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The child'proof lotch of the reor door.scon be

" n g " ! J U y t i p P i n g d o w n i t s l e v e r 'T h e d o o r s
; ; ; ; " o p e n " d ' f r o i r o u t s i d eo f t e r d i s e n g o g i n g
pulling the Press'
i u n f o c t i n ' g 1t h e l o t c h b y
button.

F i g . 1 . 3 1 1I n s i d eD o o r M e c h o n i s m s
12345-

Hondle
Lock Press-button
Drop window cronk
Door pull
A s h t r o y ( d e p e n d i n go n r e o r d o o r o u t f i t )

F i g . 1 . 3 1 2C h i l d ' P r o o fL o t c h

I N S T R U M E N TP A N E L

9 1 0
F i s . 1. 3 / 3

12

1978 only'
S K O D A 1 O 5 S l n s t r u m e n tP a n e lu p t o O c t o b e r

1 - W o r n i n g l i g h t o f l e f t - h o n dd i r e c t i o n
indicotors,green
2 - Speedometer
3 - W o r n i n g l i g h t o f r i g h t ' h o n dd i r e c t i o n
indicotors,green
4 - H i g h - b e o mw o r n i n g l i g h t , b l u e
5 - T h 6 r m o m e t e r( o f e n g i n e c o o l i n g l i q u i d )

678I 10 1 11 2-

C h o r g i n gw o r n i n g l i g h t , r e d
Oil pressureworning light, reo
Distonce recorder
Fuel reserveworning light, omber
Broke sYstemworning light, red
Fuel gouge
U n o c c u P i e dg, r e e n

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W o r r r i n gl i g h t s :
5 - left-honddirection indicotors,green
6 - oil pressure,red
7 - right-hond direction indicotors,green
8 - broke system,red
9 - chorging, red
10 - fuel reserve,omber
1 1- h i g h b e o m ,b l u e

12 - unoccupied,green- fog lomp worning light

included in speciol
extros
13 - unoccupied,green- low-beomworning light
i n c l u d e di n s p e c i o l
extros
1 4 - u n o c c u p i e d r, e d

s w i t c h s w i t c h e so n t h e h e o d l o m p s t, o i l l i g h t s ,
o n d t h e l i c e n c ep l o t e l i g h t .

The thermometer indicotes the temperoture

of the coolont with the ignition switched on.
The optimum operoting temperoture ronge is
from 75 to 105oC. In SfOon 105 S, this ronge
is identified by the green zone of the scole.

The heodlights,i. e. driving (high beom) ond

dipped (low beom), ore switched on by throwing the switch to the second right-hond position. The switch switches on oll porking lights
ond the heodlights in occordoncewith the position of the switch stem-type lever: centre
position- dipped lights, towords the instrument
p o n e l- d r i v i n g l i g h t s .W h e n t h e d r i v i n g l i g h t s
ore on, the blue worning light glows.

The fuel gouge indicotes the level of the fuel

with the ignition switched on. The scole is
provided with divisions 0 - r/2- 1, i. e., empty,
holf full, ond full tonk.
The driver is worned by the red worning light
w h e n t h e n eo r e l e s s t h o n 5 l i t r e s o f f u e l i n t h e
fuel tonk.

The ouxiliory heodlomps come on ofter pull.

ing the switch knob, but only while moin heodlomps ore on.

The tochometer indicotes the speed (revolutions) of the engine. The speed should never
rise to the red zone. When chonging the geors,
on increoseof speed within the ronge of the
yellow zone is permissible.

The heodlomp flasher storts floshing when

p u l l i n g the switch lever toword the steering
wheel ring.

The porking lights come on when the switch

is thrown to the first right-hond position. The

The horn is sounded by depressingthe lever

toword the steering wheel shoft.

Fig. 1.3/6 Switches - port I

1 Porking light switch ond feederof heodlomp
dipswitch
2 - Horn switch, direction indicotor switch,
ond dipswitch
3 - Switch of ouxiliory (extro) heodlomps
4 - Door switch

Fig.1.317Switches- port ll ond oshtroy

Switchbox ond steering lock
Switch of windscreenwipers ond wosher
Heoter switch
Switch for on odditionol device- not
stondord fitted
D i s o b i l i t yw o r r n i n gl i g h t s w i t c h - n o t o n
SKoDA 105 s
Heoter control
Ashtroy

1234567-

12

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Boot lid up to 1978 - To open it, press down

t h e r e l e a s eo n t h e r i g h t - h a n ds i d e u n d e r t h ef a c i a
o a n e lT
. h e nl i f t t h e l i d o n t h e r i g h t - h a n sd i d e a n d
s e c u r ei t i n i t s r a i s e dp o s i t i o nw i t h t h e a i d o f t h e
articulatedstrut. After loweringthe lid, lock it by
go.
p
' u l l i n gt h e r e l e a s ea s f a r a s i t w i l l
S i n i e 1 9 7 8 o p e n l i d b y p u l l i n g h a n d l ea n d
l o w e ra s d e s c r i b e da b o v e .T o l o c k p r e s sl i d a b o v e
catches.

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F i g . 1 . 3 1 1 1C o n t r o l s b e t w e e n F r o n t S e o t s
1 - Geor lever
2 - Hond broke lever
3 - Choke

Fig. 1.3/13 lloot Lid Releose

Engine bonnet - To open it, pull the lever in
the operture of the left-hond reor door. To close
the bonnet, press it down with the hond into
oosition.

't488

For ony work in the engine comportment see

the notice in porogroph 1, Chopter 2'1.

F i g . 1 . 3 1 1 2S w i t c h i n g P o s i t i o n so f S w i t c h b o x
c/w Steering Lock
0 - A l l f u n c t i o n so f f , e n g i n e s t o p p i n g
| - lgnition on - ignition systemond oll ports
o l e l e c t r i c o l e q u i p m e n t o r e s u p p l i e dw i t h
current
stortll Engine storting - before repeoting the
"0" posthe
key
to
the
return
ing procedu,re,
i t i o n o n d o n l y t h e n s t o r t t h e e n g i n eo g o i n
S T O P- P o s i t i o n f o r w i t h d r o w i n g t h e i g n i t i o n
k e y o n d e n g o g i n gt h e s t e e r i n g l o c k ( o f t e r
h o v i n gw i t h d r o w nt h e i g n i t i o n k e y ,t u r n t h e
steering wheel till the lotch of the lock
c l i c k s h o m e) .
l f t h e k e y c o n n o t b e t u r n e dw h e n u n l o c k i n g
t h e s t e e r i n gr,e l i e v et h e s t r e s so f t h e s t e e r i n g
g e o r b y t u i n i n g t h e s t e e r i n gw h e e l s l i g h t l y -

Fig.

OT

Set
Cor
by thr
only r
is pro

The
ofter
lifting
bock,
by its
positi

F i g . 1 3 l M R e o r B o n n e t R e l e o s eL e v e r

Ash
tion o
open i
its cos
hold i
inworc
first it
oshtro

LUGGAGE AND ENGINE COMPARTMENTS

SEATS,ADJUSTMENTAND CONVERSION

1.4 C

T h e m o i n l u g g o g ec o m p o r t m e n t( b o o t ) i s i n
the forebody,the interior (inbuilt) luggoge
comportmenb
t e h i n dt h e r e o r s e o t b o c k r e s t s .

To moke the seot slide, unlock it by lifting

t h e l e v e r o n d t i l t t h e b o c k r e s tb y r o t o t i n g t h e
rosette.

Jqck
iock is
held in

14

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A f t e r h o v i n gc l o s e dt h e c o r r i e r( b y l i f t i n g i t ) ,
push the releoselever under the bumperto the
right os for os it will go.
F u e lt o n k - T h e f i l l e r n e c kw i t h c o p i s i n t h e
r e o r o n t h e r i g h t - h o n ds i d e o f t h e c o r - l t c o n
be locked ond unlocked by meons of the re'
spective key.

Lifting the cor with o Power iock - When

r-rsingo service Power iock, let the cor rest on
the points shown in Fi1.1.412.
To tow the cor, hook the towing rope on to
the brocket under the cor nose.Threod the pin
through the loop of the rope ond the brocket
l u g s o n d s e c u r et h e p i n w i t h o c o t t e r p i n ( b o t h
t h L p i n o n d t h e c o t t e r p i n o r e i n c l u d e di n t h e
cor occessories).

1 . 6 S T A R T I N GT H E E N G I N EA N D C H E C K I N G
ITS CORRECTRUNNING
1. Moke sure thot the geor lever is in its
n e u t r o l p o s i t i o n ,s w i t c h o n t h e i g n i t i o n ( p o s ition I on the switch box) ond wotch the
c o m i n g o n o f t h e o i l p r e s s u r eo n d c h o r g i n g
worning lights, i. e. check the function of the
olternotor- see the informotion in porogroph4.

1 . 5 S P A R EW H E E L A N D F U E L T A N K
Spore wheel - After having opened the luggoge boot lid, pull the hondle of the spore
wheel corrier releoserod. The corrier is rel e o s e do n d s w i n g s d o w n ( s p e c i o le q u i p m e n to f
the cor includeso sofety lotch behind the
bumper which hos to be pushecloside to
r e l e o s et h e c o r r i e )r .

P r e p o r e t h e e n g i n e for storting occording

to its temperoture:
- S t o r t i n g f r o m c o l d i n winter - do not touch
the occelerotorpedol ond use the full choke
- S t o r t i n gf r o m c o l d i n summer - do not touch
the occelerotorpedol ond use only holf of the
choke
- Storting o wormed-upengine - depress the
occelerotorpedol slowly to tlre toe-boord,do
not touch the choke
2 . D e p r e s st h e c l u t c h p e d o l ( o d v i s o b l e i n
summer, necessory in winter) ond stort the
e n g i n eb y t u r n i n gt h e i g n i t i o n k e y t o p o s i t i o nl l .
Let go of the key os soon os the engine fires
o n d r e l e o s et h e o c c e l e r o t opr e d o l{ i f i t h o s b e e n
clepressed).
It the engine ,refusesto fire, return the key
" 0 " o n d r e P e o tt h e s t o r t i n g
to the position
Prois wormed up, depressthe
engine
cedure.lf the
occelerotorpedol to obout one third of its totol
trovel.
lf the cold engine stolls even ofter the
second ond third storting ottemPt, enrich the
s t o r t i n g m i x t u r e b y q u i c k l y d e p r e s s i n gt h e o c c e l e r o t o rp e d o l o n c e o r t w i c e t o h o l f o f i t s
t r o v e l d u r i n gt h e n e x t s t o r t i n g o t t e m P t .
Never let tlre storter motor run for more thon
obout 5 seconds.Woit some 5 seconds before
r e p e o t i n gt h e s t o r t i n g .
Fuel is injected by every quick depressionof
the occelerotorpedol ond enriches the mixture
so thot it is difficult to ignite. lf the engine
is flooded, stort it with o fully depressedocc e l e r o t o rp e d o l .

F i g .1 . 5 / 1 H o n d l e o t S p c r e W h e e l L o c k Relecse
R o d ( f r o n r o b o v e) c r n r lS a f e t y L o t c h L . e v e r

3 . I n c r e o s et h e e n g i n e s p e e d c o r e f u l l yw h i l e
r e l e o s i n gt h e c l u t c h p e d o l . l f t h e e n g i n e s h o w s
signs of stolling, depress ogoin the clutch
pedol.

F i . 1 . 5 t 2 F u e l T c r t r kF i l l e r N e c k

16

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L' t-9', L

ENGINE
Model
- for Skodo 105 S ond 105 L

Skodo 742.10 Engine No/l

Skodo 742.12 Engine No/2
Skodo 742.12x Engine No/9

Type

four-stroke,spork-ignltion,
corburettor engine with overheod volves
4
in line
pump-circulotedontifreeze,
thermostotic temperoture control

- for Skodo 12o L

- for Skodo 120 LS

Number of cylinders
Cylinder orrongement
Cooling
Swept volume
- Skodo 105 S ond 105 L
- Skodo 12OL ond 120 LS

1,046 c. c.
1 , 1 7 4c . c .

Bore
- Skodo 105 S ond 105 L
- Skodo 120 L ond 120 LS

68 mm
72 mm

Stroke

72 mm

Compressionrotio

ii

- Skodo 105 S, 105 L ond 120 L

- Skodo 120 LS

8.5:1
9.5:1

Engine power output to CSN ond DIN

- Skodo 105 S ond 105 L
- Skodo 12O L
- Skodo 120 LS

33.9 kW (46 h. p.) ot 4,800 r. P. m.

38.3 kW (52 h. p.) ot 5,(X)0r. p. m.
42.7 kW (58 h. p.) ot 5,2(X)r. p. m.

Moximum torque
- Skodo 105 S ond 105 L
- Skodo 120 L
- Skodo 120 LS

7 4 . 5 N m o t 3 , 0 0 0r . p . m .
8 5 . 2 N m o t 3 , 0 0 0r . p . m .
9 0 . 2 N m o t 3 , 2 5 0r . p . m .

Fuel - recommendedoctone number

- Skodo 105 S, 105 L ond 12O L

- Skodo 120 Ls
Corburettortype
i

90 minimum
95 minimum
duol, twostoge, downdrought
nrodel JIKOV 32 EDSR
d i o p h r o g mp u m p , m o d e l J I K O V M F

Fuel lift pump type

CLUTCH

dry, single-plote,with direct disengogement

hydroulic

Type
Control
GEARBOX

Type

with helicol spur geas

4 forword ond 1 reverse, synchrolock on the
1st-, 2nd-, 3rd-, ond 4th-speed geors
3.8
2.12
1.41
0.96
3.27

Speeds

Geor rotios - 1st-speed geor

2nd-speed geor
3rd-speed geor
4th-speed geor
reverse geor
18

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B r o k ef l u i d :
- clossificotion
- brond filled-in in the foctrY -

SAE J 1703C
SYNTOL HD 190

FUELTANK
suspendedunder floor boord of cor reor holf
s t r o i n e ri n f u e l t o n k , f u e l f i l t e r , o n d s t r o i n e r
in corburettor

Locotion
F u e lc l e o n i n g( f i l t r o t i o n )

1.8 Tt(
BC

1. Ap
vonized
out o sL
2.tt

Generol

CHASSIS LUBRICATION
s e l f - l u b r i c o t i n bg e o r ni g s , r e p o c k i n gw i t h g r e o s e
b y g r e o s en i p p l e s ;w h e e l beoringspocked with
greose

TyPe

Threo

ELECTRICALEQUIPMENT
n e g c t i v ep o l e
12 volts
14 volts
bottery (coil) type
type AKUMA 6N 37 - 12 volts, 37 ompere-hours
1 O 5 / 1 2 OL
1976-79
35 amps
14V
1 O 5 / 1 2 OL
1979 on
42 amps
14V
120 LS
1976-79
42 amps
14V
120 LS
1979 on
55 amps
14V
type PAL Mogneton, 14 volts
t y p e P A L M o g n e t o nw i t h c e n t r i f u g o lt i m i n g
d e v i c e o n d v o c u u mu n i t
type PAL Mogneton, 12 volts
t y p e P A L M o g n e t o n ,1 2 v o l t s
0 . 6 6k i l o w o t t s ( 0 . 9 h . p . )

Eorthing
Roted voltoge
Servicevoltoge
lgnition
StorogebotterY .
Alternator
PAL Magneteton
Voltoge regulotor
Distributor
l g n i t i o nc o i l
Storter motor
S p o r k i n gp l u g s - s e e C h o P t e r1 3 7

BODYWORK
o l l - m e t o l c, l o s e d ,f o u r ' d o o r c, h o s s i s l e s sb o d y
5 occuponts
0.40 mi (0.28 rn: moin luggogecomPortmentfor
q l o o d o f o b o u t 0 k g , 0 . 1 2m r i n t e r i o r l u g g o g e
comportmentfor o lood of obout 10 kg)
hot-woter heoter with fon, fed with woter from
t h e e n g i n ec o o l i n gs Y s t e m

Type
S e o t i n gc o p o c i t y
Luggogecomportments,coPocitY
Heoter
F I L L I N GC A P A C I T I E S

4 l i t r e sm o x i m u m- 2 . 5 l i t r e s m i n i m u m
o f e n g i n eo i l
4 . 6 l i t r e sm o x i m u m- 3 l i t r e sm i n i m u m
o f e n g i n eo i l
2 . 5l i t i e so f g e o ro i l ( 2 l i t r e sw h e n c h o n g i n go i l )
0 . 1 6 l i t r e s o f g e c r ro i l ( o b o u t 0 . 2 5 l i t r e s w h e n
t o p p i n gu p )
O . 4 At i t r e s o f b r o k e f l u i d ( f i l l i n g f o r t r o p i c o l
r e g i o n s ,e t c . s e e C h o P t e r1 6 . 2 )
12.5 litres of ontif'reeze
38 litres

E n g i n e- S k o d o 1 0 5S , 1 0 5L o n d 1 2 0L
Skodo 120LS
G e o r b o xo n d f i n o l d r i v e c o s e
S t e e r i n gb o x
B r o k es y s t e mo n d c l u t c h
C o o l i n gs y s t e m
Fuel tonk

20

ENGINE

Connect

Nut of c
Nut of c
Nut of v
Nut of fr
Nut of c
Nut of s
Nut of c
Cylinder
Bolt of c
Flywhee
Bolt of cr
Oil sump
Oil sump
Droin plu
Bolt of ft
Bolt of o
Socket ol
Oil press
Sporking

CLUTCH
Connecti

Bolt foste

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8'l

iltli
GEARBOX. FINAL DRIVE
Connection

Dimensions

Nuts of cosingclompingbolts .
Nut of primoryshoft
Plnlonnut .

M
M
M
M
M
M
M
M
M
M
M
M
M
M
M

Nut
Nut
Nut
Nut
Nut
Nut

of
of
of
of
of
of

pinion beoring coP

releose sleeve bol
front cover bolt
speedometershoft clip bolt
speedometerdrive beoring bolt
reverse-georpin bolt

pin
Bolt of reverse-geor
Bolt of shifter forks
Bolt of cop of lock-bollsprings
Silentblock bolt
Bolt of differentiol cose
Bolt of crown geor
Droin ond inspection hole plugs
Switch or bolt of reversing lomps .

