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