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Workshop Manual
Volkswagen Taro 1989 b
When flllng a technical instruct~onsheet, please enter the sheet number after the tltle of the Instruction.
T h ~ sw~llenable you to see immediately which ofthe service bulletin topics have been publ~shedas tech-
n~calinstruction sheets
T
.
--p
r ~ e p a ~Group
r Workshop Bullet~ns
ENGINE MECHANICAL 1 1 I
I
TROUBLESHOOTING
COMPRESSION CHECK
.
REMOVE AND FIT ENGINE
ENGINE TUNE-UP
CYLINDER HEAD
I
1
l
1
!
l l
1
i
+--. l
--
TIMING CHAIN AND CAMSHAFT
FUEL SYSTEM
CYLINDER BLOCK 1
1 ~
l l
.
C : 4
TROUBLESHOOTING ON-VEHICLE INSPECTION
p-
1
CARBURETOR FUEL PUMP l
,-
DECELERATION FUEL CUT SYSTEM
- - 1 l
1
' +
. THERMOSTAT .
CHECK AND REPLACEMENT OF ENGINE COOLANT
WATER PUMP RADIATOR l l l
l
t
I
l
LUBRICATION SYSTEM
,P-------.--
TROUBLESHOOTING . OIL PRESSURE CHECK
.--
REPLACEMENT OF ENGINE OIL AND OIL FILTER OIL PUMP
1 1
1
1
IGNITION SYSTEM l !
TROUBLESHOOTING IGNITION SYSTEM CIRCUIT 1 1 1 1
ON-VEHICLE INSPECTION DISTRIBUTOR 1 1 l
normal safety ~recautlonsto be observed when work~ngon motor veh~clesare also appl~cable
SPECIFICATIONS
TORQUE SPECIFICATIONS
REMOVE AND FIT ENGINE
TROUBLESHOOTING
ENGINETUNE-UP
COMPRESSION CHECK 20
CYLINDER HEAD 22
TIMING CHAIN AND CAMSHAFT 38
CYLINDER BLOCK 52
I FUELSYSTEM 1 I
COOLING SYSTEM
SPECIFICATIONS
TORQUE SPECIFICATIONS
TROUBLESHOOTING
CHECK AND REPLACEMENTOF ENGINE COOLANT
WATER PUMP
THERMOSTAT 117
RADIATOR l18
I INDEX
I LUBRICATION SYSTEM I I
SPECIFICATIONS 120
TORQUE SPECIFICATIONS 120
TROUBLESHOOTING 120
OIL PRESSURE CHECK 121
REPLACEMENT OF ENGINE OIL AND OIL FILTER 122
~ I PIIMP
I 123
I AUXILIARY SYSTEMS
I
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the right slde d the cylinder
block
3 Observe thefdlowing:
(a) Beforeperformingelectricalwork, disconnect the negatlve
(-) cable from the batterytermtnal
(b) If 8 is necessary to disconnectthe battery for inspectionor
repair, always disconnectthe cable from the negative (-)
termlnal whlch is groundedto the vehicle body.
(C) TOprevent damage to the baneryterminal post, logsen the
termmal nut and ralse the caMe Rralght up without twisting
or prymg 11
(d) Clean the battery terminal posts and cabieterminaiswnh a
shop rag Do not scrape them with a file or other abraslve
object
(PI lnsta l tne cable termlnal to the banery post wnh the nut
loose and t ghten the nut aner mtatlatlon Do not use a
nammel to tap the termlnal onto the post
(Q Be sure the cover for the posnive(+) terminal is propedy in
place.
5 Non-reusable pans
(a) Always replace coner plns gaskets. 0-nngs, oil seals, etc.
with new ones.
(b) Non-reusablepans are indicated in the component illu-
strations by the " + ' symbol.
6 Precoated pans
Precoated pans are boks and nuts, etc that are coated with a
seal lock adhesive (arrow) at the factory.
l 0 When replacing fuses, be sure the new fuse 1s the correct ampe-
rage DO NOT exceed the rating or use one d a lower rating
Class Class
Hexagon
head bolt head No 5-
Hexagon
wlwasher
hexagon bolt
Hexagon
16 N o m 4. 1
head ball
wlwasher
hexagon bolt
Hexagon
head bOiT
1 r): a , .1
SPEClnED TORQUE FOR STANDARD BOLTS
125
125
4T
125
15
1 5
SSM (SPECIAL SERVICE MATERIALS)
ENGINE MECHANICAL
SPECIFICATIONS
Spaw plug
Type Convent~onal
tipped type
ND
ldle speed
wlthour Power Steerlng 700 rpm
with Power Steer~ng 800 mm
Valve guide
bush Standard
Oversize
0 05
4Y Standard Mark 1
Mark 2
Mark 3
Limlt Standard
Overslze 0.50
2Y Standard Mark l
Mark 2
Mark 3
Overslze0.50
Oversize0 75
Oversize 1.00
4Y Standard Mark 1
Mark 2
Mark3
Oversize0 50
HARD STARTING
Engme will not cran' Staning system faulty Trouble shooting see manual
or cranks slowly procedure startlng Electrical
system System
Engine will not start, No fuel supply to carburetor Checkfuel h e
Hard to start
(cranks OK)
...