8
22x1.5
24x1.5
8
6
8
6
6
8
8
6
6
10
8
10x1

Tightening
torque Nmt)

22-25
35-45
40-50
14-17
6 - 8
19-25
7 - 9
7 - 9
17 -20
7 - 9
14-17
7 - 9
30-40

M 22x1.5
M 14x1

20-30
70-80
30-35
7-9

Connection

Dimensions

Tightening
torque Nmr)

Rood wheels nuts .

Nut of oxle-shoft boll ioin; boit
Nut of oxle shoft .
Bolt of broke bocking plote
Bolt of wheel cylinder

M
M
M
M
M

REAR AXLE

12x1.5
8
18x1.5
8
10

60-70
20-25
17O*)

40-50

FRONT AXIE
Connection

Dimension

Tightening
torque Nml)

Nut fostening lower wishbone fulcrum brocket to bodywork

Nut of lower wishbone fulcrum brocket
(next to rubber bush - inner)
Ditto - outer lock nut .
Nut of upper wishbone fulcrum brocket
(next to rubber bush - inner)
Ditto - outer lock nut .
Nut of upper wishbone pin (connectionwith steering
knuckle pivot)
Nut of lower wishbone pin (connectionwith steering
knuckle socket)
Nut of wheel hub beoring .
Nut of steering knuckle pivot .
Nut of lower wishbone brocket bolt .
Nut of bolt fostening shock obsorberto its onchor brocket
Nut fostening shock obsorber to bodywork
Wheel nuts
Bolt fostening front oxle to bodywork .
Bolt of onti-roll bor brocket

M 12x1.5

6s-70

, M 12x1.5
M 12x1.5
M 12x1.5
M 12x1.5

45-60
70-90

M 12x1.5

70*)

M 12x1.5
7 0* l
see Chopter 6.5, points 24 ond 25
see Chopter6.5, point 21
M10
40-50
M 12x1.5
50-55
M10
12-14
60-70
M 12x1.5
M10
40-45
M 7
12-16

*) Furthertighteningos requiredfor olignlngholesfor the cotterpin.

22

45-60
70-90

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metre), ond the relotion of 1 kpm :9.806 Nm is'

o p p l i c o b l e .W h e n o p p l i e d t o t i g h t e n i n g t o r q u e s
of bolts ond nuts, use the relotion 10 Nm :
: 1 kpm.
tW' (wott)
d) The unit of power (output)
"h.p." (horsepower)
r e p l o c e st h e f o r m e r
ond
t h e r e l o t i o n o f t h . p . : 7 3 5 . 4 9 9W i s o p p l i c o b l e .
F o r p r o c t i c o l p u r p o s e s ,o m u l t i p l e o f k W ( k i l o wott : 1,000 wotts) is used, i. e., t h. p. :
:0.736 kW.
"Po"
(poscol) or, in
e) The unit of pressure
p r o c t i c e , M P o ( m e g o p o s c o l: 1 , 0 0 0 , 0 0 0p o s c o l s )
o r k P o ( k i l o p o s c o l : 1 , 0 0 0p o s c o l s ) r e p l o c e s t h e
"bor"
"kglcmz",
former
ond
ond the following
r e l a t i o n i s o p p l i c o b l e : 1 M P o : 1 0 b o r s: 1 O . 2
kg/cm2 (kp/cm2). For current meosuringof tyre
p r e s s u r ee t c . , u s e t h e r e l o t i o n : 1 0 0 k P o : 1 b o r :
: 1 k g l c m 2 ( k p / c m , ): 1 o t m .

1.10 GENERAL INSTRUCTIONS

With the exception of o few speciol procedures or ossembly techniques mentioned in
the respective section of this monuol, every
removol ond refitting (disossembly ond reossembly) should be governed by the following
g e n e r o lp r i n c i p l e s :
o ) U s e s u i t o b l e t o o l s o n d e s p e c i o l l yt u b u l o r
box sponners which couse the leost domoge
to nuts ond bolt heods.
b) During disossembly note corefully how
t h e p o r t s h o v e b e e n o s s e m b l e d .T h i s k n o w l e d g e
is involuoble for correct reossembly.
c) Cleon ports in trichloroethylene or technicol petrol. They do not contoin substonces
(esoeciolly leod) which horm the skin os motor
petrol does. Current bronds of seoling compounds con be removed with denoturoted olcohol or scroped off. For o speciol seoling
compound see the note ot the end of this
chopter.
A v o i d c o n t o m i n o t i o n o f s e l f - l u b r i c o t i n gm e t o l
beorings with ony degreosing ogent os this
would unfovouroblyoffect their self-lubricoting
properties.
Cleon ports of the broke ond clutch hydroulic
system with olcohor.
d) Lubricote oll ports moving on or in eoch
other before their ossembly. Operoting lubric o n t s d o n o t s p r e o d e o s i l y o n d r y s u r f o c e s ,t h e
ports ore not properly lubricoted, ond friction
oreos ore opt to get domoged. Coot the ossembled ports with the lubricont which is used
t o l u b r i c o t e t h e m i n o p e r o t i o n .W h e n l u b r i c o t e d
with oil, dip the ports in motor oil, the fluidity

o f w h i c h m o k e s i t e s p e c i o l l ys u i t o b l e f o r t h i s
p u r p o s e .U s e g r e o s e s o n d h y d r o u l i c f l u i d b r o n d s
specified in the Toble of RecommendedLubriconts.
e) Use new cotter pins ond metol lock
woshers if you ore not convinced of the perfect
condition of the old ones which could breok
o n d l e o v e t h e j o i n t s u n s e c u r e d .M o r e o v e r , t h e r e
is o risk of the broken ports domoging other
functionol ports.
f) Cleon new ontifriction beorings (boll, roller, ond topered roller beorings) of preserving
g r e o s e u s i n g k e r o s e n e .P r e s e r v i n g g r e o s e i s n o t
suitoble for lubricotion ond it mixes bodly with
Iu b r i c o n t s .
g) Some of the joints hove to be tightened
with o moximum occurocy to the specified torques listed in the previous chopter.
'Ihe
p e r m i s s i b l er o t o t i o n u n b o l o n c e i s s p e h)
cified for some of the rototing ports, usuolly in
gcm (gromcentimetres). A well boloqced port
con be stopped in ony position if it is instolled
so thot no rototion resistonce octs on it. With
the exception of dynomic boloncing, the ports
ore usuolly tested on on ouxiliory shoft ploced
on the edges. The unbolonced port moves from
the deflected position with its heoviest (i. e.
unbolonced) port downword. The volue of unbolonce con be determined when fostening
o weight correspondingto the permissible unbolonce to the opposite side of the unbolonced
port. lf the port does not move when deflected
or if it moves with this weight downword; the
u n b o l o n c ei s w i t h i n t h e r e c o m m e n d e d l i m i t s .
The weight of the testing weight sholl be determined by dividing the volue of the permissible unbolonce by the distonce of the weight
from the rototion centre of the port.
i) Even slightly domogedseols ond pockings
must be reploced with new ones
Note:
In the foctory, the speciol seoling compound
"Velvonton
of the
C" brond is used for seoling
the engine reor cover on the cylinder block, the
m o t i n g s u r f o c e so f t h e g e o r b o x h o u s i n g h o l v e s ,
ond the guide of the clutch releose beoring.
This seoling compound is mode on the bose
o f o p o l y u r e t h o n e p l o s t i c o n d i t c o r r e s p o n d st o
" H y k e m o r " , " R e i n e p l o s t " ," C u r i l
K" ond similor
compounds. lt con be removed from the ports
by scroping ond woshing with ocetone, butylocetone or chlorinoted solvents, for exomple
c h l o r o f o r m ( t r i c h l o r o m e t h o n e )o n d c o r b o n t e t r o chloride.

24

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ENGIN

33
46_

o
3t32.
5'
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ENGINE

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6 . I n s c r t t h e b e o r i n g s h e l l h o l f i r - r t ot h e c o v e r
o f t h e b e o r i n g N o . - l o s d e s c r i b e d i n p o r o g r o p h4 ,
ond fit the cover with the recess for the guide
ring turned outword. Proceeding from the front
of lhe block, slip on the next guide ring with
the oil groovespointing owoy from the block so
thot itJ lip engogesogoin into the slot in the
c o v e r . C o o t t h e r i n g w- i1t 'h1 1o2i l o n d s l i p o n t h e
thrust colloron the
thrustring. Fit the MP
cronkshofi ond tighten the beoring slightly
u s i n g t h e b e l t P r r l l e Yb o l t .
7. Instoll the next two beorirrg covers corl'l'
p l e t e w i t h b e o r i n gs h e l l so n d l i g h t l y t i g h t e n l . h e
cover nuts. Press the cork seol into the reo'r
cover moking sure thot it f its the groove snugly
ond slightly bverlops the lower seoting surfoce'
Before titting the cork seols,compressthem for
o while in o vice to distort them. Insert the
distorted seols in the grooves or gops between
the cover qnd the cylinder block where they
will expond onci provide for perfect seoling.
lnsert tob woshers under the nuts of the
beoring covers ond while tightening the rruts
check their correct position so os to enoble
o s u b s e q u e n tc o r r e c t l o c k i n g o f t h e n u t s .

t h r e o d s .F i l l t h e e t r g i n ew i t h o i l o n d t h e c o o l i n g
systenr with on ontifreeze,ond bleed them.

2 . 3 R E A S S E M B L I N GT H E E N G I N E
The reossembly procedure depends on the
extent to which the engine hos been disr n o n t l e d .F o r b e t t e r u n d e r s t o n d i t r g o, r e o s s e m b l y
o f o c o n r p l e t e l yd i s n r o n t l e d e n g i n e i s d e s c r i b e d
in the following porogrophs.
lnspection of Cylinder Block
1. Clomp the thoroughly cleoned cylinder
block into the MP 9-101stond with the engine
c o r r i e r t y p e M P 1 - 1 0 1o n d c h e c k i t f o r c o m p l e t e ness - see Chopter 2.6. Fit the block with its
l u g s o n t h e e n g i n e c o r r i e rp i n s o n d u s e t h e s i d e
bolt for ltolding it down.

DK 1188

10. F
specio
end on
Drive
s u c h ro
be turn
cover. I
ever, tf
the cy
speciol
note in
1 1 .T i
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in the
covers.
hoving
does no
must ro
Then lo
wosher
ond nut

To Refi
12. R
greose i
it with i
o flywh
engine,
with rec
under tt
Chopter
bending
shoft og
powl ins
For flyw

F i g . 2 3 1 1 - C y l i n d e r B l o c k F o s t e n e do n t h e
A s s e n r b l y S t o n d b y l V l e o n so f t h e M P 1 - 1 0 - l
Corrier
2. Rernove the pressure relief volve, moke
sure thot the boll contoct {oces ore cleon, ond
r e f i t t h e c l e o n e d v o l v e . F o r rf i t t i n g o n e w v o l v e
see Chopter 2.6.
3. Removethe cronkshoft beoring covers ond
tlre i;ylinder block reor cover.

F i g . 2 . 3 1 2- M e o s u r i n g C r o n k s h o f t P l o y
1 - Thrust collor, type MP 1 112
2 - Diol indicotor in o speciolly mode yoke

To Refit the Cronkshoft

8. Rotote the cronkshoft severol times ond

using o mollet top the covers ond both shoft
ends to ensure o correct bedding of the covers
ond cronkshoft guide rings.
9. Tighten the belt pulley nut to clomp the
thrust ring, ond rotote ond force off the cronkshoft to check its ploy. The cronkshoft must be
free to rotote but without ony noticeoble ploy.
lf there is o noticeoble ploy, recheck its volue
ond odiust it by replocing the guide ring with
o new one. The moximum ploy should not exceed 0.10 mm, the recommendedminimum ploy
being 0.04 mm.

4. Force the beoring shell lrolves with the

fingersinto the cronkshoft beoring boresso thot
the shell lip snops home into the slot (cut-out)
in the block ond so thot the shells do not pro'
trude over the beoring surfoces for the beoring
covers, ond lubricote them with engine oil. Be
r;ure to fit shells motching the cronkshoft
i " : u r n o l s- s e e C h o p t e r 2 . 7 .
5. Slip the oiled guidering on the cronkshcft
"vith oil groovespointing toword the cronkshoft
'.vebond {it the cronkshoft with the pressed-on
boll beoring (see Chopter 2.7) into the shell.

30

Fig.2.3l3
Using thr

Screw
holes, for
con be u
further o1
the hond

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14. Hoving fitted the piston rings ond connectlng rods on the pistons,turn the piston ring
gops so thot they ore stoggered through 120o.
Coot the entire surfoce of the piston with the
fitted rings with oll ond insert the pistons
ossembledwith the connecting rods into the
liners in the sequence of the corresponding
numbersof cylindersond connectingrods.Moke
sure thot the orrow in the piston heod points
toword the morking of the cylinder liners, l.e.
toward the comshoft, ofter the ossembly with
the cylinder block. This is importont in thot it
does owoy with odditionol turning of the pistons in the liner ond o posslble displocement
of the piston ring gops.
Smeor the top surfoce of the cylinder block
with point or o seoling compound before instolling the liners with the pistons ond connectlng
rods into the cylinders in the order of their
numbering.
It is odvisoble to prepore o sheet sleeve or
o pilot ring occording to Fig. 2.317 to compress the piston rings when fitting the piston
Into the cylinder liners. Force the piston into
the sleeve or pilot ring so thot the piston heod
is flush with its edge or protrudes sllghtly
over it, locote the piston on the liner, ond then
force down the piston through the sleeve or
pilot ring into the liner.
15. Ploce suitoble ouxiliory devices over two
holes for cylinder heod bolts, for exomple
lorge-diometerwoshers, ond screw them down

Fig.2.3/6- Position of Cylinder Liners, Pistons

ond Connecting Rods in Engine
1 Proiectlon of cylinder liners obove the top
foce of the cylinder block (0.125- 0.155mm)
- Connecting rod splosh hole
2
'3 Arrow on the piston heod pointlng toword
the comshoft
4 - Comshoft

Fig.2.317- Pilot Ring for Piston Rings

Dimensions of pilot ring to motch cylinder
liner diometer:
dio. 68
D:68 H 7
dio. 68.25 D :68.25 H 7
dio. 68.50 D :68.50 H 7
dia.72
D:72 H7

Fig. 2.3/8- Fitting Piston into Cylinder Liner

U s i n gt h e P i l o t R l n g
1 - pilot ring
2 - c y l i n d e rl i n e r

32

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11
s e 6 n o 6 J e l e e l p u o e l n r o 6 u 1 s 1 ' '1l l D q s I U o r c e q l
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greot thot it connot be corrected by rototing

the distributor, remove the timing geor cover,
rotote the distributor slightly ond repeot the
entire procedure of refitting the timing geor
cover.
26. Smeor the protruding end of the cronkshoft ond the outer shoft end (stem) of the belt
p u l l e y w i t h o i l , f i t t h e b e l t p u l l e y ,t h e n e s p e c t i v e
wosher, ond tighten the bolt. Bolt the PumP
suction stroinertothe cronkshoft centre beoring
ond use o spring wosher under the bolt heod.
27. Bolt down the timing geor cover using
s p r i n g w o s h e r s o n d c h e e s e - h e o db o l t s ( e x c l u s ively) cnd finolly fosten the timing geor cover
in such o position thot the contoct breoker
p o i n t s o p e n b e f o r e t h e c r r o n k s h o f tw i t h t h e c o n necting rod ond piston hos ottoined the top
deod centre (TDC) position (see the lgnition
Timing Toble in Chopter 15.3).
F o r c h e c k i n g t h e i g n i t i o n o d v o n c e ,o n e l e c t r i c
power supply is requiredwith o bulb connected
in o circuit with the distributor. this circuit
being interrupted by the oction of the contoct
breoker.
An odopted conventionol torch with o metol
iocket con be used with odvontoge for this
purpose.
Remove the flywheel powl ond set the required ignition odvonce by turning the cronks h o f t w i t h o s c r e w ' d r i v e ri n s e r t e d i n t o t h e g e o r
ring ond propped ogoinst the cylinder block
f l o n g e . R o t o t e t h e s h o ft o n t i c l o c k w i s e o b i t
more thon necessoryond bock it off so os to
o d i u s t t h e b o c k l o s ho f t h e t i m i n g g e o r s o n d t h e
distributor drive geors.

p r i m o r y f e e d t o t h e d i s t r i b u t o rc o i n c i d e sw i t h
t h e c o n n e c t i n g l i n e o f t h e d i s t r i b u t o rc e n t r e
line ond the first cylinder heod bolt os per
F i g . 2 . 3 l 1 0 .S e c u r et h e d i s t r i b u t o ri n t h i s p o s i t i o n b y l i g h t l y t i g h t e n n i n gt h e t i e - b o l t o n d
r e m o v et h e t i m i n g g e o r c o v e r f r o m t h e c y l i n d e r
b l o c k .T h e u s e d t y p e o f d i s t r i b u t o ri s d e s c r i b e d
in Chopter 13.5.

