mm
o 10mm
301.459
€8'
30'. 45'. 65'
45'
12-l6mm

SPECIFICATII
3NS (CON'
Tensloneran
damper
Valve hner
Camshaft
Cyllnder
block
Tensionerheadth~ckness Standard
Damperthickness Llmlt
Standard
Llmit
Liftdiameter
Cylinder block
lifter bare diameter
Oil clearanc Standard
Limit
Leakdowntest at
l96 N
Thrustclearance
Journal 011clearance
Journal dlameter Standard
Bearlng inslded~ameter Standard
Circle runout Llmct
Camlobe helght Standard
Standard
Llmlt
Standard
Llmlt
NO
1
NO 2
NO 3
NO 4
NO 5
NO 1
NO 2
No 3
NO 4
NO 5
Intake
Exhaust
Intake
Exhaust
Cylinder head
surface warpage Limlt
Cylinder, bore diameter
2Y Standard Mark 1
Mark2
Mark
3
Limil Standard
Overslze0 50
Overslre 0 75
Oversize 1 00
4Y Standard Mark 1
Mark 2
Mark 3
Limlt Standard
Overslze0.50

:onnectlng rod
2Y Standard
4Y Standard
Plston oil clearance
4Y
2Y
Piston ring grooveclearance
Plston ringend gap
4Y Standard
Limit
2Y
Standard
Limit
Mark l
Mark 2
Mark3
Overslze
0.50
Oversize 075
Oversize 1.00
Mark 1
Mark 2
Mark3
Oversize
050
NO. 1
NO 2
011
NO 1
No. 2
Oil
NO.
1
NO. 2
011
NO
1
NO 2
011
Thrust clearance Standard
Ltmlt
Connecting rod bearingcenter wall thickness
Standard Mark 6
Mark 7
Mark 8
023-051mm
040-067mm
013 050mm
l llmm
1
27 mm
l 10mm
022-051mm
035-067mm
013-050mm
l llmm
127 mm
l lomm
0160 0312mm
035
mm

SPECIFICATIONS(CONT'D)
Conneaing
rod (cont'd)
Crankshaft
Connealng
rod oilclearance
Standard Standard
UnderSiZeO.25
Limit
Bent Llmlt per 100
mm
Twlsl Limil per 100mm
Thrust clearance
Thrustwasherthickness
Malniournaloilclearance
Standard
Limit
Malnjournal diameter
Mainbearing
centerwall lhlckness
Standard
Standard
Limit
Standard
Standard
Undersize025
Slandard
Undersize0.25
Mark
1
Mark2
Mark
3
C."...,"..,

TROUBLESHOOTING
ENGiNEOVERHEATING
HARDSTARTING
Englneoverheats
Engmewill not cran'
or cranks slowly
Page
Problem
Possible cause
Engine
will not start,
Hardto start
(cranks OK)
Remedy
Cooling systemfaulty
Incorrect ignition timing
Poss~blecause
Staning systemfaulty
No fuel supply to carburetor
Trouble shooting
procedure coollng
system
Resettiming
Carburetor problems
. Choke operation
.Floodlng
.Needlevalvestlcklna or cloaaed
113
13.14
.Vacuum hosedisconnected or
damaged
.Fuel cut solenoidvalve not open
lgnit!on problems
.ignitlon col1
D~strlbutor
Spark plug faulty
High-tenstoncords disconnected
or broken
Vacuumleaks
. Positive CrankcaseVentilation
. Intakemanlfold
Brake booster line
Compressionlow
Remedv
Troubleshooting
procedure startlng
system
Checkfuel he
Repairas necessary
Performsparktest
Inspect plugs
inspect cords
Repairas necessav
Check
compression
Page
see manual
Electrical
System
132
I2
12
20

Remedy
inspect
plugs
lnspect
leads
Inspect c011 133
Inspect
distributor
Resettiming
Repalr as necessary
Adjust idlespeed
Repair as necessary
Reparr as necessary
Check Hot Air Intakesystem
Troubleshoot coollngsystem
Check compression
Remedy
lnspectplugs
lnspectleads
Repair as necessary
Page

ENGINEHESITATESIPOORACCELERATION (CONTD)
1 Problem Possiblecause
Incorrect lgnniontiming
Fuel systemclogged
Air cleaner clogged
Carburetor problems
.Floatleveltoo low
. Acceleratorpump faulty
Powervalvefaulty
Choke systemfaulty
Emfssloncontrol systemproblem
. Hot Alr Intakesystemalwayson
(hat engine)
. AuxiliaryAcceleration Pumpsysten
faulty (cold engine)
Engineoverheats
Low compression
Remedy
Resettiming
Checkfuel system
Check airfilter
Repairas necessary
Check Hot
Air Intakesystem
CheckAuxdiary Acceleration
Pump system
Check cooling system
Check Compression
Page
13.14
11
20
ENGINEDIESELING
Enginedtesels
(runsafter lgnmon
swltch
IS turned oHl
Problem Passlblecause I Remedy
Carburetor problems
Page
. Llnkagest~cking
. Idle speed or fast idle speedout of
adlustment
Fuelcut-out solenold faulty
Repairas necessary
BACKFIRE
Incorrect ignition tlmlng
1 Problem I Posslblecause ( Remedy I page
Mufflerexplosion
(bacMlre)on
decelerat~ononly
Resettiming
Air Suction systemfaulty
13. 14
CheckAir Suction system
I I Incorrect lgnnlontimlng I Resettiming 1 13.14
Mufflerexplosion
(bacMlre)all the time
Throttle Posnloner
Air cleaner clogged
Choke systemfaulty
CheckThrottle Positloner system
Checkair fklter
Checkchoke system
11