Carburetor problems
Choke operation
Repair as necessary
..
Floodlng
Needle valve stlcklna or cloaaed
Vacuum hose disconnected or
damaged
Fuel cut solenoid valve not open
.
lgnit!on problems
ignitlon col1
D~strlbutor
Spark plug faulty
Perform spark test
Inspect plugs
132
I2
High-tenston cords disconnected inspect cords 12
..
or broken
Vacuum leaks Repair as necessav
Positive Crankcase Ventilation
Intake manlfold
Brake booster line
inspect plugs
lnspectleads
Reset timing
Repalr as necessary
Repair as necessary
Reparr as necessary
Check Hot Air Intake system
Troubleshoot coollng system
Check compression
Remedy Page
lnspect plugs
lnspect leads
Repair as necessary
ENGINE HESITATESIPOOR ACCELERATION (CONTD)
..
Air cleaner clogged
Carburetor problems
Float level too low
Accelerator pump faulty
Power valve faulty
Check air filter
Repair as necessary
11
..
Emfsslon control system problem
Hot Alr Intake system always on
(hat engine)
Auxiliary Acceleration Pump systen
Check Hot Air Intake system
ENGINE DIESELING
..
Engine dtesels Carburetor problems Repair as necessary
(runs after lgnmon
swltch IS turned oHl Llnkage st~cking
Idle speed or fast idle speed out of
adlustment
Fuel cut-out solenold faulty
BACKFIRE
Muffler explosion
(bacMlre) on
decelerat~ononly Air Suction system faulty Check Air Suction system
Englne bacMires Choke valve open (cold engine) Check choke system
Carburetor vacuum leak Check hoses and repair
as necessary
Vacuum leak Check hoses and repair
as necessav
. Brake booster h e
Pulling ~nair between air flow meter and Repair as necessary
thronle body
Insufficient fuel flow Troubleshoot fuel system
Incorrect lgnltlon timlng Reset tlmlng
Carbon deposns m cambustton chambers Inspect cginder head
EXCESSIVEOIL CONSUMPTION
Repair as necessary
consumption
Ventllatmn system
Plston rlng worn or damaged Check rlngs
Valve stem and guide worn Check valves
Valve stem seal worn Check seals
.
Carburetor problems
Choke faulty
ldle speed too hlgh
Repair as necessary
ENGINE TUNE-UP
INSPECTION OF ENGINE COOMNT
1. Check engine coolant level at reserve tank
The coolant level should be between the'LOW'and 'FULL
hnes
If low, check for leaks and add coolant up to the 'FULL' line
-
If excessively d l w , replace the coolant.
10
2. Check engine oil level
The oil level should be between the 'C'and " F marks on the
dispstick.
If low, check for leakage and add oil up to the"P mark
INSPECTION OF BAlTERY
(See manual ELECTRICAL SYSTEM)
Normal densiiy,
1 25 - 1 27 at 20 'C when fully loaded
MA-
(b) Check the drive belt deflectton by pressmg on the belt at the
pomts indicatedin the figurewlth 10 kg of pressure
Drive belt deflection
New belt 5 - 7 mm
Used belt 7 - 8 mm
If necessary, adlust the drive belt deflectton
.
Hint
'New belt" refers to a belt which has been used less than S
mmutes on a runningengine
.'Used beir refers to a belt which has been used on a runnlng
engine for 5 minutes or more
After lnstallatingthe drive belt. check that ~tflts properly In the
rlbbed grooves
(1) Correct
(2) Wrong
Disconnect MCUI
phragm, and piu(
.
Notice
A ways m e a CO metar wnen sdjusllng the oole m nJre It
.
1s no1 neceruv to aqust ~ r l the
n d e mtnurr a0 -51 ng
Frrew n most .oh rlrz l they are n go00 conu Ion
If a CO-meter is not available and it is absolutely necessav
to adjust wlth the idle minure adjustlng screw, use the
alterndtlve method
(See page 17, 18)
2. Initial condlliona
(a) Air cleaner installed
(b) Normal operatingcoolant temperature
(c) Choke fully open
(d) All accessories swltchedoff
(e) All vacuum lines connected
(f) lgnitlon timing set correctly
(g) Transmission in neutral
I ((h) Fuel level (1) should be about even wlth the correct level In
- glass
the sioht -
(i) CO-meter operates normally
I l U) Use SST ii necessary.
SST W24300020
I EUli2,l
5. Inspect COconcemration
(a) Check that the CO-meter is properly calibrated.
(b) Race the engine at 2.500 rpm about 3 minutes.