F i g . 2 . 3 l 1 0- P o s i t i o n o f D i s t r i b u t o ro n E n g i n e
-l -

screw of primory power feed

2 - cylinder heod bolt
3 - index line rnorking the position of the
distributor ornrwhen cvlinder No. 1 f ires
24. Coot with oil the moting surfocesof the
timing geor cover ond the cylinder block, locote
the cover gosket on the block, oil the timing
choin ond the comshott worm geor. Removethe
f lywheel powl ond rotote the cronkshoft through
360o so os to bring tlre pistons of the cylinders
No. 1 ond 4 to their TDC position ogoin. This
p o s i t i o n c o r r e s p o n d so p p r o x i m o t e l y t o t h e v o l v e
geor position when the cylinder No. 1 f ires (the
tips of the coms of cylinder No. 1 ore turned
downword, owoy from the engine). Lock the
cronkshoft in position by refitting ond tightening the flywheel powl.
25. Turn the distributor orm in the direction
of the screw (1) in occordoncewith Fig. 2.3110,
hold it down with the finger in this position,
o n d r e fi t t h e t i m i n g g e o r c o v e r o n t h e c y l i n d e r
block. By sliding the worm geor of the distributor drive into the comshoft worm geor, the orm
is turned to coincide with the timing mork for
cylinder No. 1 on the distributor housing. lf
t h e r e i s n o c o i n c i d e n c eo f t h e o r m o n d t i m i n g
m o r k , o dj u s t t h e p o s i t i o n o f t h e o r m b y s l i g h t l y
rototing the distributor.
lf the misolignment of the distributor ornr
o n d t h e t i m i n q m o r k o f t h e c v l i n d e rN o ' 1 i s s o

34

oK6ls
F i 9 . 2 . 3 1 1 1 -L o m p f o r C h e c k i n g t h e O p e n i n g
of Contoct Breoker Points
- 1t o r c h c o m p l e t ew i t h d r y c e l l o n d b u l b
2 - leod with olligotorclomp
3 - botterv cell
4 - torch coo
5 - contoct spring
6 - i n s u l o t i n gp l o t e
7 - e l e c t r i c o l - c o n t o c tc o n n e c t i o n o f t h e l e o d
with the drv cell

Con
using
torch.
the br
slowly
indico
A corr
is not
timing
28.L
beorin
Then f
while
oil sun
the thr
the tyl
see Cl.
s h r in k s
of the
woter
move i
ively.
To Fit
Toppet

25. r

remove
positio
sure thr
cylinde
cylinde
n u t s .F <
first bo
woteir p
oir clec
finol ti1
2.16.
Ploin
heod bo
which t
wosher
no wos
heod bo
cy I i nder
the outs
hove to
of the rc
Tighte
broce or
30. Sc
thermom
into the
cosingo
ofter ho
Use spri
thermos
cooted g
with the
with the
The th
s h o u l db

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eql uMop lloq puD pDeq rapur;{c eq} o}ul
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sql jo slnu eqt Jo] peilnba: erD sleqsDM ou
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slloq onnl orll lo uolldacxa eql ql!M stloq poerl
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.91'Z
raldoq3 eas 'cla slloq eq] ;o 6urualqDll lDull
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eql llDlsul 'lloq prlql eq] ol reploq edld ialoM
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spring woshers under the pump fostening nuts.

36. lnstoll the oil filter - see Oil Filter in
Chopter 15.3.
37. Bolt the brocket ond the reloy lever of the
occelerotorlinkoge to the intoke monifold, Use
spring woshersto lock the bolts in position.
38. Locote the corburettor gosket, sheet
guord, onother gosket, the insuloting wosher,
ond o third gosket (oltogetherthree goskets of
the some type) on the intoke monifold inlet
socket, instoll the corburettor, ond tighten it
down with nuts.
On 105 ond 120 l- engines, the sheet guord
must be fitted to the intoke monifold inlet
socket with o throttling spider, while 120 LS
engines must hove the possoge unobstructed.
39. Smeor the boll pins of the linkoge ond
corburettorlever with greosecontoining molybdenum disulphide ond mount on them the occelerotor link (tie-rod). Hold the link in pliers
ond slip securingclips over the heods.
Hook o spring on the shonk of the reloy linkoge boll pin ond on the rib of the forehousing
on the corburettor.
40. Screw down the vocuum control pipe on
the corburettor (using double-sided seoling
rings) ond slip on the rubber hose connecting
the pipe with the distributor vocuum control
unit. Securethe pipe by bending the clip under
the nut of the intoke ond exhoust monifold.
To Refit Alternotor
41. Attoch the olternotor brocket to the side
of the cylinder block while putting ploin
woshers under the nuts. Mount the olternotor
holder together with the engine mounting lug
on the bolt of the timing geor cover ond the
front lug of the cylinder block. Use self-locking
nuts for the bolts f ostening the olternotor
holder.Lock the lower bolt of the lug by meons
of o spring wosher ond nut. Using onother bolt,
bolt together the lug ond the brocket. lnsert
the tie-bolt from the side of the lug, slip on
o ploin wosher ond tighten the nut. Fit the
short-circuit strip on the bolt ond lock it in
o position porollel with the olternotor brocket
by screwing down the respective nut with
o ploin wosher.
42. Put the olternotor into the holder, ttrreod
in the bolt, ond screw down the nut with o ploin
w o s h e rw i t h o u t t i g h t e n i n g .W i t h o u t t i g h t e n i n g
the self-locking nut, bolt the strut into the
brocket on the cylinder heod. Swing the olternotor toword the engine, fit the V-belt ond,
w h i l e t e n s i o n i n gi t , c o n n e c tt h e o l t e r n o t o rw i t h
the strut using o bolt, spring wosher ond nut.
At the some time, tighten the nut of the bolt
holding down the olternotor in the holder ond
the nut of the bolt connecting the strut with
the holder. For the belt slock odiustment see
Chopter 15.3.

43. Fosten the second engine mounting lug

using nuts with spring woshers.
To Fit Cylinder Heod, Air Cleoner,
ond Sporking Plugs
44. Fit the cylinder heod with cemented.on
gosket on the cylinder block ofter hoving slipped o seoling ring ond o wosher on eoch bolt,
the some os in the cose of the push-rodcover.
In oddition, fit the fuel pipe holder on the reor
b o l t o n d h o l d i t d o w n b y s l i g h t l y t i g h t e n i n gt h e
nut.
45. Fit the oir cleoner in position ond fosten
it to the corburettorwith o bolt using o seoling
ring ond wosher. Put o spring wosher under the
nut on the brocket ond screw down the nut on
the bolt of the cover without ony wosher.
46. Threod the fuel hose through its holder
on the cylinder heod ond use clips to fosten it
to the corburettor ond pump. Adiust the most
suitoble position of the hose by rototing the
holder ond then tighten the nut.
47. Attoch hoses connecting the oir cleoner
with the corburettorond the oil filler neck.
When preporingthe cc for driving in winter,
instoll the winter oir-intoke tube (hose) - for
detoiled instructions see Chopter 15.3 "Air
Cleoner- Winter Operotion".
48. Screw in the sporking plugs with seoling
iings ond fit the ignition cobles. For the recommendedtypes of sporkingplugs see Chopter
13.7.
The outlet on the distributorcop morkedwith
o notch is intended for the coble to cylinder
No. 1. The remoining outlets ore.to be counted
clockwise ond in direct order from 1 to 4 ond
the cobles will be connected to sporking plugs
in the order of numbers cost on the cylinder
heod beside the recessesfor sporking plugs.
Plug Screws ond Lubricotion System
Accessories
49. Plug the oil sump with the conicol screw
p l u g w i t h i t s s e o l i n gr i n g . I n t h e c o s e o f o n
e n g i n e w i t h o u t t h e o i l c o o l e r ,p l u g t h e o i l w o y
on the timing geor cover with o screw plug
w i t h o s e o l i n gr i n g , o n d t h e o i l w o y o t t h e r e o r
end of the cylinder block with o pressure
switch. lf the socket for screwing down the
pressureswitch is missing,instoll o new socket
together with its respectiveseoling ring.
lf on oil cooler is provided,hosesond o pressure switch should be connected to the oilwoys
occordingto Chopter 11.9.
Put the oil dipstick with the f itted rubberring
in its ploce. For the type of the dipstick see
Chopter 2.17.
50. Using spring woshers with the bolts,
screw down the flywheel guorclofter removing

36

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- u ! l A o a ( 1 u o s l l o q o q l e n o u r o ru e q l p u D e 6 u o l l
rll
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'loLl
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'g'7 leldoq3 aes A l q r u e s s Ds l t r o 1 s D
p u D l s e r u D So r l ] 6 u r s n a u r 6 u e e q ] e l l u D u r s r C. l

r a l l n d s O L ' Ld y \
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r . l l r Mp u a J a q l o s l ! J o l s r a q s o M 6 u r . r d sp u o u r o ; d
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'sJaqsoM
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lsel e{Dr8 eroleS ro rDc u!

e u ; 6 u 3 6 u ; 1 ; o g s u ; e ge r o l e g u o ; l o r e d g ; o u 1 3
'I;qtues
-so aur6ua at{t 6ultelduroc uor}orado 1ou1e
; qt
s ! s l q l ' l e e q r r r r A 1alq l u r o r f s e l P u o q f u o 1 1 1 x naoq 1

6n; 6ur1

t z-E'z

( D e u t s c h eI n g e n i e u rN o r m e n ) , i . e . w i t h o l l o c '
cessoiresreducing the gross engine horsepower
(woter pump, olternotor, oir cleoner, exhoust
silencer). The effective horsepower con vory
with respect to the diogrom volues within
o toleronce limit of minus 100/s.
Every engine ofter o top overhoul or reploce'
ment of individuol ports of the cronk mech'
onism hos to be run'in exoctly like o new
engine. Do not forget to drow your customer's
ottention to this foct!

5. Use the MP 1'105 puller for removing

cylinder liners from the block. Turn the centre
bolts of the iig to expond the iig iows in the
cylinder liner (ot the top flonge of the liner)
ond pull out the liner by turning the vwench.
6. Before removing the comshoft, lift owoy
the volve toppets. lf o removol of the cylinder
heod is not considered,releosethe boll pins of
the rocker orms, lift cwoy the push rods,remove
the si'de cover of the push rods, ond withdrow
the volve toppets.

'",ffi
15

2.5 BRAKE TEST AND ENGINE

LUBRICATION SYSTEM DIAGRAM

NM

Broke Tcst

In view of the very specific chorocter of

the test, especiolly with regord to the speciol
testing eguipment,wedo not intend to describe
the test procedure,restricting ourselvesto men'
tioning only the moin volues which the test is
supposedto verify.
Volues indicoted in the diogroms ore oppli'
coble to o new engine or on engine ofter o top
overhoul, which hos been correctly run'in by
running for o period of obout 50 hours (2,500 km
trovelled). lf the engine is tested under other
conditions, the meosuredvolues must opprooch
the diogrom volues conformoblywith the mechonicol condition of the engine.
ln diogroms, peok performonce volues ore
indicoted os meosuredin complionce with the
CSw (CzechoslovokStote Standords) ond DIN

300

som t/n{a

t000

Fig.2.5l2 - Power Output ond Fuel Consumption

Diogrom- Skodo 120 L engine
1- 3 see Fig.2.5l1
csilr
kwuril'
50

,CsNr
kwrotN'
1{J
I

ilii

20

r5

t0
5000

t/mrn

Fig.2.511-Power Output ond Fuel Consttmption

Diogrom- Skodo 150 S engine
1 - power output, 2 - torque, 3 - specific fuel
consumPtion
1 / m i n: r . P . m .
k/SAE: h.p. (SAE)

38

5000

l/rnrn

Fig.2.513- Power Output ond Fuel Cons

Diogrom- Skodo 120 LS engine
1- 3 see Fig.2.5l1

6e
leeqM^lJ Puo
ou!6u3 ,o suolsueurlc6ullunotN- Vlg'Z'6lJ

e
uo!ldutn

0s
/ Nto\r(l
TiSJ'

uo!lduns
i4,r{t

a3t! xo

gt

ru,*
S,JeUlOlSnC

Mau o e)l
-qceut luol
-acoldet Jo
utr{}!/li{ se
l.ron uoc .
lsnoqxe 'lq
rarvrOdesl
-cD llo rll!,r

F o r t h e i n s t o l o t i o n o f t h e e n g i n eo n t h e t e s t
b e n c h ,w e i n d i c o t e t h e d i m e n s i o n so f t h e e n '
g i n e f l o n g e o n d f l y w h e e l .D u r i n g b r o k i n g ,t h e
engine qnd the engine oil must be properly
cooled to preclude exceeding the oPtimum
s e r v i c e c o n d i t i o n s , i . e . w o t e r t e m p e r o t u r eo f

o b o u t 8 0 t o 9 0 o C ,o n d o i l t e m p e r o t u r eo f 1 2 O " C
m o x i m u m- s e e C h o p t e r2 . 5 , p o r o g r o p h5 1 .
Engine Lubricotion
T h e i n n e r l u b r i c o t i n go i l d i s t r i b u t i o ns y s t e m
i s s h o w ni n F i g . 2 . 5 / 5 .

2.6 cYL

The cyl
mochine
the cron
ports, forr
ore mode
B locks fo
72 mm di
Ii n e r s .

Oilwoys, I

o) Befo
o new cyl
ossemble
blow thror
b) Coot
pound or p
the oilwoy
c) Likev
into the e
pound or p
of the cyli
one (of lo
limits ind
Ports) to e
d) Tighte
ot cylinder
underit.
e) Foste
the cop of
Fosten the
with o bolt

I
?
?
I

t
7

DK .r5+9

F i g . 2 . 5 1 -5 E n g i n eL u b r i c o t i o nD i o g n o m
Skodo 120 LS engine hos, in oddition, on oil cooler incorporoted between the punrp delivery
b r o n c i ro n t h e t i m i n g g e o r c o v e r o n d t h e m o i n o i l w o y ( s e e F i 9 . 1 1 . 9 )
4
t -

s r l c t i o n s t r o i n e r , 2 - p u m p , 3 - p r e s s u r e r e l i e f v o l v e , 4 - m o i n o i l w o y f, i5l t- eo ri l, 6 - b y - p o s s

o i l h o l e , 7 - o i l p r e s s u r es w i t c h , 8 - p u l s o t i n g c h o m b e r ,9 - r o c k e r o r m s , 1 0 - c o n n e c t i n g r o d

s p l o s hh o l e , 1 1- c h o i n s p l o s hs c r e w

Fig.2.61
ond
1 choin gre
plug,3 - inie
relief volve,
with cop, 6 inlet from o
p t u g ,I

LV
e q l u l a u o q l l D q e q l d D l ' e n 1 o ne q l 6 u l l q u e s s D
'MeJcs e^lD^ puD ';oas '6uuds 'llDq
ls.rll ueq6
:ropJo 6urr*o;1o; eql ul e^lD^ eq] elquressv
o^lDn le!lou srnssajd
'DaJD
lcDluoc eql Jo
6u1co1lods deap o ;o itllssaceu eql puo dlqc
ue^sun puD Ic!rl1 D lo lD^ourer eql u! llnsor o1
1do s1 epnsse;d ueneun puo q6;q A;;.rossacauun
u V ' , , p u D L ll q 6 ! 1 , , D q l l M q c u n d e q l e l p u D H
'lrotu qcund o Iq
'uo11rsod
Ilqo:e;ard
slql ul dnc asoa:6 aql )col
'lcolq eql ul s:epur;Ac eql
lo eutl erluac aql
t u o ; I o g t l n o q o i q p a l c a g ; e p ' e ' ! ' d r . u n dJ a I D M
eLll q}!M 3u!l u! s! eloLl uo!lDc!rqnl oql lDq}
os uloqc eq] ]o dnc asoa:6 aq1 uelq6ll (g

p D e q r a p u r l , t co 1 A o r t l l o - 3 ' 6 n 1 d
M o l c s 1 a 1 c o ! J o I D M- L ' J e l o o c l t o L u o J l l e l u !
.ro e6no6 arnsse:d Jot uollceuuoc - g 'dDc tlllm
u o 1 1 ; 1 . r o dr a l l ! + l ! o p u o M o r c s - g ' e ^ l o ^ l a l l e r
'6n1d
a r n s s e l d- p ' d u n d u o r l l o u u D q c l e l u l - g
'dnc asoelD ulDqcluoJ, - Aom11o ulDtu - 7
L
Mercs 6n16 1e1cof relo6 puo
' s e l r o s s e c c v r l o q l ' s A o r * 1 1 6Llg'Z'6lJ

po.r
sSDd

Itarr

u D q s L u D Cp u D
tloLlsluorC lo sacuDtslCarluaC -tlg'Z'6lJ

vo

' r a q s o M 6 u t . t d sp u D
lloq o qllM
u o g 1 1 1 . r oadq l p u D ' M e l o s D q l l M d D c e q l u e l s D l
'6u1:oaq
U D q s r u D c e q ] o l A o n n l l oe q l l o d D c e q l
r o l o r e t l ! + l ! o o L l ] ; o u o 1 1 ; 1 r o da q l u a l s D l ( e
'l! rapun
6 u 1 r l o e s o 1 n d 6 u g n o q r e ] + D t ' o 5 : a p u g ; d c1 o
1 e 1 c o ! r e l D M o q ] l o 6 n ; d a n a r c sa q l u e 1 q 6 ; 1 ( p
'l3olq aql u! ploq urrtl sl! arnsue o1 (s1lo6
arodg,o
a n 6 o 1 o 1 o 3e q l u ! p a l D c l p u ! s l l r u l l
ecuorelol oq] ulLlllM ralarrDlp la6lo; 1o) auo
Ja)orql D esn 'slloq phls poaq ioputlAc aq1 1o
e u o e c o ; d a l o 1 f u o s s o c e u s r l ! 1 1' 1 u t o d . t o p u n o d
- t u o c 6 u 1 1 o o so r l l l M r o l J e l u ! a u 1 6 u a e q t o l u !

6u1pn.r1ord
suoq pnls aql ]Doo"ri5"#l,o(3u*

rassorc 901-Ldt l 6 u 1 s p s r o u ! 1. r e p u 1 1 It3o ;

ssaceu Io sacDlrns6 u r 1 o 6 16 u r s s a r 6- Z l g ' Z ' 6 l J

olu! uMop ueql 6u1r*ercsaroleq 1u1od.ropunod

-ruoc
6u11oas
D qllM s6n1dr*e.rcsaql ]DoC (q
'.r1opassa:druooqllM q6no:ql molQ
puo por unB o qllM ueql uoelc '(pe;qruesso
c euD
A1e1a;drue
oq
c o l s ! l l 1 ) l r o l q . r e p u 1 ; IM
a:o;eg (o
; o s l o r u l r o o q l o l u r s 6 n 1 d6 u t 1 1 r 1
'c1e 's6n16'sllog 'sAorrrr;gg
' s r e ur l
reputl{c ro} saroq .r1eq1Iq ,{1uo-ra1ppww Zl
'Dlp
puD tutu
s e r o q l e p u r l A cr o ] s l c o l g
' A 1 1 o u o r8191 pppaDl t]!ol p u o I l e l o . r o d a sa p o u a r o
'1runilquessD uD
's1.rod
lcolq oq] gllrrrr6ulurro;
6 u 1 u 1 o u a :a q r l l V ' r o n o c r D a r l l D q s l u D r c a q l
puD sJe^oc 6ugroaq q11melaldruoo peulqcou
6 u ; 1 s o ce 1 pi o 1 l o - 1 q 6 o
; ps g) o o l q . r a p u r l Aacq 1

)cols

ufoNtl^c

9'z

uelsA
'1

c,oz

2.6-2.7

seot in the cylinder block using o copper or

o l u m i n i u mr o d .

domoged mechonicolly, use the MP 1-106

d r e s s e r ,o r t h e M P 1 - 1 5 7i i g w i t h u n i v e r s o l g u i c c
rings.

ReconditioningRecessesfor Cylinder Liner

Flonges

Reconditioning of Comshqft Beorings

B e f o r e o s s e m b l i n go u s e d c y l i n d e r b l o c k ,
i n s p e c t o n d c l e o r r t h o r o u g h l yt h e m o t i n g s u r f o c e s o f t h e r e c e s s e sf o r c y l i n d e r l i n e r f l o n g e s .
lf chemicologents (petrol,etc.) foil to hove
t h e r e q u i r e de f f e c t ,o r i f t h e s u r f o c e sh o v e b e e n

lf on oversize comshoft is to be f itted (excessive beoring cleoronces in on otherwise

sound block), drive out the plug on the reor
side of the cvlinder block ond reom the beori n g s t o d i m e n s i o n s s p e c i fi e d i n t h e f o l l o w i n g
Toble:

To Grind

For gri
shoft by t
between 1
'Ihe
reor
ond there
for detoils
beoring.
For grir
prepored
clomped t,
pins must

Stondond comshoft

D i o m e t e ro f b e o r i n gi n c y l i n d e r b l o c k
mm
38.5

D i o m e t e ro f c o m s h o f ti o u r n o l s
mm

l s g
38sl-

+0.02s

-0.025
-0.041
-0.020

l-;-

+0.021
Oversize comshoft

=l__i
tl
o

Volve Toppet
Stondord

on;rsizt-

L_

_-L1il

Reconditioning
of Volve Toppet Guides

T h e n u m e r i c a ls y m b o l s o f t h e b e o r i n g s ( l - l l l )
indicote the respective front, centre, ond reor
b e a r in g s .
Close the newly mochined bore with o new
plug ond seol it with o dob of point. A poor
seoling would result in oil leoking from the
engine into the clutch.
When reboring the bore for the comshoft,
observe the centre distonces of the cronkshoft
o n d c o m s h o f t .O t h e r w i s e t h e t i m i n g c h o i n w i l l
be either too slock or too tout. For the correct
distonces see Fio. 2.6/3.

l f t h e r e i s o n e x c e s s i v ec l e o r o n c e i n t h e
guides (beorings)of the volve toppets, it is
p o s s i b l et o r e c o n d i t i o nt h e g u i d e s o n d t o r e ploce stondord toppets by toppets of o lorger
diometerT
. h e c e n t r el i n e o f t h e b e o r i n g si s p e r p e n d i c u l o r( n o r m o l ) t o t h e s e o t i n g f o c e o f t h e
c y l i n d e r b l o c k . T h e r e l o t i v e d i m e n s i o n so f t h e
beoningond toppet ore specified in the Toble
below:

Diometer of Beoring
in CylinderBlock, mm
21
21.2

+0.021

-t
t o i. l l

-T-

QZt0.l

Azi' r

Toppet Diometer
mm

21
21.2

-0.020
-0.007

@)
Externol Col

2.7 CRANKSHAFT
AND ITS ACCESSORIES

Cronkshoft Beoring (for clutch shoft)

I t w i l l b e d r i v e n o r p r e s s e di n t o t h e s h o f t
l u b r i c o t e dw i t h t h e r e c o m m e n d e dg r e o s ew i t h
its cover turned outword. After its pressing-in,
odd odditionol greose by forcing it into the
s h o f t b o r e b e h i n dt h e b e o r i n g .
Use the extroctor MP 1-109for the removol
of the beoring.

T h e c r o n k s h o f th o s t h r e e r n o i nb e o r i n g so n d
f o u rc r o n k p i nb e o r i n g sl.t i s o f o r g i n gw i t h s o ft ,
n o t h o r d e n e di o u r n o l s .W h e n w o r n , i t m u s t b e
r e g r o u n dt o d i m e n s i o n so s p e r T o b l e f o r f i t t i n g
o v e r s i z eb i g - e n d o n d m o i n b e o r i n g s h e l l s o s
w e l l o s c n o v e r s i z eg u i d e r i n g .
42

Nomir
iourn
Stondord
1st regrin
2nd regrin
3rd regrin
4th

t0'0-

w
zt,

066'L
s98'L

ovt'L

9/8'Lr
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929'Lt
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ecuojslof

t9'o!p 9Z't9'olp0 9 ' t 9 ' D ! p9t'v9'otp 9 9 ' D ! P-

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prg
6u;pu1.rDe.r
pu7
6urpur.r6e.r
6urpug.rOer
1s;proPuDls

IDAOUI

oql ol
'u1-6u
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tuul
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ruut ssoulc!rll
ecuoJololI
q16ua'1 | ,,o,, q16uel lDuJnol
6u1.rep;n9
uoqsluorc lDu!uroN
sseulclrll 6u1X ep;ng; puo (,,o,,) ql6uo'l lournof lo uolptaiJoc lDuralxf

sugdluo.rclD - B
uollouo;dxe puo elqol eql ess - ;ournol
lsrrl eql ;o uogldecxaeql qlltl,t sloulno! lo - V
sqeM uoqsluDJc lo secDlJns
apls ol leeqM 1o 6u;peel puD sn!pDrleeqM
6 u l p u u b - s l D u r n o fl u o r o 6 u t p u t : g - Z l t ' Z ' 6 l J

elqol
eql lo
eql io
-redsg
:a6.ro
-ar ol
s! lr '
oq] u!

iD/Tz9 r1d

s e u 1 1A n o e q u ! u M D l p e l o s e o D l J n sp a u o t l l P u o c e l
e q l - s fo u J n o f l u o l C 6 u l u o l y p u o c a y - y 1 7 ' 7 ' 6 t 7

lDurnor

9Z'V9

920'0600'0-

9Z'VV

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99

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6 u r p u r i 6 e :q l f

zt

t9
620'0010'0-

ultll

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0920'0+

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6u1pu;.r6a:

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ez!s pJopuDls

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ulut
ecuoJalol
q16ue1

'q16ue1
re^eMoq
6u16.ro1ue
eq1
u1d1uo.rc
lnoql!M
'seoDl puo aql qcnol ol pelllt-uJeds1
leeqM
eql lo ,8, uotlcas oql
6u;pu116eq1 '6ugrvroJp
'PopuouutocoJ
o1 6u;puodseJlocecuolsu! oql ul
s! ZtL'Z '6lJ .rad sD leeqm 6utpug.t6oql Jo
6u;peal 'punol6 eq ol sDq ecDl er.lloslD qclqM
'u1d4uo.ro
uolgdacxeaql qll4l1
lsrll eql
1o
lo
'Zll'Z'6lJ o1 6ulp.roccosn!pDro qllr*
leeqM
6 u r p u r . r DD o s n s l o u . r n o !e q l 6 u t p u 1 : 6 J o J
'unurlxotu
1s.t11
,0to0 s! u1d>1uo.tc
orlt lo eu!l elluec eq1 qbnolql
aql puo sgou.rno!
6u;ssodeuopdaql ol lcedser qllM lueuu6;1os1tu

ultu..D,,
q16uep
louJnor

slouJnor lo ez!s

rleql puo LutugO'0+96eq lsnu suld

agqlsslturad
-luD.rceql lo rl!l aql 'puo tlDrls eqt ol paduolc
aq ot e^Dq qclqm 'se1o1d- saJnlx!' peroderd
.ro1
l;;onprngpu;esn suldluDrc or.ll 6u;pu1.16
'6u1.roaq
eql aes sllDlap ro,
eqt qllM 6u11oepqdorBo.tod
- po^ouer eq lsnu 6u1:oeqoq] aJolelaql puD
6u;roaq aql Jepun sr eoDlJnslocluoo rDaJaql
'au!qcou 6u;pu1.rD
sql lo serluec oLll ueemlsq
spue UDqs eql lo secDlrnslDcluoceq1 lq 1loqs
-luoJc aq1 duolc 's;oulno! aq1 6u;pu;:6 .ro1
lloqsluorc eql Pulr)ol

6ulrvt

-JDAq e
JDoJ AL
es!MJe

-xa) p

op1n6
901-L

2.7.-2.8

i s w o r n t o o n e x t e n t w h i c h m o k e s d o m o g eo f
t h e g u i d e r i n g l i k e l y ,r e p l o c ei t w i t h o n e w o n e
or regrind it.
T h e m o x i m u mp e r m i s s i b l er e g r i n d i n gi s , h o w e v e r ,t o o t h i c k n e s so f o n l y 3 . 7 5 m m .

Guide Rings
R e g r i n d i n go f t h e f o c e o f t h e f r o n t c r o n k s h o f t
w e b r e s u l t si n o n i n c r e o s e d( o x i o l ) p l o y o f t h e
shoft.
R e p l o c et h e r e f o r et h e o r i g i n o lg u i d er i n g w i t h
o n o v e r s i z eo n e .
O v e r s i z eg u i d e r i n g s o r e f i t t e d e x c l u s i v e l yt o
loterol foce of the cronkshoftweb.
the regrround
S t o n d o r ds i z e r i n g s s h o u l d b e o l w o y s f i t t e d t o
t h e t h r u s tr i n g s i d e ( n e x t t o t h e t i m i n g g e o r ) .

Cronkshoft
Moin Beoring Shells
F i t t h e c r o n k s h o f tm o i n b e o r i n g s ( s h e l l s )
occording to the respective nominol diometer
o f t h e c r o n k s h o f ti o u n n o l s T
. he shells ore not
p r o v i d e dw i t h o d i o m e t e rs y m b o l s o t h o t t h e y
hove to be checked for the respective woll
t h i c k n e s sw i t h o m i c r o m e t e r .

Thrust Ring
l f t h e t h r u s t r i n g u n d e rt h e c r o n k s h o f t i m i n g
g e o r ( s p r o c k e t )o b u t t i n go g o i n s tt h e g u i d e r i n g
Motching Cronkshoft Main Beoringswith Journols
N o m i n o l c r o n k s h o f t iournol diometer
mm

d i o .5 5
dio.54.75
d i o .5 4 . 5 0
dio.54.25
d i o .5 4

stondord
1st regrinding
2nd regrinding
3rd regrinding
4th regrinding

T h i c k n e s so f b e o r i n g
s h e l lw o l l
mm

T o l e r o n c el i m i t
of woll thickness
mm

1.497
1.622
1.747
1.872
1.997

- 0.007

l f o n e o f t h e s h e l l si s w o r n o r d o m o g e d ,o l l
cronkshofm
t o i n b e o r i n gs h e l l sm u s t b e r e p l o c e d
w i t h o u tf o i l!

2.8 FLYWHEELWITH GEAR RING

For the respective correlotion of the cronkpins ond connecting rod big-end beorings see
Chopter 2.11.

A n e w f l y w h e e l o s s e m b l yi s o s t o t i c o l l y b o l o n c e d u n i t , i t s m o x i m u m p e r m i s s i b l er e s i d u o l
' 1 0g c m . T h e f i n o l
o u t - o f - b o l o n cw
eeight being

Boloncing- Removol ond Refitting

dynomi
ism sh
sembfe
Thus
sitioqof
shoft be
from o 1
When
rnork on
zero line
ond prol
mork op
cylinder
the rem
gcm sin
mosses(
concent
cronksho
holes rot
wheel ir
interfere
For thi
on the r
sition, i.
cronksho
fore the
When
one or wl
follows:
1. Fit .
r e s i d u o lo
olly offec
2. The
bolonce r
hos o hig
correctio
once. lt
occording
porogroph
Chopter 1
b e n d i n gt

To Reploc

F i g . 2 . 8 l 1 -M o r k i n gC o r r e c tP o s i t i o no f F l y w h e e l
o n C r o n k s h o f t( p r i o r t o r e m o v i n gt h e f l y w h e e l )
44

Reploce
worn or d,
ring, toke
the interf
sion). The
prime imp
ossembly
storter mo
The gec
removed b
port pod cr
MP 1-153.I
ing the ge
it off. The
monufoctu
When ur
front foce
ond drill o

9?
'sl!ru!l aouDreloluorlcnpoJdeql ol 6upploc
-cD 'C puD 'g 'y sessolc ecuoJolol ul pessDlc
ero dno.r6releuDlp rlcDa lo s.reulg.repulg{3
'Pesn eq o1 a^Dq
s u o l s l d e z ! s r e ^ op u o t a l q D l u o t l D O ! l ! s s D lrco p
-u1glceql qllr* ecuopJoccDu! JeteuDlp lDulurou
lxau eql ol psroqer ro euo /vlauD qyrvr peco;del
eq lsnu Jeull aql 'utu L'0 speacxa JoaM eql ]l
'lapoureugDueeql uo 6urpuedap'ww
ZL lo gg sl
a r o q r a p u r l l c 1 o u 1 r , u co lus D qo q l ' I c o l q L a p u l ; A c
aql olu! pauosur 6ureq uor lsDc la.r6 lorceds1o
s r a u r lr a p u l ; A ce q l ' a l o . r o d a o
s l o s l e p u q l l ca q 1

(uarurr)ufoNrrlc 6'z

e c o d s q l o o l D M o l e q 6 u g . r. r o a 6 o q l ] , o l l t r p p u o
( e c o l l n s p a u a p t o q ) 6 u g . r. r o o 6 e q l l o e c o t l u o J l
eql llo pur:6 'poqletu reqlo eq] 6u1sn ueqg
'lsanber uo Jelnl3olnuoul
r o c a q l A q p a r l d d n s e q l l l t * 6 u r n n o . r pe q l ' , l o l l
6 u 1 s s e . r de J o l o q i l e l o l p e u r u r 6 u r . r : o a 6 a q 1 6 u 1
- 1 o e q l l l o c o l r o ; q c . r o 16 u r p ; e M o e s n ' S S L - L
d17!
D u l r v r o r pe q l o l 6 u l p : o c c o e p o u r e q u o c p o d l r o d
- d n s o ' ; ; o 6 u g s s e . r d. r o 3 ' u o l l c n r l s e p l q p a n o u a " r
r o l l o p e s s a . r d r e q l l e s q u o c 6 u 1 . r. r o a 6 e q 1
' u o 1 u 1 dJ o l o u r J e U D l s
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'aco; 6urloes s!ql
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-rns srLll1o auold aql loql erDc elol qolnlc eq]
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'lD^orrsJ
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-luDJc eql ol lcadser ql!M leoqMrtll aqr lo uo!US
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- u D q o a u l u o J c e J r l u o e L l l l o 6 u g c u o l o qc l u o u l p

lou!' eq
lDnp!se
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llD/vl e^l
laql 1o
]ou oJD
JOlsirD!

( s 1 1 e)

-rvroq's1
gUO MeU

;o eOou

toleronce closs occording to the clossificotion

toble, for exomple dio. 68.25 1A, dio. 68.50 24.
However,only cylinder liners of o nominol dio'
meter of 68 mm con be rebored.Worn liners of
72 mm nominol diometer hove to be reploced
with new ones.
For the cylinder liner otrd pistotr ossembly
see Chopter 2.12.
Check the diometer (bore) ot o temperoture
of 20oC which must be constont for both the
c y l i n d e rl i n e r o n d g o u g e s .
Mochining (Reboring) Cylinders

DK 626
Fig.2.911-Morking of Cylinder ToleronceCloss

F o r m o c h i n i n g( r e b o r i n g ) t, h e c y l i n d e rs h o u l d
be clomped only in the oxiol direction to
preclude ony distortion ond deformotion of its
bore. Depending on the mochine used for
reboring,moke o centering heod to be centred

Grode the rebored cylinder liners in the some

monner while odding the number of the respective rebore before the designotion of the

Groding of Cylinder Liners According to Diometers ond Toleronce Closses

Nominol diometer
mm
Dio. 68

Toleronceond I
rebore closs I

Diometer
mm

Diometer
toleronce

A
B

68.00
68.01
68.02
68.25
68.26
68.27
68.50
68.51
68.52

+ 0.009

72.OO
72.O1
72.O2

+ 0.009

(stondord)

68.25 (1st rebore)

1A
1B
1C
2A
28
2C

68.50 (2nd rebore)

A
B

Dio.72

Fig.2.912- Outside Dimensionsof Cylinder

Liner
Cylinder bore 68 mm
Cyf inder bore 72 mm

dio. D :75f7
Fig.2.9/3- Mochining the Cylinder
1- cylinder liner, 2 - centering heod, 3- clomp.
ing plote, 4 - clomping bolts, 5 - cutting tool

dio. D:76t7

46

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The cle
shouldbe
cleoronce
the rings

T o b l e o f Motching Gudgeon P i n s t o P i s t o n so n d S m o l l ' e n dB u s h e s

Pin bore
in piston
nl n]

G u d g e o np i n
diometer

Nominol diometer
mm

mIn

- 0.003

20

20

20.0s

20.0s-- 0.003

zu

,o05,33?3

p i n i s c r s l i g h t i n t e r f e r e n c ef i t i n
Tlre gr-rdgeon
t h e p i s t o n - l t s c l e o r o n c ei n t h e c o n n e c t i n g r o d
s m o l l - e n db u s h i s : ; p e c i f i e d i n t h e C h o p t e r
" C o n n e c t i n g R o c "l .
The steel gudgeon pin is lrollow ond hos
c r r o n r i n o lc li o m e t e r o f 2 0 n t n r , r e p l o c e m e n t p i t t s
l . r o v i r r go; n o m i n o l d i o n r e t e r o f 2 0 . 0 5 m n r . W h e n
f i t t i n g o n o v e r s i z eg u d g e o n p i n w i t h 2 0 . 0 5 m m
n o m i n c l d i o m e t e r ,t h e b o r e t o k i n g t h e p i n m u s t
b e r e o m e d t o d i m e r r s i o n ss p e c i fi e d i r r t h e r e spective l-oble.
PISTON RINGS
To ensure their correct function, they must
b e f i t t e d i n t h e c o r r e c t p o s i t i o n ,t h e y m u s t h o v e
no or onlv c minimum cleoronce clong their
r : i r c u m f e r e n c eo, s m q l l c l e o r o n c e i n t h e g o p s '
o n d t l r e y m L r s tr r o v e f r e e l y i n t h e p i s t o n g r o o v e s .