(C) lnsen atesting p r o b a t least 40 cm into the tailpipe
(d) Measurethe concentrationwithin 1 - 3 minutes after racing
the engineto allow the concentrationto stabilize
1 If the CO concentratooncannot be W ~
ID
I by d e nnwe
adiustmenl,see tabe below for olher possfoietames
TROUBLESHOOTING
I Problems I causes
2
..
Fouled, shorted or Improperly
gapped plugs
Open or crossed lgnitlon wlres
Cracked dlstrlbutor cap
Leaky exhaust valves
3 Leaky cyl~nder
Rough idle 1
...
Vacuum leak
Vacuum hose
intake manlfold
Posithe Crankcase Ventilation line
Carburetor base
.
Incorrect float senlng
Leak~ngneedle or seat
Leaklng power valve
B. ALTERNATIVE METHOD
To be used only 1CO meter IS not available
2. Initial conditions
(a) Air cleaner installed
(b) Normal operating coolant temperature
(c) Choke fully open
(d) All accessortes switched off
(e) All vacuum llnes connected
(1) lgnltlon tlmlng set correctly
(g) Transm!sslon m N range
7 1 (h) Fuel level (1) should be about even with the correct level in
the slght glass
Hlnt Check that the fast (diecamp 1s set at the 1st step
Non-reusable part
PREPARATION FOR REMOVAL
1. Drain engine coolant (See page 114)
(b) Lilt the cylinder head from the dowels on the cylinder block
and place the head on wooden blocks on a bench
l. Remove carburetor
4. Remove valves
(a) Using SST, press the valve spring and remove the two
retainers
SST 09202-43013
(b) Remove the spring retainer (or valve rotator), spring, seat.
valve and oil seal
ir l r :....,.
3. Clean combustion chambers
Usmg a wire brush, remove all the carbon from the combustion
chambers
CAUTION Be careful not to scratch the head gasket
contact surface.
1-I
5.
/F-- U~lna
g son brush and solvent, thoroughly clean the head
CAUTION DOnot clean the head in a hot tank as thls
would seriously damage it
Inspect head for flatness
Usmg a preclslon straight edge and feeler gauge, measure the
surfaces Contacting the cylmder block and manifolds for
warp
Mav~mumwarp.
Cylinder block slde 0 15 mm
Mantfold slde 0 l 0 mm
if warp 1s greater than maximum, replace the head
Clean valves
(a) Uslng a gasket scraper, chip any carbonfrom the valve
head
(b) Uslng a wire brush, thoroughly clean the valve
(C) Using SST and a hammer, tap ouf the valve guide bush
SST 09201-60011
cMx.I
intake 107 7 mm
Exhaust 108 0 mm
(e) If the valve stem tip is worn, resurface the tip whh a grinder
or replace thevalve.
CAUTION DOnot grind off more than the minimum
amount
.
(C) Check the valve face i
If blue appears :
. concentric If no
If blue appears :
and seat are cor
Check that the S
valve face with 1'
12-t6mm
If not, correct the valve !
(1) If the seating is I
450 cuners to carre,
(2) (Intake) (1)
If the seating Is too low on the valve face, use W a n d
4S0cunersto correct the seat
(Exhaust) (2)
If the seating is too low on the valve face, use 65'and
4S0cunersto correct the seat
(3) Width
Maximum dwiatior 2 0 mm
If squareness is greater than maxlmum, replace the valve spring
(b) Using calipers. measure the free length of the valve sprlng
Free length 47 0 mm
if the free length is not as specified replace the valve sprmg
..
Note'
Thoroughly clean all partsto be assembled.
Before lnstalllngthe pans, apply new engine oil to all sliding
1. Install valves
(a) Insert the valves (6) in the cylinder head valve guide bushing.