105

r20

'.;iA
\Lt

l
{

2a 1333?
,oos1333?

g > o i n t i r i gd o w t r w o r d . l f t l - r e r ei s o n y d o u b t o s t o
the coriect selection of the rings, check them
for proper seoling in the cyli.nder.before osrurbty. ltrserttlre ring into the cylinder ond
l e v e l i t b y p L r s h i n gh o m e t h e p i s t o n h e o d ' I n
the cose of o used cylinder, insert the ring
obout 20 ntin below the top edge of the cylinder
lirrer, i. e. o plcce rvhere the cylinder. liner is
olreodv worn, while checking for the right
clecronce in the piston groove ond for the
correct gcrpin the cYlinder bore.
F o r r i " n g st h o t h o v e n o t b e e n r u n - i n , t h e f o l '
lowirrg circumferentiolgop or contoct cleoronce
with rlgord to the cvlinder liner is permissible:
n o n e f o i t h e c h r o m i r - r m - p l o t ecdo m p r e s s i o n r i n g ,
two in c totol ronge of on ongle of 35 degr' for
the bevellecl compression ring ond the oil
control ring. Lcrger contcct cleoronces olong
t h e c i r c u m T e r e n c ed e n o t e e i t h e r o n i n c o r r e c t
selection of the ring, for exomple the ring does
not correspond to the cylinder bore, or on
e x c e s s i v ew e o r o f t h e c y l i n d e r l i n e r .
Check the ring gop cleorcnce using feeler
g o L r g e s -F o r n e w c o m p r e s s i o l l n g s , t h i s g o p
.leo"ronc" should be 0.25 to 0.40 ntm, for new
o i l c o r r t r o l r i n g s 0 . 2 0 t o 0 . 3 5 n r n r .T h e n l o x i n r t l t t t
o e r n r i s s i b l ec l e o r o n c eo f w o r n r i n g s i s 1 m m '

GUDGEON PIN

'!.t

- 0.004
- o.o1o

C o n n e c t i n gr o d
s m o l l - e n db o r e
(br-rsd
hiometer)
mm

.,

x),:=

2.11 COn

The con
o brorrzeb
b e o r i n gs h
in the big
Before r
for compli<
weight, ol
ond motch
shoft.
For its <
ter 2.12.

To Check
Connect
weight gro
foctory, ligl
yellow po
Shouldthe
during stor
been fitted
determined
remove o c
smoll ond t
the smoll r
in the engi
(+2 gr.).
When re
odjust its w
connecting

s!-9

DK63

D K1 4 3 6

F i g . 2 . 1 O l 3. - S e q e r e n c eo n d [ J l e t h o d o t F i t l i n g l
PistonRings ( Mork Positioning).
Fronr top to bottom: chromium-plotedcompress i o r . rr i n q , b e v e l i e d c o m p r e s s i o n r i n g , s p r i n g
l o c r d e de x p o n d i n g o i l c o n t r o l r i n g
Fit the {irst ring in cny orbitrory position
( i t s c y l i n d r i c o l c h r o m i u m - p l o t e dp e r i p h e r o lp o r t
is chomfered on either side, focilitoting identificotion), the second, bevelled ring with the
'TOP" or onother mork on top, ond
lettering
llre oil lontrol ring with its outer shorp edge

Fig
'l -

f : i g . 2 . 1 A 1 -4 C h e c k i n q P i . ; t o n R i n g G o p

48

boloncin
2 - numerico

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l o l o l o l D p e a c x ol o u l s n u e u g O u e q l u 1
p o : D u l l c e u u o cD J o s p u e 6 g q p u o l l o r r s o q l
'pua 61q puo
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' 6 u r q O r a nI n
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eq lsnur lq6;anneql 'aug6uaaql ul pelll' uooq
sDq pol Duglceuuoceql raUD .ro eDorcls 6u1rnp
pe6ouop eq 6ul1roruaql plnoqS
(pa1o.re111qo)
' 1 u 1 o de n l q q l ! , v r r e ! ^ D o L le q l ' 1 u 1 o d m o l l a l {
'I.to1co1
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- d o q C a e s u o l s 1 da q ] q ] ! M A l q u r a s s os ] ! J o J
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spond with the number of the respective gVtinderwithwhich theconnectingrod is ossembled.

When replocing o connecting rod, provide the
new connecting rod with its very some identificction numbel. Stomp the figures os much
toword the for end of the boss os possible to
ovoid fouling the loterol guide foce.

Smoll End ond Big End Alignment

A misolignment of the centre line of the
smoll-endbush ond big-end beoring or the bore
for the big-end beoring shells must never ex'lO0
mm of the connecting
ceed 0.03 mm per
r o d l e n g t h .F o r c h e c k i n g o n d o l i g n m e n tu s e t h e
M P 1 - 1 0 2o r 1 - 1 5 9f i x t u r e .
Insert the odiusting pin into the fixture ond
set both its diol indicotors to zero. Clomp the
connecting rod without shells into the fixture,
threod the pilot pin in it, ond swing down the
connecting rod. The recdings of the diol indic o t o r s w i l l s h o w o n y m i s o l i g n m e n to f t h e s m o l l
o n d b i g e n d . T h e m o x i m u m m i s o l i g n m e n tm u s t
not exceed 0.03 mm os olreody mentioned.
C h e c k f o r m i s o l i g n m e n ti n t w o p l o n e s b y t i l t i n g
the diol indicotors.
T w o p i l o t p i n s o r e s u p p l i e d ,o n e w i t h o d i o m e t e r o f 2 0 r n n r .t h e o t h e r w i t h o d i o m e t e r o f
20.05mm, to motch the gudgeon Pins.

2.12 CYLINDERS, CONNECTING RODS

AND PISTONS
o )' O n l y o c y l i n d e r ( l i n e r ) o n d p i s t o n o f e q u o t
diometer ond the some toleronce closs con
be ossembled qs s unit.
b) Theengine cs qn ossemblyunit con befitted
cnly with cylinder liners ond pistons of the
some diometer, the pistons being of the
some weight grnLtp.
T h e i n c l i v i d u o lc y l i n d e r ' c n d - p i s t o n q s s e m b l i e s
con be, however, of dif ferent toleronce
closses. On the othe'r hond, connecting rods
of only the sqme weight group con be used-

To Motch Connecting Rod with Gudgeon Pin

ond Cronkshoft

These ore the cc;tditions for the correct operotion of pistons in the cylinders ond for the
correct boloncing of the cronk mechonism.
F o r d e t o i l s c o n c e r n i n gd i m e n s i o n s ( d i o m e t e r s ) ,
toleronce closses (cylinder liners, pistons) ond
weight groups (connecting rods ond pistons)'
r e f e i t o f h e c h c p t e r s d e o l i n gw i t h t h e i n d i v i d u o l
pc|rts"

With regord to the reciprocoting movement

of the piston, the gudgeon pin must hove the
smollest possible cleoroncein the connecting
rod small end (ony lorger cleorcnceresults in
pin knocking). Therefore select from severol
g u d g e o np i n s o n e w h i c h w i l l b e o c l o s e r u n n i n g
fit in the smoll-end bush. lf no suclr pin is
ovoiloble, reom tlre bush but never exceed the
moximumtoleroncelimits.
An oversizebuslr lros to be reomed to o nominol diometer of 20.05 mm. For the respective
dimensions refer to the Toble supplied with
gudgeon pins. The big"end beorings i:;hells)
inouta be selected occording to the nominol
diometer of the cronkpin.The shells lrove no
d i o m e t e r n t o r k i n g o n c l h o v e t o b e i d e n t i f! e d
by meosuringtheir woll thickness with o mi'
crometer.

To Assembie Cylinder Liner with Piston

qnd Connectirrg Rod
1. Toke cylinder liners ond pistons with
m o t c h i n g d i n r e n s i o n s i, . e . c y l i n d e r l i n e r s o f t h e
s o m e b o i e ( t h e y n e e d n o t b e n e c e s s o r i l yo f t h e
scrmetoleronce closs), pistons of the some
c l i o m e t e r< , n r lt c i e r o n c e c l o s s t o m o t c h t h o s e o f
t h e c v l i n c l r : i i t r e r so n d o f t h e s o n r ew e i g h t , o n c l
c o n n e c t i t r c tr o r l s , < r l l o f r t n e o f t l l e t w t l w e i g l r t
clroLrPS.

lti''

(stondord)
45
4 4 . 7 5( 1 s t r e g r i n d i n g )
4 4 . 5 0( 2 n d r e g r i n d i n g )
4 4 . 2 5( 3 r d r e g r i n d i n g )
44
{:lttrregrinding)

1.490
1.615
1.740
1.865
1 990

5- P
the crc
ond co

In o
t e ri s ti c
comso
comsh
c leoro
the cor

M o t c h i n g C r o n k p i n o " | , , n " i i f l " , , rl o , u , o n

1 thick"ness
mm

3.L
the gr
80"c i
Sme
home
some
threod
Pin, o
circlip
on thr
pressiI
Fit
hole ir
the orr
4 . F
or exp
detoils
the ri
groove

2.13 I

Motching Big-end Beoring shellswith Cronkpins

nominol diometer
mm

2. 1
OCCo
Selec
cyl i nd
tolpro
the (
motch
Son
pin or
gudge
in wh
suitob
bush.
Mor
respo
with v
meric
Rod'.

mm

0.007

Volve

'

with
DK 1161

N u m e r i c o l l d e r r t i fi c o t i o n o f C o n n e c t i n g R o d s
For better identificotion, {igures con be
stomped on the bosses of the connecting rod
b i g e n d ( s e e F i g 2 1 1 1 ). T h e f i g u r e s c o r r e -

- P r e s s ' ift t i r r g o f G u d g e o n P i n i n t o
Fi,c 2.1211
Piston Usinq MP 1-i04 Drift

50

lntoker

open be
closeo

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s r r l J oJ a l c o J a A l D ^ e q l ] o l u e u r e ^ o u Je q l u a q n n
'pasolc eAlD^
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e 6 n o 6 J e l e a l D e s n a c u o J D e l ce ^ l o A a q l 6 u 1 1 c a q c
ro3'Arosseceu sD sJe)cor e^lo^ oql lo u!d
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-uraq]ro; surd uoa6pn66urqclour
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ees) spo.r6ullcauuoc eql u6!lo :ssolc acuoJalol
a n l l c a d s e .ar q l q l ! M 6 u 1 d a a 1u r r e u ! l r a p u ; ; l c
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Et z-zl'z

link from the choin front side ond fit the clip
from the reorwith its openend pointing in the
d i r e c t i o no p p o s i t et o t h e c h o i n m o v e m e n t .
Before storting work on the volve geor, remove the oil sump (engine bottom cover to
w h i c h t h e t i m i n g g e o r c o v e r i s b o l t e d ,t h e s u c t i o n s t r o i n e rb e i n g o t t o c h e dt o t h e c r o n k s h o f t
c e n t r e b e o r i n gc o v e r ) o n d l o c k t h e c r o n k s h o f t
i n p o s i t i o n i n t h e o x i o l d i r e c t i o nb y d e p r e s s i n g
t h e c l u t c h p e d o l ,i f r e m o v o lo f t h e e n t i r e e n g i n e
. or speciol
i s n o t i n t e n d e df o r o n o t h e rp u r p o s e F
p o i n t s o f t h e r e m o v o lr e f e r t o C h o p t e r2 . 4 .
2.14 WATER PUMP
Disossembly
F i 1 . 2 . 1 3 1-2 V o l v e C l e o r o n c eA d j u s t m e n t
Alternoting

A d j u s t c l e o r o n c eo n

c y l i n d e rN o . 1
c y l i n d e rN o . 3
c y l i n d e rN o . 4
c y l i n d e rN o . 2

c y l i n d e rN o . 4
c y l i n d e rN o . 2
cylinderNo.1
c y l i n d e rN o . 3

@@@@
DK 1240

F i g . 2 . 1 3 1-3V o l v eA r r o n g e m e nitn C y l i n d e rHr e o d

B l o c k d i s k s- e x h o u s tv o l v e s
W h i t e d i s k s- i n t o k e v o l v e s
TimingChoin ond TimingGeors
M o d i f i e dc h a i n a n d g e a r sf i t t e d s i n c e O c t o b e r
1 9 7 9 r e c o g n i s e bd y s q u a r e dg e a r t e e t ha n d c h a i n
with split rollers.

1. Unlockthe wosherof the belt pulley nut,

r e m o v et h e n u t o n d p u l l o f f t h e b e l t p u l l e yu s i n g
t h e M P 1 - 1 2 0p u l l e r( o f i x t u r r ef o r S k o d o M B 1 0 0 0
c o r s ) o r o u n i v e r s o pl u l l e r ,f o r t h e b o l t s o f w h i c h
i t i s n e c e s s o r yt o c u t t h r e o d s M 8 i n t h e b e l t
p u l l e yh o l e s .
B y p u l l i n g o f f t h e b e l t p u l l e y ,o c c e s sw i l l b e
g o i n e d t o t h e n u t s f o s t e n i n gt h e p u m p t o t h e
e n g i n e .T h e s o m e p r o c e d u r eh o l d s g o o d w h e n
d i s m o n t l i n gt h e p u m p o f t e r i t h o s b e e n r e m o v e d
fromthe engine.
2 . W i t h d r o w t h e k e y f r o m t h e s h o f t o n d ,u s i n g
the drift MP 1-121,drive or press out the shoft.
Then lift owoy the housing plote from the
seoting foce of the pump.
3 . R e m o v et h e c i r c l i p l o c k i n g t h e o u t e r b o l l
beoring in position. Proceeding from the reor
s i d e o f t h e p u m p h o u s i n g ,d r i v e o u t t h e b o l l
b e o r i n g sw i t h t h e i r s p o c e rt u b e , o n d r e m o v et h e
r u b b e rs e o l i n gr r i n gf r o m t h e h o u s i n g .

Fig.2

Reossembly

T h e t i m i n g c h o i n h o s n o s l o c k o d i u s t e r( t e n sioner).A slock choin does not substontiolly

offect the volve geor occurocybut its operotion
i s n o i s y .T h e r e f o r ei t s c o r r e c t l e n g t h s h o u l d b e
e n s u r e de i t h e r
o ) b y s e l e c t i n go s u i t o b l ec h o i n f r o m o n u m b e r
o f c h o i n s o v o i l o b l e- t r y i t o n t h e t i m i n g
geors, o1r
b) by replocing the stondord comshoft geor
with on oversize geor (with greoter toleronces).The comshoft geors ore groded in
k e e p i n g w i t h t h e i r p r o g r e s s i v es i z e ( t o l e r o n c e s )i n t o c l o s s e sA , B o n d C . W i t h t h e
exception of closs A, the closs morking
l e t t e r so r e s t o m p e dn e x t t o t h e p u n c h m o r k .
For trying, the choin con be disconnected
t o o v o i d r e m o v i n go n d r e f i t t i n g o f t h e t i m i n g
g e o r s .T o r e c o u p l et h e c h o i n ,i n s e r tt h e c o u p l i n g
52

1 . S m e o rt h e r u b b e rs e o l i n gr i n g w i t h g r e o s e
o n d i n s e r t i t i n t o t h e p u m p h o u s i n g .U s e t h e
M P 1 - 1 2 3d r i f t t o d r i v e h o m e t h e i n n e r b o l l
beoring (without sheet guord) pocked with
g r e o s e .W h e n o p p l y i n g t h e d r i f t , f i t i t s g u i d e
ring into the bore for the oute,rboll beoring.
2. Fit the gosket on the pump seoting foce
o n d p l o c et h e p u m p p l o t e w i t h i t s c e m e n t e d - o n
gosket (focing outwordsfrom the pump) over it.
F o s t e nt h e p l o t e t o t h e p u m p p r o v i s i o n o l l yw i t h
one bolt to prevent the gosket from being domo g e d d u r i n g t h e f o l l o w i n g o s s e m b l yi o b s .
Insert the rubber seol, wosher,ond conicol
spring into the speciol (bokelite) seolingring
of the pocking glond. Instoll the spring with
its nose into the hole in the bokelitepocking.
S l i p t h e o s s e m b l e dp o c k i n g g l o n d o n t h e s h o f t
with the spring toword the shoft geor,ond drive
t h e s h o f t h o m e i n t o t h e p u m p b e o r i n g ,w h i l e
s u p p o r t i n gt h e b e o r i n gw i t h t h e M P 1 - 1 2 3d r i f t .