Make sure thevalves are installedin the correct order
(b) Install thevalve spring seat (5) and a new seal (4)
(C) Installthe spring (3) and spring retainer (or valve rotator) (2)
on the valve (6)
Note lnstall the spring (7) with the yellow or white paintmark
faclng down
(d) Using SST, compress the mlve spring and place two
keepers (1) around the valve stem
SST 0920243013
(e) Uslng a plastic-facedhammer, tap the stem lightly to assure
proper f t
S. Install carburetor
1. FI cylinder head
(a) Fi a new cyllnder head gasket (1) on the cylinder block
NOTE. Observe the installationdirectton
Arrow indicatesfront
AFTER INSTALLATION
1. Fi Vacuum pipe w l h vacuum hoses to cylindl
carburetor
2. Fit heater pipe bracket to exhaust manifold
3. Connect fuel hoses t o fuel pump and carbure
4. FI air suction (AS) reed valve with air injectio~
to cylinder head
5. Fill w l h englne coolant (See page 114)
6. Stalt engine and check for leaks
7. Check engine oil level (See page 11)
TIMING CHAIN AND CAMSHAFT
COMPONENTS
Seal Washer
Cylinder Head Cover (with Gasket)
Rocker Shan Assembly
Push Rod
Valve Liner
Camshafl
Vibration Damper
Tlming Chain
Crankshan sprocket
Gasket
Crankshan Front Oil Seal
Crankshah Pulley
Timino Chain Cover
Camsian Sprocket
Chain Tensioner
Thrust Plate
PREPARATION FOR REMOVAL
1. Remove drive ben
2. Remove tan and water pump pulley
(See page 115)
5. Remove c h d n tensloner
Remove the fwo bolts and chaln tensloner
EM2349
(C) Apply engine oil to the chain tensioner body and plunger
shding suriace
(d) Fit the spring and a new chain tensioner plungerto the
chain tensloner body
(f) Using a socket wrench (1) and hammer, tap in the plate
Uslng SST, pump the plunger several tlmes to bleed the air from
the lltter
SST 09276-71010
Type (2)
Disassemble and reassemble the ilner while Immersed In dlesei
fuel Use a leak tester to install the snap rlng and the push
rod seat
INSTALIATION OF TIMING CHAIN AND CAMSHAFT
(See page 38)
4. Fk chain tensioner
Fin the chaln tensloner with the two bolts
Torque, l8 Nm
(b) Apply a light c w t of engine 011to the threads and under the
bolt heads of the pulley bolt.
(c) Using SST, fit and torque the pulley bolt.
SST 09213-70010and 0933000021
Torquc 157 Nm
AFTER INSTALLATION
F1push rods and rocker shan assembly (See steps 2
and 3 on page 36)
Fit distributor (See page 144)
Fk fuel pump
Fit water pump pulley and fan
(See pages 116. 117)
Fit and adjust drive bell
(See page 13)
Start engine and check for leaks
Check engine oil (See pages 10.11)
CYLINDER BLOCK
COMPONENTS
Piston Ring (Side Rail)
Piston Pm
Flywheel
Rear End Plate
Crankshall Rear Oil Seal
Gasket
Rear Oil Seal Retainer
Crankshall
Main Bearmg
Crankshall Thrust Washer
M m Bearing Cap
Drain Plug
Gasket
0 1 Pan
Oil P u m ~
Tlming chaln Case
Gasket
Cylinder Block
Connecting Rod Cap
Connecting Rod Bearlng
Connecting Rod
Piston
Piston Rlntl (Exoanderl
Piston R ng (No 7 Compressoan)
P ~ l o Rlng
n (No l Comprewon,
Non-reusable pan
-
PREPARATIONFOR DISASSEMBLY
Remove clutch cover and disc
Remove flywheel
Remove rear end plate
Fit engine to engine m n d for disassembly
Remove alternator and bracket
Remow oil filter bracket and oil finer
Remove cylinder head assembly
(See page 24)
Remove the rune bolts and one nut and remove the t m n g chaln
case and gasket
Remove the flve bolts rear 011seal retamer dust seal and gasket
4. Check connecting rod thrust cleamnce
Using a dial indicator,measurethethrust clearance While
mwmg the connectingrod back and lonh.
Standard t h ~ sclearance-
t -
0 1W 0 312 mm
Max~murn thrust clearance: 0 35 mm
If the clearance is greater than maximum, replacethe connecting
rod assembly.
Remove crankahatt
(a) L i i out the crankshaft
(b) Remove the upper bearings and upper thrust washers from
the cyllnder biock
NOTE Arrange the main bearing caps, bearings and thrust
washers In correct order
(1) = Upper (Cylinder Block Side)
(2) = Lower (Bearing Cap Side)
Arrow indicatesfront
INSPECTIONOF CYLINDER BLOCK
1. Removegasket material
Using a gasket scraper, remove all the gasket material from the
cylmder block surface
NOTE
*The plston and pln are a matched set
Arrange the plslons. pins, rings, connecting rods and
bearings in correct order
Standard dlameter
2Y Standard Slze
M ~ W I 85915 -85925 mm
Mark"? 85 926 - 85 935 mm
ark "3" 85 936 - 85 945 mm
Oversize 0 50 -
86 415 86 445 mm
Overslze 0 75 -
86 665 86 695 mm
Oversize l 00 86 915 86 945 mm
4Y Standard size
Mark ' l " 90 938 - 90 948 mm
Mah"? 90 949 - 90 958 mm
Mark ' 3 90 959 - 90 968 mm
BORING OF CYLINDERS
NOTE.
Bore all four cyllndersfor the oversized piston's outside
.drameter
Replacethe piston rings with ones 10 match the oversized
plslans
0921540250)
(2) = Front
(b) Coat the piston pin (3) and the piston pin hole of the piston
with engine o ~ l
(c) Using SST, press in the ptston pin (3).
l rUIW
3. Fit bearings
Fit the bearings in the connecting rods and rod caps
CAUTION- FR the bearingwith the oil hole in the
connectingrod.
LMrn91
ASSEMBLY OF CYLINDER BLOCK
(See page 52)
NOTE
Thoroughly clean all parts to be assembled
Before Installing the parts, apply new engine oil to all sitdlng
and rotatlng sulfaces
Replace all gaskets, and oil seals with new pans.
72
(c) Apply a light coat of engine oil to the threads and under the
connecting rod nuis
(d) Fit and aiiernateiy tightenthe connecting rod nuts and in
several stages.
Torque 49 Nm
(e) Check that the crankshat turns smoothly
(1) Check the connecting rod thrust clearance
(See page 55)
7. F
R rear oil seal retainer
Torque 12 Nm
9. F
R water by-pass pipe
Flt a new gasket and the water by-passpipe
POST ASSEMBLY
1. Fit oil pump and engine oil pan
(See page 126)
r-
SPECIFICATIONS
Float level
Raised position 11.0 mm
Lower position 12mm
Thronlevalve closed angle Primary P from horlzontal
Secondary 2Vfrom horizontal
Thronle valve full opening angle Primary 90'from hor~zontal
Secondary 83'from hor~zonlal
Secondary throttle valve kickup angle 2l0fromhormontal
Secondary touch angle 520 from horizontal
Fast idle angle pre-sening 15 5D from horizontal
Unloader angle 504rom horizontal
Choke breaker angle (Double diaphragm type)
1St 4o'from horizontal
so' from horizontal
Acceleration pump stroke 32mm
Idle speed angle pre-setting 120 from horizontal
2Y Screw out approx 2 318 turns
4Y Screw out approx 3 213 lurns
Choke heater resistance 17-29 R
OVCV resstance 35-43 n
PRECAUTIONS
1. Before working on the fuel system, disconnen the cable from the negative banery terminal.
2. When working on the fuel system, keep away from possible fire hamrds and do not smoke.
3. Keep gasoline on rubber and leather parts.
4. Work on only one component group at a time to help avoid confusion between similar locking parts
5. Keep work area clean to avoid contamination of the carburetor and components.
6. Be careful not to mix up or lose clips and springs.
TROUBLESHOOTING
0 Fuel cut-out solenold valve not open Check fuel cut-out colenoid valvt 92
P
I
..
Rough ldle or stalls Carburetor Droblems
Idle sbeed incorrect Adjust idle speed 15
..
slow ,et clogged
Idle mixture ,"correct Adjust Idle mlxture
Fuel cut-out solenoid valve not open Check fuel cut solenoidvalve
15
92
.
Fast Idle speed senlng incorrect Adjlrst fast Idle speed 19
(cold englne)
Choke vaive open (cold engine) /Check choke system
Engme mlsfiresi
poor acceleratton ...
Carburetor problems
Float level too low Adlust float level 98
..
Accelerator pump faulty
Power valve faulty Check power piston and valve 92
Choke valve closed (hot englne) Check choke system
Choke valve stuck open Check choke system
(cold engme)
Fuel line clogged Check fuel line
.
P
Poor gasoline
mileage .
Carburetor problems
Choke faulty
Idle speed too high
Check choke system
Adlust idle speed 15
(d) With the engine idling, blow air into the outer vent pipe (5)
(C) Stan me engine
and check that the OVCV 1s closed.
(1) Coil
(2) Chc
(3) Alr l
(4) Pur
(5) Nef
(6) Floi
(7) Ga!
(8) The
(9) Gar
(10) 0-n
(11) Gas
(12) 0-ri
(13) Sigl
(14) Gas
(15) Gar
(16) Sec
(17) Ins(
(18) ldle
(19) Car
(20) ldle
(21) Fas
(22) Fas
(23) Car
(24) Car
(25) Hot
(26) ACC
(27) Gas
COMPONENTS (Cont'd)
Plunger Arm
Thronle Posk~oner
Power Jet
Plug
Gasket
Slow Jet
Primary Main Jet
Slow Air Bleeder
Plug
Plug
Pump Discharge Weight
Auxiliary Acceleration Pump Outlet Spring
First Fuel Cut-Out Solenoid Valve
(14) Auxiliary Acceleration Pump
(15) Gasket
(16) Passage Plug
(17) Prlmary Small Venturi
(18) Step Jet
(19) Secondary Small Venturi
(20) Plug
(21) Prlmary Main Air Bleeder
(22) Secondary Main Air Bleeder
(23) Cannectlng Llnk
REMOVAL OF CARBURETOR
1. Remove air cleaner assembly or air intake connector from
carburetor
2. Disconnect carburetor connector
Disconnect the connectorfrom the main wire
3. Disconnect linkages
Accelerator connectingrod
5. Remove carburetor
(a) Remove the carburetormount nuts
(b) Lift out the carburetor
(C) Cover the Inlet hole of the intake manifoldwith a cloth
DISASSEMBLY OF CARBURETOR
The following Instructions are organized so that you work On
nntv one camoonent orouo at a tlrne. This w l i l ~ n
&o
,'n arwng irom S;! ar'pans from oltlerent suo-assemoln~s
oe ng on your worko~nrna1 the same Itme
(a) To faclhtate reassembly, arrange parts In order
(h) Be careful not to mix up or lose clips or sprlngs.