Fig.2.1t

4. Fit t
shoft ond
s t o l l i n gt h
in positior
it with gre
sheet guo
5. Top t
lieve the r

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6 . C o m p l e t et h e p u m p o s s e m b l yb y f i t t i n g t h e
Stoufferlubricotorfilled with the recommended
greose.
2.15 ROCKER SHAFT AND ROCKERS
Assembly (on Skodo 105 engine)
1. Instoll the lock ring, ploin wosher, ond
spring wosher on the ro6ker shoft with both
e n d s p l u g g e d .S m e o rt h e s h o f t w i t h o i l , f i t t h e
rocker (with its orm with the thrust foce def l e c t e d t o w o r d t h e n e x t o s s e m b l e dp o r t s ) , t h e
shim, the rocker support, ond the other orm
deflected toword the support,i. e. the complete
r o c k e ru n i t o f c y l i n d e r N o . 1 .
2 . T h e n s l i p t h e s p r i n g , t h e r o c k e r ,t h e s u p port, the shim, ond the next rocker, i.e. the
c o m p l e t er o c k e r u n i t o f c y l i n d e r N o . 2 , o n t h e
shoft.
3 . T h r e o do n t h e s p r i n g o n d , u s i n g t h e m i r r o r
orrongement of the ossembled rocker units,
i n s t o l l t h e r o c k e r u n i t s o f t h e r e m o i n i n gt w o
c y l i n d e r s .U s e o l o c k r i n g s u p p l e m e n t e dw i t h
o ploin ond o spring wosher to lock the oss e m b l e dp o r t s i n p o s i t i o n .
T h e r o c k e rs u p p o r to f t h e c y l i n d e r N o . 4 m u s t
be providedwith on oil hole to provide for the
s u p p l yo f o i l t o t h e r o c k e rs h o f t .
4 . C o m p r e s st h e s p r i n g sb y h o l d i n g d o w n t h e
rocker orms ond lubricote oll loterol contoct
s u r f o c e sw i t h o i l .
Assembly(on Skodo 120 L ond 120 LS engines)
The rocker shoft is provided with two odd i t i o n o lr o c k e rs u p p o r t sf i t t e d f r o m t h e o u t s i d e
o f t h e r o c k e r u n i t s ( t h e s h o f t i s l o n g e r ) ,r e p l o c i n gw o s h e r so b u t t i n g o n t h e l o c k r i n g s . F o r
t h e r e s t ,t h e o s s e m b l yi s i d e n t i c c lw i t h t h e p r o ceduredescribedin porogrophs1 to 4 obove.
NJote:Rocker orms on the Skodo 120 LS eng i n e o r e s h o r t e r ( 1 8 . 5m m ) t h o n t h o s e o n t h e
-120
Skodo
L ond Skodo 105 engines, in order
to obtoin o higherrotio.
Disossembly

o r e o f d i f f e r e n t d i o m e t e r s ,t h e i n t o k e v o l v e s
b e i n g l o r g e r .O u t e r ( e x h o u s t ) p o r t s o r e s i n g l e ,
o l l r e m o i n l n g o r e d o u b l e d , i . e . b i f u r c o t e do n d
b r o n c h i n gt o t w o v o l v e s i n o d i o i n i n gc y l i n d e r s .
The centre exhoust port bronches to the cyl.
i n d e r sN o . 2 o n d 3 , t h e n e i g h b o u r i n gi n t o k e p o r t
to the cylinders No. 1 ond 2, ond No. 3 ond 4.
T h e c y l i n d e rh e o d c o n b e h o n d l e di n t h e c o r o s
o u n i t . O f t h e i n d i v i d u o li o b s , o n l y t h e r e p l o c e ment of volve springs,cotters, ond cylinder
h e o d b o l t s c o n b e c o r r i e do u t w i t h t h e e n g i n e
i n . p o s i t i o ni n t h e c o r . F o r o l l t h e r e m o i n i n g
i o b s ,t h e c y l i n d e rh e o d h o s t o b e r e m o v e df r o m
the cor.
To remove the volve springs, screw out the
sporkingplugs ond, using o tommy bor with
o curved end (steel bor of obout 5 mm diometer), broce the volve to prevent it from
s l i d i n g d o w n i n t o t h e c o m b u s t i o nc h o m b e r .
To RemoveCylinder Heod from Engine
1 . L e t t h e e n g i n e c o o l d o w n b e f o r er e m o v i n g
t h e c y l i n d e r h e o d t o p r e c l u d ew o r p i n g o f i t s
beoring surfoce.
2. Droin the coolontinto o cleon vessel(see
C h o p t e r1 5 . 1 3 ) ,d e t o c h o l l p o r t s c o n n e c t i n gt h e
cylinder heod to the vehicle,ond remove oll
p o r t s w h i c h o r e l i k e l y t o o b s t r u c tt h e r e m o v o l .
3. Remove the oir cleoner, lift owoy the
c y l i n d e r h e o d c o v e r , o n d r e m o v et h e n u t s o n d
bolts holding down the cylinderheod (on engines of Skodo 120 L ond 120 LS cors, two
bolts olso hold down the end rocker shoft supports) reversingthe order of the numbers ind i c o t e d i n F i g . 2 . 1 6 1 1B
. y pulling the exhoust
m o n i f o l d ,d i s e n g o g et h e c y l i n d e r h e o d o n d l i f t
it owoy.

Cylinder Hr

Disosse
heod on o r
o support i
it does not
o iob from t
An exomple

1. Remov
the cosing
control, end
geor ofter
supports.

To Refit Cylinder Heod on Engine

. 1. Locote the cylinder heod gosket on o perf e c t l y c l e o n s u r f o c eo f t h e c y l i n d e rb l o c k ( c l e o n

(\-/3 r--{/\.4)

?,3

\I
I
I

/
"'@-:lOt___v'
,/

R e m o v et h e l o c k r i n g f r o m t h e s h o f t e n d o n d
strike off the entire volve nockergeor from the
shoft.

the cylin
the oilwo
structed c
Releos
once odju
h e o d .l f n
the rocke
2. Swin
down the
porogroph
opply the
liminory o
the sequ
(Fig. 2.16
shoft supp
3. Adjus
ter 2.13, re
cleoner, re
tighten oll

t l
I
I

Fig.2Je

2.16 CYLINDERHEAD, VALVES AND

SPRINGS
T h e c y l i n d e rh e o d i s o c o s t i n go f s p e c i o lg r e y
c o s t i r o n .T h e v o l v e s e o t s o n d g u i d e so r e c o s t
o n d m o c h i n e dd i r e c t l vi n t l r e h e o d .T h e v o l v e s

F i 1 . 2 . 1 6 1 1T- i g h t e n i n gD i o g r o mo f C y l i n d e r
Heod Bolts ond Nuts
F o r t i g h t e n i n gt o r q u e ss e e C h o p t e r 1 . 8
54

For holding c
bolt M 8 scr
rocker-shoft st
1 - M P 1 - 1 1 3v
2 - MP 1-114v

99
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The rocker-shqft support hos o poper seol

preventing leokoge of the oil fed from the cylinder block to the rockers vio the support. lf
o r e o d y - m o d e s e o l ( g o s k e t) i s n o t o v o i l o b l e ,
moke it yourself using poper 0.1 mm thick.
A t h i c k e r s e o l i s u n p e r m i s s i b l eo s i t w o u l d
couse c distortion of the rocker shoft. The hole
in the seol must coincide with the oil hole of
the rocker.

3. To ensure o leokproof condition of the

volves, grind them in with their seots in the
cylinder heod.
Volve GuideS
The volve guides ore formed directly by the
cylinder heod motericl. lf reconditioning is
n e c e s s q r y ,r e b o r e t h e g u i d e h o l e o n d p r e s s - f i t
o bush.
Volve guide bushes ore not ovoiloble os
s p o r r ep o r t s . T h e y c o n b e m o d e i n d i v i d u o l l y o c cording to the following drowing. The required
moteriol is grey cost iron of 200 N/mmz (2O kpl
mm2) tensile strength, in Czechoslovokio cost
iron to specificotionsof theCzechoslovokStondord CSN 422421.
Hoving press-fitted the bush, correct ony
shrinkoge of the inside diometer ond, to motch
the new guides, rrecondition the volve seots
ond grind-in the volves.

A p p l y t h e s e o l o n d r e fi t t h e e x h o u s t o n d i n toke monifolds. For detoils see Chopter 2.3.

porogroph30.
6. Reinstoll the thernrostotic temoeroture
control cosing with its gosket ond do not forget
to put spring woshers under the nuts.
N o t e : W h e n r e o s s e m b l i n gt h e c y l i n d e r h e q d
of on engine removed from the cor, it is odvisoble to proceedwith the iobs os per porogroph
5 ond 6 with the cylinder heod refitted on the
engine to focilitote the tosk.

Valve guide tolerances

Guide

lf the cylinder heod gosket hos been reploced

with o new one, invite the customerto bring in
the cor ofter trqvelling 500 to 1,000kilometres
for o retightening of the cylinder heod ond
odiusting of the volve cleoronce.

7.94 - HB + O.O22
mm

Fig.2.16

o.oo

l n l e tV a l v e

7 . 9 4- F 7

t 9 9?q .n+ 0.013

0.025

DK 1+J6

F i 1 . 2 . 1 6 1-3 R e c o n d i t i o n i n gC y l i n d e rH e o d
f o r F i t t i n g V o l v e G u i d eB u s h
Seoling of Cylinder Heod
As o seporote unit or forming o unit with
the cylinder block, the cylinder heod must be
seoled ogoinst leokogeof goses ond woter, i.e.
it must be gos- ond wotertight.
1. When replocing some of the bolts protruding into the woter iocket, seol them with
point. The woter iocket of the cylinder heod
must be leckproof when tested with woter
u n d e r c p r e s s u r eo f 0 . 5 M p o ( 5 k g / c m 2 ) .
2. lf it is necessory to restore the flotness
o f t - h ec y l i n d e r h e o d m o t i n g s u r f o c e ,, e g i i n d t h e
s u r f c c e o n l y t o t h e l e o s t p o s s i b l e e x t e - n ts o o s
n o t t o i n c r e o s e t h e e n g i n e c o m p r e s s i o nr o t i o .

x 1Tr9
F i 1 . 2 . 1 6 1-4 V o l v e G u i d e B u s h
56

To Recon

These
volves fo
groph 3),
new volvt
Use o
conicol s
with its r
1. Che
necessory
volves. F
s h o n ko f ,
eter, ond
will resul
ing in oc
seot widtl
Check 1
occordinq
Coot the"s
volve in tl
troces of
centre of t
2. Coot 1
volve with
of oil with
volve into
seot ond 1
severof tin
onother po
round the I
volve ond
grinding-in
the volve c
grey. Use
down the v

L9
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ur-Bugpu1r6
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eu!] o qllM a^lD^
arnlxlru) punoduoc 6u1pu1.16
eql Io esDllns lDcluocoql ro lDes aql lDoc'z
'o^lDAaql
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eql ls!lvr] puo lugod 6u1>;.rotu
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JoUDJo 'sa^lD^Meu
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eqr ll i.tosseceu etuoceq suo11o:adoesgql

t
Irrol uMop-ssard
'eca1d
- L
pua
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.r;y pessetdruo3
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o
suoglo:adg;o acuenbes- rallnC 6ut11ty11
6 u 1 s 1]'D
1 a S e ^ l o n 6 u r u o 1 1 1 p u o c-a9l 7 9 ; ' 7 ' 6 ; 1

"fLr,e

6trrl ll

so^lDn u!-Pu!19puD slDes e^lDn uolllPuocouol

uo!ltsod
rounC 6ut1tn - toes e^lDn 6uttltn - 9l9L'Z'6lJ

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punoduroc 6u1pug.16

eql
at{i

2,15-2.'t8

h o n d l e )o n d t h e s h o r t o i l p u m P ,t o t h e c o s t o i l
s u m p t h e 3 3 0 m n - rl o n g d i p s t i c k o n d t h e l o n g e r
o i l p u m p - s e e C h o p t e r2 . 1 8 .

3. The leokogetest should be corried out with

the cylinder heod fully ossembled by pouring
o smoll quontity of petrol into the exhoust ond
intoke ports. The petrol must not leok post the
moting foce of the volve in the combustion
chomber. Another method involves pouring
o smoll omount of thin oil into the combustion
chomber ond introducing compressed oir into
t h e e x h o u s t o n d i n t o k e p o r t s u s i n g ,f o r e x o m p l e ,
o rubber cone. No oir bubbles must oppeor
oround the volve heods.
T h i s t e s t c o n b e s i m p l i fi e d b y o m i t t i n g t h e
fitting of vclve springs while pressing the
volves into their seots by hond using o suitoble
Jixture (fork) for holding down the volves.

2 . 1 8 T I M I N G G E A R C O V E R. O I L P U M P
l n o d d i t i o nt o t i m i n g g e o r s ,t h e t i m i n g g e o r
c o v e r h o u s e s o l s o t h e o i l p u m p ( f o r mi n g i t s
h o u s i n g )o n d t h e d i s t r i b u t o rd r i v e .
A g e n e r o ld e s c r i p t i o no f r e m o v i n gt h e t i m i n g
geor cover from the engine con be found in
C h o p t e r2 . 4 o n d f o r d e t o i l s ,r e g o r d i n gi t s f i t t i n g
o n t h e e n g i n e ,r e f e r t o C h o p t e r2 . 3 , p o r o g r o p h s
22 to 25.
The enginewith the sheet oil sump hos the
shorter oil pump with the suction stroiner
h o l d e r7 2 m m l o n g .T h e e n g i n ew i t h t h e c o s t o i l
s u m p h o s t h e p u m p3 0 m m l o n g e r .

Volves
The volves ore forgings of speciol high-temperoture steel with o conicol seoling surfoce
o n d h o , r d e n e ds t e m e n d . T h e v o l v e h e o d s o r e
of unequol diometers (lorger with intoke volves
o n d s m o l l e rw i t h e x h o u s tv o l v e s ) .
Current reconditioning of the conicol seoling
surfoce is done by grinding-in with the respective seot. lf o mojor repoir is required, regrind
the seoling surfoce of the volve heod on
o grinding mochine to on ongle of 91o +10',
ond then grind it in with the seot.
When regrinding the conicol surfoce, it is
obsolutely essentiol to keep it in correct olignment with the volve stem.

Valve Springs

Free Length

Wire
Diameter

rcs/po

Outer

Inner

45.85

43.6

3.75

2.5

Mean Spring 26.75

urameter
T
S p r i n g P r e s - L""En-I
sure
3Omm
In s t a l e d
2 9 9 - 3 5 8N
length

A s s e m b l i n gO i l P u m p
C o o t t h e p u m pg e o r so n d t h e d r i v e g e o ' rs h o f t
w i t h o i l , o n d i n s t o l lt h e m i n t o t h e t i m i n g g e o r
cover. Insert the gosket ond close the pump
w i t h t h e l i d w i t h s u c t i o np i p e o n d s t r o i n e r .U s e
spring woshers to prevent the lid screws from
s l c r c k einn g .

Fi t t h e
t i gh t en i n
thot it pr
edge of tl

45.20

Assembli

4.OO
26.5

Length

Length

Betwee

I d r iivveenn
I Axiolc
I betwee
I and lid
Seol

1201S

18.5

For eg
s t r o i n e rv
brrocket r
6 5 m m ) ,1
(the len
proximot
The go
provides
geors. lf
gosket is
thicker tl"
To pre
obnormo
respectiv
limits sp

30mm
29mm
108-127N460N

2.17 OIL SUMP

A s h e e t o i l s u m p i s u s e d o n e n g i n e sw i t h
o 68 mm cylinder bore. Use o rubber gosket
w h e n i n s t o l l i n gt h e o i l s u m po n t h e e n g i n e .
E n g i n e sw i t h o c y l i n d e r b o r e o f 7 2 m m h o v e
o c o s t o n d r i b b e do i l s u m p .F o r i t s i n s t o l l o t i o n
u s e i t s r e s p e c t i v ec o r k g o s k e t . A s h e e t b o f f l e
i s b o l t e d o v e r t h e b o t t o m o f t h e o i l s u m p .U s e
b o l t s w i t h s p r i n g w o s h e r st o b o l t i t d o w n .
R e l o t i o nb e t w e e no i l s u m p ,o i l d i p s t i c k ,o n d
oil pump:

F i 1 . 2 . 1 8 1 1T- i m i n g G e o r C o v e rA s s e m b l yS e c t i o n o lV i e w
( f o r b e t t e r i l l u s t r o t i o n ,t h e p i n n e d c o n n e c t i o n
of the shoft ond geor is somewhot turned, its
correct position being describedin the text)

T o t h e s h e e to i l s u m po p p e r t o i n st h e d i s p s t i c k
of o totol length of 305 mm (including its
58

1. Thre
brocket, s
p o i n t i n gr
odio.4
in the pr
bore (pin
the pinne
When c
sure thot
line with
is import
i g n i t i o nd
To prev
ing durin
o pilot m<
Then con
u s i n go s
2. After
ensure tl'
0.1mm) I
3. Fit t
into the f
u n d e rt h e

69
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Technical Description

Carburettortype and model

1979 onwards*

Car Model

1976/1979

105 S and105 L
120 L
120 LS

JlKOV32EDSR- 443751290 100

JrKOV32EDSR- 443751319 800
J|KOV32EDSR- 443751290000

JlKOV32EDSR- 443751 292400

JlKOV32EDSR- 443751 292500
J|KOVg2EnFF- 443751 292600
to

Types of carburettors and their functional elements according to the,polex cdnparison table or
their bore (in millimetres)
Carmodel

1 0 5 S 1, O 5 L

'

itZOr-

; 1

l2OLs:

Se.Babove

Carburettortype and model

E l e m e n t so f s t a g e I a n d l l o r i n c o m m o n

Fge
t

A t o m i z e rc o n e d i a m e t e r
Main petroljet
Main airjet
P i l o tj e t
P i l o ta i r j e t
A u x i l i a r yp i l o t j e t
Econostatpetrol jet
Econostatmixture jet
Econostatair jet
Choke petrol jet
C h o k ea i r j e t d i a m e t e r
Diaphragmcontrol air valve
Pump by-pass orifice
Injector
N e e d l ev a l v e d i a m e t e r
S u c t i o nc o n n e c t i o nd i a m e t e r

21
105
170
50
140

22
120
160
45

A c c e l e r a t i o np u m p d i s c h a r g e
Float weight 2O t 1 gram

7 to 9 c.c. per 1O strokes(1976-79)6 to 8.$19f9 onwards)

t'1mm frEmbp face
Fuellevel.FloatRemoved.'28mm

Jo

60
95/85'
70
90
4.5/5.5*
130
80
40/45*
50
1.5
1.2

22
1 1 2 / 11 0 *
170
50
140

23
125
160
45

Jo

60
110
70
100/90*
4.5/5.5' *erF
or"fs?
160
,.w'1'
40/45*
50
1,5
1.2

' . 122
12/110*
170
50
140
70
1'to
70

23
130/125*
160
45
60

1Orygo*
4.5/5.s*
.
8
40/45*

50

1.5
1.2

interferencewith the smooth flow ot o hlgtler

u n d e r p r e s s u r(ev o c u u m ) .
.
ln stoge ll, the by-poss hole enhonces
o smooth ond continuous intgrconnection of
both corburettor stoges.

Moin System (Fig. 2.1gl1l

Both mixing chombers hove self-contoined
moin systems.Air is mixed with petrol in the
emulsion tube ond the finol odiustment of the
mixture tokes ploce while it is corried off by
the oir flow with the throttle disc open.

Econostot or rich-mixture syste4 (Fig. 2.19/3)

This system enriches the mixture in stoge I
ot higher engine lood (output). lt operotes
outomoticollyoccording to the volue of under',
pressurein the otomizer ond in dependence onf
the flow of oir sucked-inby the engine.

ldle Run ond By-poss System

(Fis.2.19l2l
These ore token core of by two circuits - by
the idle run system in stoge I ond the ouxiliory
oir system in stoge ll. Both systems ore connected to the moin systems of both stoges in
the zone of the emulsion orifice by the respectiveelementsterminoted by the odiustoble
idling screw ond fost-idling (ouxiltory oir)
screw.
- Stoge I incorporotes the petrol iet seporotor
for the preventionof self-ignition.The idling orifice is interconnectedwith the mixing chomber
by two by-poss bolts enobling c smboth tronsition to the moin system, ond o hole is provided in the mixing chomber to obviote ony

AccelerqtionpumP (Fig. 2.19i5)

This is o mechonicol, diophrogm-typePumP
controlled by the throttle disc of stoge l. Fuel
sucked-in by the diophrogm from the floot
chomber posses through o non'return boll volve
to the iniector ond through the by'poss orifice
bock into the floot chomber. At o sudden opening of the throttle disc, the moior part of the
fuel poses through the iniector, ot o slow
opening into the by-poss without the oction
of the iniector.

60

llr-

&
t9
w
tolld -vLL 't o6Dls lo re! lolld - LL 'te! rlD
- 0L 'Mercs uo!]ceJroc6u;lp1-1sol- Merss 6ulu
puo
ll puDI e6ols rouarnqroc
Isz
'rolorDdas
-n6eJ alnlxlLu-rlclu - 6 '/v\ejcs uollcejrcc.tty i
(1;) le! rolld - 9e 'lt e6o1s1o1e!
lS L
Luelslsunu alpl - Z16L'Z'6tJ

n,4"

'll
e6Dls
eqnl uolslnut3- ve 'l
v
ll puo I a6Dls rollarnqroS - ls z puD
lo
'Je^oc
-t '1; e6o1slo 10! rlo
uolslntrJ3
lepun
orll
eql
ls L
le^sl
lo oqn]
lo euDld Jall^ol
'uollceuuoc
-VZ 'l e6ols
rlD ulDW- Z '!l e6Dlslo
lolu! lonJ
la!
lenl to rqoloq : L + 0z
lo
'l e6Dls
- I " e u l o J l s l o n J - I ' o A l D A e l p a e N- g ' l D o l J
lo lo! lorlad uloytl
lorlod utow - VL
requoqC polJ puD ruels{S ulDt4 - LIBL'Z'6lJ

Choke - Cold-stortingDevice (Fig.2.1916)

c r o n k c o s ed u r i n g i d l e r u n o n d i t r e m o v e sf o r
burning ony residuesof unburnt hydrocorbons
which hove got into the cronkcose.

Bosicolly,the choke is o self-contoinedcorburettor consisting of o fuel reservoir,o petrol

jet, on oir iet, o vocuumcontroller,ond o throttle
volve. The mixture is formed in the throttle
volve zone where it is sucked out from under
the corburettorthrottle disc.
At increosingengine speed,the rising vocuum
movesthe plungerof the chokevocuumcontrol,
t h e h o l e s i n t h e p l u n g e ro v e r l o p o n d t h u s t h e
mixture is enriched outomoticclly.The driver
controls the richnessof the mixture by opening
or closing the choke throttle volve.
Auxiliory Devices
Vqcuum connection for the vocuum odvonce
control picks up vocuum (the underpressure)
obovethe throttling disc of stoge | (see Fig.
2.1st4).
The suction connecticri is led out of the corburettor lower flonge os o tube from under the
throttle disc of stoge ll. The suction prevents
o generotionof vocuum (underpressure)in the

Fi1.2.1913- Econostot- Rich-mixtureSystem

13 - Econostotoir iet, 14 - Econostotpetrol iet,
15 - Econostotmixture iet "2"

Fig.2

23- Inie
p u m p ,c (
Acceler
v e n t in g

i:lr

I
32 and3
30 - Chol
Choke vr
volve
- StogeI
Fi1.2.1914
16 - Ffoot chomber cover, 17 - Floot chomber
body, 18 - Stoge ll control, complete, 19 - Diophrogm spring, 20 - Diophrogm,21- Diophrogm
control oir volve - stoge ll, 21A - Diophrogm

62

Control Elements

CARBUR
AND RE'

control oir volve - sttfge l, 22- Vocuum connection, 1 ST ond 2 ST - Corburettor stoge I
ond ll

Diogno
rect chec
reossem

t9
A ; u op u n o ; e q u D c l u a u d l n b e q c n g ' A l q u e s s o e r
r l e q l p u D s l . t o d . t o u a r n q r D c ; o6 u t l c a q o l c e l
-roc D ro; pel;nbe.rs1 luaurdlnbe c1lsou6og6

'o poJ D lJesu! ol Pepueuuocel sl r!) tuu 0L eq

looll eql +o d;; eq1 ueem
lsnu lelsD6 ",,1tpuD'l;;oc11:an
-loq
Jeloc aql ocDld
sql
ocuoJDelc
'looll eql
1sn!po ueq] puD uollcnrlsu! sno
-1ne.rd
oql ol 6ulp.roccoJeloc aql enouer lsJ!l

I e6o1
-uoc rui

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AISWf SSVSIO UOi.rsUnsUVC

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ll!'l
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- s r o c s g ' J s n o c e q l A o n r r oU l l p u o J e n o c e q ] u o l ,
I 1e 6 o 1 sJ o l l e J n q r D ca q l l o s l o r l u o o e q l e ^ o u l e u
le{sog

sAlD^
elllorql - tt 'le! llo eloqc - gg 'en1or eloqc
- 79 '(.renocu1) ad;d o)toqC- L0 ']al sloqC -0t
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6 t 6 ! r a q o l c o a c u t sp e l e l o p s L'Z
'6tJ
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egttv0

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eql - la^el lenl eql lsnlpo o1 1a6Jo; ra^eN
'qdo.r6o:od
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6
u
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r
r
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q l ! r l r ra ^ l D ^ 6 u r 1 o a 1o e c o l d e g ' p e n o u e r r o u D e l c
A11cel.rad
eq lsnu lelur eLll u! Jeulorls lenl eql
' 6 u l l n s o e u l 6 u 1 . r n 6' s p u o o e s g . r a d ( 7 u c 7 6 > t
S OO )
Dd4 6t00'0 s! luaunrlsul 6ulrnsoau eql ]o uollD
- ! ^ a p o l q l s s l t u r a d y ' ( 7 u c 7 6 1 6 t ' 0 ) D d U 1 18 t 0 ' O
; o a l n s s e : d : o p u n u o u r D l u r D u rl s n t x a A I D Ae q l
e^lon elpeeN lo ssauloo.td>;na1
'lugl'u
-slour qlootus Jloql eJnsue o1 aptqd;nslp unugp
- q A l o t u l o s r s D q a q l u o p u n o d u o c 6 u 1 1 o c 1 L q no1
q1;lrr s1.rod Jol!ru!s puD srelal lo sDsJo uo!]
-c!Jl aq] lDoc 'rolleJnqJDceql eP!su! slueusle
pessard
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-r.Iloc ql!/v\ Jlo Molq puD lol1ed qt!M acDlrns
sll uDelc'JolleJnqroc eqt 6u!1puoU arolaB
'(g'gg raldorlc)
lueLu
-gsnlpo unr elpr o!sDq eql Aq pepnlcuoc slonn
-lD aq plnoqs Aeqt puo 'suollcesqns 6uglrro;1o;
aql u! paq;:csap sqol epnlcu! Plnoqs sl33q3
l D n p ! ^ r p u r p u D u o l l c a d s u l p e l ! o t e p V '(tq' 9 1

'a^lo^ 6u11uen
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97
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- 97
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uelsrtg

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- p D c l s D q p u o ' D u g l s n l p ou n l e l p t ' J e u l D J l sl e n ]
a q l l o 6 u 1 u o a ; c' e ' ! ' e c u D u e l u ! D t ue u ; 1 n o y ( o
ecuDuelu!DW

sl lSrs^s 'lvNolrcNnJ Jo
IN:lWrSnfCV

CNV 3CNVNAIN|VI l

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epoJj u61eto3491
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-roC lDuollDN UO1OU1;)
leln1co;nuDurrolleJnq
-Joc eql iqs uo;1crulsu!]uaull:ad qtlrvr.req1a6ol
pera^!lep ueeq sDq lueudlnbe s!ql qc!qM ol
'sdoqs :1ode.r
puDsuo!lols ec!^respazl;olcadsu;

suoqJDc
JOI SoAO

//"\
'//
\
/\\
-.---

V,I

rrr)

\trV

1. Excessi
- overfloc
o) leoky n
b)
c)
d)
e)

too hig
incorrec
too lorg
too sm
oir-ven

2. lncorrec
- engine
o) choked
b ) choked

- F l o o t A d j u s t i n gb y B e n d i n g
Fi1.2.1917
the Lip of the Floot Honger

F i g . 2 . 1 9 / 8- A d j u s t i n gT h r o t t l e D i s c s U s i n g
MP 1-120'lndicotor

c)
d)
e)

i ncorrec
defectiv
errotic i
portioll

f) folse oi
10 mm in diometer between the gosket ond the
floot). The lip must lightly touch the springl o o d e db o l l i n t h e n e e d l ev o l v e . T h e l i p m u s t
not press- in the boll or move owoy from it.
T h e d o s h e dl i n e s s h o w t h e f l o o t i n i t s l o w e r
position.
Petrol and Air Jets
C l e o nt h e m b y s w i l l i n g i n p e t r o lo n d b l o w i n g
t h o u g h w i t h c o m p r e s s e do i r . W h e n r e m o v i n g
t h e m , n o t e t h e i r l o c o t i o nt o f o c i l i t o t e r e i n s t o l l o t i o n i n t h e i r p r o p e rp l o c e s .
Volume Iniected by Accelerotion Pump
ond Pump Hondling

it down till the pointer of the diol indicotor

touches the disc. Zero the scole ond rotote the
reguloting (odiusting) screw while forcing
down the indicotor till the throttle disc porti'
olly opens (3 mm from the edge of the throttle
d i s c ) o n d t h e i n d i c o t o rr e o d s 0 . 1 0 t o 0 . 1 2 m m .
Proceed in the some woy to odiust the other
throttle disc.
Setting ldle Run Adiusting Screws
A f t e r o d i s m o n t l i n g ,e t c . , s e t t h e s c r e w s i n
t h e i r b o s i cp o s i t i o n ss o t h o t t h e e n g i n ec o n b e
storted up ond be kept running.
o) Rotote the oir correctionscrew (Fig. 14.3/9)
four times through 180" to closed position.
b) Rotote the idle run odiusting screw (Fig.
15.3/10)five times through 180oto closed
position.
Do not tighten the screws forcefully in their
c l o s e d p o s i t i o n s .T h e y m u s t b e o r o g o i n s t t h e i r
s e o t si u s t l i g h t l y s o o s n o t t o f o u l t h e m .

Fill the corburettorwith fuel ond operotethe

corburettorlever10 times through its full stroke
to iniet fuel. Operote the lever ot intervols of
3 to 4 secondsond cotch the fuel into o groduo t e d v e s s e l . T h e i n i e c t e do m o u n t s h o u l d b e 7
to 9. c. c. lf necessory,deflect the injector so
thot the iet of fuel posses directly through the
c h o m b e ro n d d o e s n o t f l o w d o w n i t s w o l l s .
When refitting the occelerotionpump cover,
prelood the diophrogm by opening the throttle
disk of stoge I to its full stroke before retightening the cover copscrews.
To Adiust Throttle Discs

Testing the Operotion of Pilot Jet Seporotor

The pilot jet operotes correctly if switching
on ond off of the current fed to the seporotor
(by switching on the ignition,etc.) is monifested by oudible clicks. The seporotorcloses
the pilot iet when the current is switched off
( s w i t c h e do f f i g n i t i o n ) .

Turn over the corburettor with the throttle

discs on top ond loosen the reguloting screws
in the flongetill the throttle discs ore fully
c l o s e d . P l o c e t h e i n d i c o t o r M P 1 - 1 2 8o n t h e
flonge necr one of tlre throttle discs ond force

Corburettor Defects ond Their Removol

Notice: Turn your ottention to the corburettor
o f t e r h o v i n g o s c e r t o i n e dt h o t t h e e n g i n e ,f u e l
supply, ond ignition operote correctly.
64

s ) l ncorrec

h ) too low

3. lncorrec

o ) i ncorrec
b ) i ncorrec

c) choked
4- Poor occ
o ) choked
b ) leokyno
c ) defectiv
5 . Loss of p
stoge | |
o ) choked,
b ) domoge

i ncorrec

||
;i ostoge
mutuoll
ndll in

6. Engine w
storting
o ) choked <
b ) low fuel
c ) i ncorrec
(excess

o) lf no ner
hold the
connecte
emergen(

99
'olnsDeul fuorodural puo Acue6.raua
u D s o p e J e p l s u o o ' J e A e M o q ' e q p l n o q s a l n p a c o . t ds l q I ' l t n c l l o - U o q s o 1 s u 1 o 6 oa l q D c P e l c e u u o c
. s ! p e q l l c a l o r d ' 1 n u 6 u 1 s o 1 c a l p e e u o q l l l o M e r c s p u D l n u e l q n o p a q l A q . r o 1 o : o d a se q l p l o t i
' a 1 q o ; 1 o n os 1 . t o l o : o d a s l l , r o uo u
,aiiread eql 6ugiotuer ueq6'l!
ll (,,
llDlsular puD elpoeu sl! e^oruer

( c s 1 pa ; 1 1 o . r qp]e u a d oA q a n l s s e c x e )
u n r a l p t p e l s n i p o, { l l c a r o c u g( c
raqrxoqclDoll ul ie^el lenl /r\ol (q
lcarrocut ro PeIoLls(o
1a! a>1oqc
a u 1 6 u ep g o c6 u 1 1 . r o -1 s
'9
uDls lou !|1rrtau16u3
anlloelap.rosa6ols qloq ul ll puo
slueu.tela
1 e 6 o 1 sl o s l u e u J e l ep a 6 u o q c . r a 1Au l 1 o n 1 n u( p
alonbapouls1 larrrod1nq suado 11e6o1s-g1a6ols lo cslp slllorrlt palsnlpoAllcarrocutic

unr olp! Aglcar.roc

lsnlpo looll eql lsn!Po
auo Meu o qllM 1gacolda.rlo 1a! aq1 uoalc

sluaurale lcelJoc llDlstl!

"*JTli;
cslponlo,qr

pa6ouop (q
lorluoo 11a6ols ;o u.r6o.rqdo1p
paloqc (o
se^lD^ ro lorluoc u.t6o.rqdo1p
uado 1ou seop I e6ots rarvrodlo sso-l '9
ru6o:qdorpa^lloelep ( c
dund uollolalac3Dlo enlD^u:n1a:'uou,t1oa1( q
rolca!u1pa)oqc { o
uo!lDleleccDrood 'v
sac!]!ro ssod'lq Peloqc ( c

1 1a 6 o 1 s l o s l u a u a l e l o l l u o c a c o l d e l
uleql trDolc

euo rrteu D Llllrln eco;da.t

fuossecau ;1 eco;del Jo 1l uDolc
e c l l l r o s l ! u D e l c P U Dl ! l c a d s u l
:1o pessarduroc r{}!rrtsaclllJo eql uDalc
souo Meu qllfv\ ueql
's1.rod
e c o ; d e . rJ o ' r u e q l u o a l c
lcaJJoc llolsul
I11cat:oc 1sn!po

suod .ropalnqJoceA!lceleplo l3eJlocul ( q

( ol
u n r e l p ! p a g s n l p oI 1 1 c e . r : o c u
't
ll Jo I a6ols ;o sessod'AqlceJrocul

a n l o ^ p a ! ] t c a d s a q l o 1 p e a d s 6 u 1 1 p 1e s ; o . t
i;1ce.rroc 1sn!po
a6uo11 eLll lo oarD
'e6uo;1
l g o l u o c a q 1 d n e n r f i { . t o s s e c e ul l
ar.ll Jepun 1a1so6 aql ecoldeJ puo lcedsu!
seuo /v\gu qllM
ruaql ecolda: :o 's1el eql lceqc Puo uDelc

p a a d s6 u t t p t M o l o o l ( q
u n r e l p t p a l s n l P oA 1 1 c a : : o c u( 6l

'itllcelloc
'eu
lan;
rollarnqJ
l

llo Paq
sesolc J
- ! u D u Js
.rolorod
6utqcl!t
rolDJ

'
reql ls

J t a q lu !
'Pasolc
6r1) rr
'uo11;

(oie'u
eq uoc
ur sMe

reqlo e
'Lutu
zL'
slllorql
-11.rod
c
6u;cto;
aql olD
roloc!p

u!-pa)cns s! JD aslol (]
s e z l s l e l l 3 e l r o s u t . r o s 1 a ! p a l o q J A 1 1 o ; 1 . r o(de
unr elp! cllDJra(' t a ! e q r s s s o l c e l p e e u ) . t o 1 o . r o d ees n. r l c a l e p ( p
r t t e r c s 6 u 1 1 p 1 - 1 s op1a l s n l p o A l l c a : : o c u l ( c

(*euo rvreuo qllrur JolDlDdeseql aco;da.t

l;1ca.r:oc1sn!po
J!D

6u1s

unr elpl lo seclllro Palor.{c(q

pesserduoc Llllm saclllro eql q6no:q1 rvro;q

lmssecau l! seuo Mau qllM
ureql aco1dal puo 'ueql lceqc PUD uoolc

sta! rottd peloqc

s l P ! l o u s e o Pe u 1 6 u e
6u1pt lcerlocul 'z

(loes st! 6u1pngcu1)

euo Meu D qllM aco;de; Jo l! lcllsun
treLll uDelc
seuo lceJloc tlllM eco;del PUD lceqc

(e
(s1cg1s)esolo lou seoP a^loA 6u11uen-l1o
oo1 ( p
slal .r1oulou (pa66o1c)11otus
sla! ulotu a6.ro1oo1
slel 1o sezts lcelJoou!
la^el lenl q6rq oo1 ( q

looll eql tsnlPo

euo Meu D
'a6o>1oe1Jol
qlllrr ecolde: Jo 'uDe;c
lceqc

(o
e^lo^ elpeau A>1oe1
rollernqloc 1o Du;pooglJelo*
'L
uolldurnsuoC lenl e^lssocxf

unstick the plunger or reploce it with

o new one

d ) choke plunger sticking in its bottom

position
storting worm engine
e ) too high fuel level in floot chomber
f ) incorrectlyodiusted idle run

o d j u s tt h e f l o o t
odiust idle run correctlY
the volves when reossemblingthe fuel PumP.
Put o spocerring under the suction volve (close
to the mud trop). Fig.2.2Ol1 shows the positions of volves ond the holding-down thrust
plote.
Put the spring of the diophrogm into the
lower port oi the pump ond engoge the pin ot
the diophrogm with the octuoting lever. Operote the hond lever to compressthe dioPhrogm
oncl hold it in position by inserting o rod of 4.5
to 5 mm diorneter (for exomple the shonk of
o drill, etc.) between the octuoting lever ond
the woll of the pump lower Port.
Now bolt both pump ports together so thot
the mud trop is on the right-hond side when
viewing the pump from obove ond the fostening
flonge from the front. Use spring woshers
u n d e rt h e c l o m p i n g b o l t s .