(C) Use SST (carburetor driver set)
SST 09860-1 1011
DISASSEMBLY OF AIR HORN
(See pages 82 to 85)
I. Disconnect wires lrom connector
(a) Wire of coil housing
(h) Wire of outer vent control valve (OVCV)
(1) Fuel cut solenoid valve (red)
(2) Outer vent control valve
(3) Fuel cut solenoid valve (black)
(4) Cod housing
-
lullis
1. Removethroltle posltioner
7
1 yk<l) 1
INSPECTION OF CARBURETOR
1. Inspect float and needle valve
(a) Inspect the pivot pin (1) for scratches and excesslve wear
ki::k16)
(b) inspect the float (2) for broken llps and wear In the plvot pln
SST 0924000014
NOTE This measurementshould be made without a gasket on
the anr horn
Float level (raised position) 11 0 mm
(c) Adjust by bending the portion of the float lip marked A (1)
(d) Lilt up the float and, uslng SST, check the clearance
betweenthe needle valve plunger and the float lip.
SST 09240-00020
Float level (lowered position) 1 2 mm
L IU?frn
9. F l a i r horn assembly
( a h c e the air horn in p m i b n m the M y
(h) Fit the following palls with the seven or SIX screws
(1) Vacuum hose clamp holder
(2) Air pipe bracket
(3) Wire clamp
I " a 2
ADJUSTMENT OF CARBURETOR
NOTE Use SST 0924040014 to make adjustment
I I Ibl
, , Deoendino
, on vehicle operating condtions, turn the coil
housing and adjust the engine startlng mlxture
If to rich Turn clockwise
If too lean Turn counterclockwise
(b) Wllh the choke valve fully closed, check the primary thronie
valve angle
Standard angle 15 5'from horizontal
104
INSTALLATION OF CARBURETOR
1. FB carburetor
(a) Placethe insulator on the intake manlfold
(b) Place the carburetoron the insulator
(C) Fit the four carburetor mount nuts
INSPECT10
Cutawa
(1) Return
(2) outlet
(3) Outlet
(4) Pump
(5) 011 Ses
(6) Dlaphr
(7) Inlet Vi
(8) Inlet Pi
(9) Return
l Prechecks
I
2. Check outlet valve
Block the inlet plpe with your finger and check that the arm
locks (2) do not operate wnh same amount of force used I"
the precheck above
NOTE Never use more force than that used in the precheck
This also appiles to checks 3 and 4
3. Check diaphragm
Block the Inlet, outlet and return plpes and check that the
pump arm locks (3)
NOTE If all three of these checks are not as specd~ed,the
sealing at the body and upper casing is defect~ve
Torque l 8 Nm
(e) Gradually increase the engine speed Check that the englne
mlsfres sllghtly
(q, Nnn Ine enq r w tullnq "np <g the W r nq connector to lhp
so ?nod . m e Cnec. tnal tnr r n q ne o es
(h) Stop the engine, and reconnect the wiring Remove the
tachometer
FUEL TANK AND LINE
COMPONENTS
A 56 Leer
B 65 Leer
Bolt, S pleces
A Small Type PRECAUTIONS
B LargeType l . Always use new gaskets when replacing the fuel tank or
component pans.
(1) Fuel Tank Protector (Small)
(2) Tank Protector Bracket 2. Apply the proper torque t o all tightening pans.
(3) Fuel Tank Protector (Large)
INSPECT FUEL LINES AND CONNECTIONS
(a) Inspect the fuel llnes and connections for cracks, leakage
or deformatlon
(b) Inspect the fuel tank vapor vent system hoses and
connections for looseness, kinks or damage
(C) Inspect the fuel tank for deformatlon, cracks, fuel leakage
or tank mount bolts looseness
(d) inspect the flller neck for damage or fuel leakage
(e) Hose and tube connections are as shown in the illustration
141 PiDe
-4 C
0-3mm
clip
(6) Hose
F"-!
111 Fan
(2) Flu~dCoupling
(3) Water Pump Pulley
(4) Water Pump
(5) Gasket
THERMOSTAT
REMOVAL OF THERMOSTAT
1. Drain Coolam (See page 114)
2. Disconnect radiator outlet hose from water inlet
I I INSPECTION OF THERMOSTAT
NOTE The thermostat is numbered according to the valve
openfng temperature
(a) Immerse the thermostat m water and heat the water
gradually
RADIATOR
CLEANING OF RADIATOR
Ustng water or a steam deaner, remove any mud and dirt from
the rad~atorcore
CAUTION If using a high pressure type cleaner, be careful
not to diston and damage the fins ofthe radi-
ator core If the cleaner noule pressure is 30 -
35 bar keep a distance of at least 40 - 50 Cm
between the radlator core and cleaner nozzle
INSPECTION OF RADIATOR
1. Inspect radiator cap or water outlet cap (3)
Using a mdiator cap tester (2).pump the tester untli the relief
'
valve opens. Check that the valve opens between 0.75 bar and
105 bar.
Check that the pressure does not drop rapldly when pressure on
the cap is below 0 6 bar
If either check is not within limits. replace the cap.
2. Inspect cooling system for leaks
(a) Fill the radiator with coolant and attach a pressure tester (1).
(b) Warm up the engine
(C) Pump it to 1.2 bar, check that pressure does not drop
If the pressure drops, check for leaks from the hoses, radiator or
water pump If no enernal leaks are found, check the heater
core, cylinder block and head
UBRICATION SYSTEM
PEClFlCATlONS
....., .
..
I at idle
at 3000 rpm 1 0 3 bar or more
2 5 - 5 0 bar I
011pump Body clearance Standard 0.10 -0.15mm
Lime 0.20 mm
Side clearance Standard 003-007mm
Llmlt 0.15 mm
Tip clearance Standard 007-0.12mm
Limit 0.20 mm
TORQUE SPECIFICATIONS
Pan tightened Nm
I
011 pump reilel valve sprlng plug - 0
11 pump body
011 pump cover - 011 pump body
011pump - Cylmder block
Oll pan Cyllnder block
011 pan - T m n g chain case
011pan Rear oli seai retamer
011stralner 011 pump cover
Oii strainer Cyilnder black
TROUBLESHOOTING
(d) Lightly screw in the oil filter by hand until you feel
resistance.
(e) Then. using SST, tighten a another 314 turn.
SST 09228-22020
(8) 0-ring
(9) 011Retainer. 2WD type
(10) Oil Retainer. 4WD type
.
NOTE
Do not use SST for the timing chain cover side. If necessary,
. use a screwdriver.
When removingthe oil pan, be careful not to damage the
011 pan flange
[b) Close the oil outlet hole with your thumb and turn the oil
pump shan as before. The oil pump shan should be difficult
to turn
. groove
Thoroughly clean all components to remove all the loose
. materlal
Clean bath sealing surfaces wllh a non resldue solvent
CAUTION Do not use a solvent whlch will aflect the palnted
surlaces
(b) Apply seal packing to the oil pan as shown in the figure
Seal packing.
Parl No AMV 188 200 03 or equivalent
F i t a nozzle that has been cut to f ~the
t 3 mm opening
NOTE Avoid applying an excess amount to the surface Be
exspecially careful near oil passages
.
P a r t must be assembled wnhln 15 mlnutes of application
Otherwise, the materlal must be removed and reapplled
lmmedlately remove nozzle from tube and reinstall cap
(c) Fit the oil pan with the elghteen bolts
Torque 13 Nm
IGNITION SYSTEM
SPECIFICATIONS
See page l
Sub
180 Advance beglns
224 3 1'
280 6 0'
Conventional type
(19100-73060)
Advance beglns
3 000
9 5"
Advance beglns
60'
Problem Possible cause Remedy Page
Engine will not stanl incorrect ignition timing Reset timing 13.14
hard to stan
(cranksok) ignition coil faulty inspect coil 133
Distributor faulty inspect dlstr~butor 134
l High-tensioncord faulty
Spark plug faulty
lqnnionw m q disconnectedor broken
1 inspect high-tensioncords
inspect plugs
insDect wlrlna
12
12
Contlnous muffler
/l Incorrect ign~lion
timing
incorrect lgnitiont~ming I
Reset timing
Reset timing
13-14
13-14
explosion (after flre)
(1) Banery
(2) MAIN (2 OL)
(3) Fuslble Llnk
(4) lgnltlon Swllch
(5) lgnnlon Coil Resistor
(6) lgnltlon Coil
171 C ~ andD Rotor
i8) spark Plug, Finng Order 1-34-2
(9) D!str~butor
(10) Breaker Po~nt
( l 1) Condenser
ON-VEHICLE INSPECTION
SPARK TEST
Check that spark occurs
(a) Disconnect hlgh-tension lead from distributor
(b) Hold the end about 12 5 mm from body of car
(c) See if spark occurs while engine is beina cranked
If the spark does not occur, petfor
I SPARKTEST
OK
Removedamping spring
INSPECTION OF DISTRIBUTOR
1. Inspect breaker plate
Turn the breaker plate and check that n has a sllght drag
If ~tsticks or strongly reslsts, replace the breaker plate
3. Inspect cam
Installthe cam to the governor shan and check that they fin
correctly
If they don't fin, replace the cam andlor governor shalt
(b) Uslng a pin punch and hammer, tap out the straight pln
(C) Remove the drive gear and plate washer
Removegovernor shafl
Remove the governor shafl and thrust washer
ASSEMBLY OF DISTRIBUTOR
(See page 136)
3. Install cam
(a) Install the cam on the governor shaft as shown
(4) Stopper Pln
(5) Cut-out
(b) installthe screw.
(C) Pack hlgh-temperature grease lnto the cam
(d) Press on the grease stopper with your flnger
Fit the gasket and gap with the two cap springs
Ft distributor
(a) Align the groove (2) of the housing with the drill mark (3) of
the driven gear (not driven gear straight pm)
(b) Insert the dlstribufor,allgnlngthe center of the Range with
that of the bolt hole on the cylinder block.
(C) L~ghtlytightenthe holddown bolt
System
Auxiliary system
1 Fuel evaporation control EVAP Improves re starting
2 Automat~chot air ~ntake HA1 lmproves runnlng when the englne
IScold
3 Choke breaker CB lmproves running when the englne
Is cold
A Deceleratlon a (1)
(2)
Thronle Posltloner FP)
Vacuum Sw~tchedValve
(3) Computer
Englne RPM Speed Sensor
B Deceleration (4)
To reduce HC and CO emissons, theTP opens the throttle valve slightly more than at ldle positions when
decelerating Thls causes the alr-fuel mlxlure to burn completely
Thronle valve IS
Except In the above condnlons OFF OFF TP IS RELEASED returned to the
idle posltlon
INSPECTION OF TP SYSTEM
1. Warm up engine
2. Check and if neceswy, adjust idling speed
(b) Check that the thronle positioner operates when the engine
speed is below 1980 rpm and vehtcle speed 1s above
38 kmih
(b) Check that the vacuum gauge (6) lndlcates make manlfold
vacuum at mtddie and hlgh speed drlvlng (above 38 kmlh
(5) and on englne speed below 1980 rpm
If problem is found, inspect the vacuum swttch~ngvalve and
speed sensor
(b) Reduce engine speed (3) and check that the vacuum indi-
cator (4) immediately returns to zero
To reduce HC and CO emmions, thls system draws air into exhaust ports to accelerate oxidation, using vacuum
generated by the exhaust puisallon in the exhaust manifold.
Remarks After a few seconds, vacuum In both chambers of the VCV equalize through the orifice
INSPECTION OF AS SYSTEM
l. Visually check hoses and tubes tor cracks, kinks, damage or
loose connections
2. Disconnect air suction hose from AS reed vavle
3. Check reed valve
(a) Start the englne and check that a bubbling nolse IS heard
fromthe reed valve at idle
(b) Disconnect the vacuum hose from the AS reed valve
(C) Check that a bubbling noise IS not heard
(d) Reconnect the vacuum hose
l. Check solenoid
(a) Usmg the wlring connector
(C) Heat the BVSV to above 45C with hot water (5)
(d) Check that the BVSV is open (6)
INSPECTION OF CHARCOAL CANISTER
Remove charcoal canister
Visually inspect charcoal canistel
Look for cracks or damage
(A) Len-hand Drive
(B) Rlght -hand Dnve
I This system leads a hot air supply to the carburetor m cold weather to improve driveabcliy and to prevent the
carburetorfrom ~clngI" evtremely cold weather
Temperaturem Alr Cleaner Thermo Valve Alr Control Valve Intake Atr
When the choke e closed, this system opens the choke valve slightly to prevent too rlch a mixture
Then. when the englne 1s warmed up, the choke valve is forcibly opened funher.
1 S seconds
(e) Heat the BVSV to above 21% (7) wlth hot water
(0 Check that alr (6) flows from plpe J to plpe K
(g) Apply llquid sealer to the threads of the BVSV and reinstall
(h) F111the radlator wlth coolant
If a problem IS found. replace the BVSV
INSPECTION OF JET
Check jet by blowing air horn each side
Check for blockage
/ The carburetor alr fuel mlxture is very lean When accelerating with a cold engine, the maln acceleration pump
capaclty 1s msufhent to provide good acceieration The AAP system compensates for thls by forcmg more fuel II
mto the acceierattan nozzle to obtaln better cold enqlne performance
Thls System CIJS oIJp a w h e fuel in the slow circuit of the carburetor to reduce HC and to prevent anerbumng
In the exhaust system
Engine RPM Vacuum in the Fuel Cut-Out Slow Crcuit m
Vacuum SW Vacuum SW Computer Solenoid Valve Carburetor
Below 295 mm ON ON ON OPEN
Below Oulcksllver (HG)
1980 rpm Above345 mm OFF ON ON OPEN
(HG)
Ou~cks~lver
Below295 mm ON ON ON OPEN
Above Ou~cksilver(HG)
2 410 rpm Above345 mm OFF OFF OFF CLOSED
Outckstlver (HG)
INSPECTION VACUUM SWITCH
(a) Usng an ohmmeter ( l ) , check for cont~nuitybetween the
switch lermlnals
I EC29.0
rcma3