2.2O FUEL PUMP

Technicol DescriPtion
The model JIKOV MF 3407 fuel pump is of
the diophrogmond lever type, controlledby the
round disc of the comshoft.The suction motion
of the diophrogm is octuoted by the lever, the
dischorge motion by the spring of the diophrogm. Fuel flows through o stroiner, o mud
trop, ond the suction volve to the delivery
volve. A priming lever is provided for hond
p r i m i n g o f t h e f u e l . T h e m o v i n g m e c h o n i s mi s
l u b r i c o t e dw i t h o i l s p l o s h e df r o m t h e c y l i n d e r
block.
4 mm
S t r o k eo f t h e d r i v i n g d i s k
1.5 mm
Suction heod
2mm
Deliveryheod.
Pump dischorge ot 2,000 strokes
per minute ond free outflowwithout
30 ltrs/hr.
counter-pressure
Mointenonce, Repoirs, Disossembly
ond Reossembly
For routine mointenonce (cleoning of the
mud-tropscreen) see Chopter 15.3.After hoving
operoted the hond-priming lever lift it till it
engogessofely in its locked position.
ln the cose of o defect,inspectthe diophrogm
ond check the volves for leokoge.After hoving
removedthe pump from the engine, removethe
mud trop, seporote the upper port from the
lower port, ond remove two screws, holding
down the thrust plote, to lift owoy the volves.
Swill oll ports in petrol ond blow off with com'
pressedoir. Reploce domoged ports with new
ones.
lf necessory,removethe diophrogmfrom the
octuoting lever in the lower port of the fuel
pump (its monufocturerrecommendsthe diophrogm to be reploced ofter obout 50,000 kilornetreswith o new one). Do not stretch the
spring of the diophrogm ond do not olter its
compressionforce chorocteristicin ony woy.
Do not forget to put fibre pocking rings under

Fig.2.2011- Section Through Fuel Pump

lf it is necessory to verify the dischorge of
the pump by o test, note the following require'
mentswhich the pump must meet otl80strokes
per minute:
o) 15 ltrs/hr. ot f ree outf low without fuel
counterpressure
b) minimum pressureof 0.018 MPo (1.8 m of
woter column) ot o zero off'toke of fuel
c) o dry pump must drow fuel from o depth of
1.5 m in 16 seconds.

Fuel Pump Defects ond Their Removol

1.
o)
b)
2.
o)

Foulty fuel supply

clogged mud trop
domoged diophrogm
Fuel pump does not hold fuel
dirty or defective volves

cleon it
reploce it with o new one
wosh them in petrol, reploce defective
volves with new ones
66

L9

aA!lc

go qldeP
lenl l
to tu 8'L
lenl ]no
selorls 0
-e.r1nbe
;o eOro
dtun

'','
'.'er/

6u!lluoruslc qclnlC t't

OL

t't

A;qurassoegqclnlC

OL

etDld uollclrJ

LL

trsluDqcew lorluoc qclnlc

LL

9't
s't

uolldglcseq loctuqcal

69

au;6u3 u! qclnlC 6u;111;aX Z't,

69

e6o6

sJaqsoM

6u1ua1
ueqM e
loql os
puD Je
lo luotl
g't lo p
r,u6o.rq
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;o ugd
3ql olu
lsnJql
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'dund

H S r n ]3 '
ql

1re

t; ,t

F i g . 3 1 1 - C l r r t c l r- S e c t i o n c r V
l iew

Alternative Diaphram Clutch available,

Center Plate,Bearingand arm of LP type.

68

69
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Turn the flonge on the centeringorbor so thot

the longer, cylindricol port foces the clutch,
p u s h i t o g o i n s tt h e f r i c t i o n p l o t e h u b , o n d o l i g n
the ends of the levers to touch the flonge.
A d e v i o t i o n f r o m t h e p l o n e n e s so f 0 . 1 m m i s
p e r m i s s i b l e .U s e f e e l e r g o u g e s f o r c h e c k i n g
this deviotion.
lf it is not possibleto odiust the out-trovelof
the clutch releoseleversto o volue given by the
length of the flonge cylindricol port due to
excessiveweor of the friction plote, odiust to
the next higher volue. Clinch nuts on the
odiusting nuts bocked off up to the end of the
threod ore o worning of o weor limit which precludes ony further odiustmentof the clutch.
4. After hoving reossembledthe engine with
o new or odiusted clutch, check ond, if necessory, odiust the cleoronce between the releose
levers ond the throw-out beoring - see Chopter 15.4.

3.3 CLUTCH DISMANTLING

O w i n g t o i t s s i m p l i c i t y ,i t i s n o t n e c e s s o r yt o
d e s c r i b ei n d e t o i l t h e d i s m o n t l i n go f t h e c l u t c h ,
but some speciol feoturesdeserveottention.
1. lf the friction plote ond clutch cover ore
intended to be re-used, mork their relotive
positions using centre punch morks to preserve
t h e o r i g i n o l b o l o n c eo f t h e o s s e m b l y .
2 . T o d i s m o n t l et h e c l u t c h , i t i s n e c e s s o r yt o
compressthe clutch cover to relieve the stress
of the releose lever bolts. For this purposeuse
t h e M P 2 - 1 0 1o s s e m b l yp l o t e s h o w n i n F i g . 3 . 4 / 1 .
A f t e r s c r e w i n g o f f t h e r e l e o s el e v e r n u t s o n d
c o m p r e s s i n gt h e c l u t c h c o v e r , t h e c l u t c h i s
r e o d yf o r d i s m o n t l i n g .

2. Instoll retoining plotes on the clutch

springs ond fit the clutch cover with releose
l e v e r s p r i n g s i n p o s i t i o n . A s s e m b l et h e c l u t c h
cover with the pressure plote, observing the
m o r k s i n d i c o t i n gt h e i r r e l o t i v ep o s i t i o n s .W h e n
o s s e m b l i n gn e w p o t ' t s t, h e i r p o s i t i o n so r e o f n o
consequence.
3. Slip o 4.5 mm high pod over the ossembly
plote bolts (the plote con be used for Skodo
1000 MB ond Skodo 100 cors os well, ond by
u s i n g p o d s o f d i f f e r e n th e i g h t s t, h e p l o t e c o n b e
odopted for different types of clutches), fit the
yokeof the iig on the plote bolt ond compress
it by screwingdown the nut till the bottom port
rests on the pod. When compressingthe clutch
cover toke core thot the projections of the
pressure plote ore correctly centered in the
cover slots to prevent o distortion of the clutch
cover.
4. Slip the bottom ends of the releose levers
u n d e rt h e s p r i n g si n s t o l l e di n t h e c o v e r o n d f i t
t h e m w i t h t h e i r l o n g i t u d i n o ls l o t s o n t h e s u p p o r t s .S l i p o d i u s t i n gw o s h e r so n t h e b o l t s o f t h e
pressureplote ond screw down the nuts with
t h e i r c y l i n d r i c o lp o r t f o c i n g t h e w o s h e r s .T h e n
odjust the height of the releoselevers with
t h e s en u t s s o t h o t t h e i r e n d st o u c h t h e s h o u l d e r
of the yoke bottom port. The difference of the
lever height should not exceed 0.'l mm. This
o d i u s t m e no
t l s os e t st h e r e c o m m e n d e d i s t o n c e
of the levers from the pressureplote beoring
surfoce.
U s e c l i n c h n u t s f o r l o c k i n gt h e o d i u s t i n gn u t s
i n p o s i t i o n ,p u t s u p p o r t i n gc l i p s u n d e r t h e r e l e o s efe v e re n d s o s s h o w n i n F i g . 3 . 1 1 1o n d 3 . 2 1 2 ,
o n d s l o c k e nt h e n u t s o f t h e o s s e m b l yp l o t e .T h e
c l i p s o r e u s e f u lw h e n f i t t i n g t h e c l u t c h t o t h e
f lywheel since it is not necessoryto overcome
t h e t e n s i o no f t h e c l u t c h s p r i n g s .
To Check Adiustment ond Bolance
The describedodjustmentof the releoselevers
in the iig is the most occurote,the ossembly

3.4 CLUTCH REASSEMBLY

1. Locote the clutch pressure plote on the
M P 2 - 1 0 1o s s e m b l yp l o t e o n d f i t s p r i n g so n t h e
c y l i n d r i c o lb o s s e s .B e f o r ef i t t i n g t h e s p r i n g s ,i t
i s o d v i s o b l et o c h e c k t h e m f o r c o m p l i o n c ew i t h
t h e v o l u e ss p e c i f i e di n t h e f o l l o w i n g T o b l e .

Mountedlength

-Lood
rrr"ltp1
lin

31.5

plote be
simuloti
For on<
porogrop
The cl
with the
friction ;
ports of '
clutch on
To bol
centering
pressure
the chips
lf thes
boloncing
ing holes
in o circk
4mmof
between
fostening

3.5 FR|C

Toble of Clutch Springs

L e n g t ho f s p r i n gi n m m

Fig.3
Dim

5'10+36
(s2t3.6)

L e n g t ho f c o m p r e s s e sdp r i n g 2 9 . 5 I 5 8 0 ( 5 9 )

F i g . 3 . 4 l 1- I A P2 l o l A s s e m b l yP l o t ew i t h C l u t c h

70

lf the f
it is odvi
8.5 mm th
When r
the frictio
ond only r
complicot
After hr
the plote
if necess
recheckin
quired.

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8S9

Z I ? L) O

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The clutch moster cylinder is port of the

ossembly of the broke moster cylinder ond
pedols. For the odiustment of the pedol free
trovel, etc. see Chopter 12.1.
Pipeline ond Hoses
The rigid port of the pipeline comprises
speciol steel pipes, the some os those of the
broke system. However, they hove o diometer
of 6 mm os comporedwith the 5 mm diometer
pipes of the broke system. For their servicing,
repoirs, ond replocement see Chopter 9.7.
The flexlble port of the clutch hydroulic
line compriseso high-pressurebroke hose. No
speciol position or fostening ore recommended.

Fig.3.612- Clutch Moster Cylinder1 Sectionol

View

l'

I
N

72

til
lt

.t*

: i'*

;:

..:t

., oilfl

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SAIUO
S W S IN V H ) l W N O I S S I W S N V U I U l r t \ O d - 7

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22--'
F i g . 4 / 1 - G e o r b o x ,F i n o l D r i v e , o n d C l u t c h
Throwout Mechonism

74

.&

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19
16. 17

'll

Technico
The gec
tegrol uni
N e i t h e ro f
Sincec
tionollytc
" g e o r b o x"
m o l l yt o d
respecti ve
The geo
from the c
reor oxle c
the so-co

2A

Fbb
r8

4.1 DtSM
PACK

q
"b

The pov
t r o n s mi s s i
plete with
Fi9.4.111
Removql

12
ik"-n

13

TO
6
q

o) Prelim
1. Jock r
the reorwl
ond remov
Drointh
see Chopt

,w

b) Operot
2 . P r i s er
of the reo
cobles ofte
3. Remo
behindthe
bottery. Re
e n g o g et h e
lever, loos
fronr the gr
it from tht
housing to
getting int
pressed on
h o u s i n gw i
4. Proce
bockrest, fr
detoch the
obsorbers,,

F I N A L D R I V EA S S E M B L Y

c) Operoti
5. Remo
connection
cooling sys
see choPte

d) Operotic
6. Disco
motor.
76

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4 . F i t t l r e M P 3 - 1 0 9j i g i n t o t h e f r e e h o l e s f o r
striking fork rods (both pins of the iig), ond
p r o c e e d i n gt h r o u g h t h e h o l e i n i t s s i d e o n d
u s i n go s t i c k o r o l e n g t ho f w i r e , p u s h t h e l o c k
p i n i n t o t h e h o u s i n go s f o r o s i t w i l l g o . P r o c e e d
i n t h e s o m e m o n n e rf o r i n s e r t i n gt h e n e x t p i n
(useone pirrof the iig). Shift it iust so thot
t h e c e n t r e l r o l e r e m o i n s f r e e f o r i n s e r t i n gt h e
striking rod. Puslr the lock pin into the end
g u i d e o f t h e s t r i k i r r gf o r k r o d s o l s o o s f o r o s i t
w i l l g o . T h e i i g i s n o t r e q u i r e df o r t h e i n s t o l l q t i o no f t h i s p i n .

_-_-- -

i\:r,,,

5. Prc
scribed
rods onc
4th spee
fork rod
irr the b
6. lns
guide bu
cover in
heods.S
tob wos
e d g e so f
Fi t t h r
stri ki ng
weoker s
ing forks
7. Tigl
the forks
fork rod
the strik
function

Reverse-

Fig. A.1l'l- Power Pock

1 e n g i n e w i t h m o u n t i n g ,2 - g e o r b o x /i fn o l
d r i v e w i t h m o u n t i n g ,3 - r e o r o x l e ( h o l f - o x l e s ) ,
4 - r o d i u so r m s
Fig.4.2l1- Clomping Georbox Housing in Stond
Using MP 3-101Rock

r e t i g h t e n i t u s i n g t h e r e c o m m e n d e dt o r q u e
( C h o p t e r1 . 8 ) o n d s c r e w d o w n t h e c l i n c h n u t .
l f n e c e s s o r yt o, p u p e n g i n eo i l , f i l l t h e c o o l i n g
s y s t e mw i t l r o n q n t i f r e e z eb, l e e d t h e b r o k e s y s t e m , o n d o d i u s t t h e h o n d b r o k e .F o r t h e f o s t e n i n g o f b r o k e h o s e s( r o u t i n g ) s e e C h o p t e r9 . 7 .
4.2 ASSEMBLING GEARBOX
G e n e r o l l yt,h e r e o s s e m b l yp ' r o c e d u rdee p e n d s
o n t h e e x t e n t ,t o w l r i c h t h e u n i t h o s b e e n t o k e n
o p o r t . F o r b e t t e r u n d e r s t o n d i nw
g ,e s h o l l d e s c r i b e t h e p r o c e d u r eo n d p e c u l i e o r i t i e so f r e o s s e m b l yo f o c o m p l e t e l yd i s o s s e m b l e du n i t .
Gear Chonge Mechonism
. 1 . C l o m p t h e r i g h t - h o n dh o l f o f t h e h o u s i n g
( w h e n v i e w e d f r o m t h e f l o n g e s e c u r i n gi t t o
the engine) in the MP 9-101 stond comp l e m e n t e dw i t h t h e M P 3 - 1 0 1g e o r b o xr o c k , o n d
c h e c kt h e h o u s i n gf o r c o m p l e t e n e s s .
2 . I n s t o l lc i r c l i p so n t h e s t r i k i n gf o r k r o d s o f
t h e r e v e r s eo n d 1 s t o n d 2 n d s p e e d .T h e r i n g
with the lower nose is to be fitted on the 1st-ond 2nd-speedrods.
3 . l n s e r t t h e r e v e r s es p e e d s t r i k i n g f o r k r o d
i n t o t h e h o u s i n gs o t h o t t h e i n s e r t e de n d p r o trudesslightly from its guide, slip on it the
strikingfork with the longerside of its heod
first,- ond push the striking fork rod through
the fork ond the end of the guide os for os=it
will go.
78

Fig

F i g . 4 . 2 1 2- L o c k i n g S t r i k i n g F o r k R o d s i n
P o s i t i o nb v M e o n s o f L o c k P i n s o n d B o l l s

-1Rever
2-1st-o
3-3rd- o
4 - Rever

8. Inst
press-fittr
verse-spe
inside th
through t
Turn tl'
end foces
lock it in
hole.Tig

Pinion Ar
F i g . 4 . 2 l 3- I n s t o l l i n gL o c k P i n s U s i n g
MP 3-109Jig

9. Instc
ing ond,

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s . l o a 6 ; o s e c D l r n s l D c ! u o c 6 u t p n . r 1 o . r dA ; 1 o c l l 1 a r u
- u i s a q l o 1 6 u r p . r o c c o s 6 u g . r6 u ; z l u o . r q c u A s ; o
l o l d a a r ; l o u o t t r n q ! r l s ! pa t D r x l x o r d d y - g l z ' V ' B l J

'reuloler 6u;.roeq
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puo 6ulsnoq sLll ul aloq pepDarLle
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s 6 u 1 . r 6 u r z r u o . r q c u A sl o s A o l d ' o u o l l n q l r l s ! p
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'alqlssod sD lDl
so 6ugsnoqeql olul paqsnd sr uotutd arll lDLll
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roeg paeds-osJo^eU
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Proceed in the some woy with the 3rd- ond

4th-speedgeors.
l f t h e m o r k e dp o s i t i o n o f t h e n e u t r o l i s n o t
m i d w o y b e t w e e nt h e s i d e m o r k s ( c h e c k v i s u o l l y ) , r e m o v et h e p i n i o n , m o r k t h e p o s i t i o n so f
the striking forks on their rods (preferobly
' r n o v e on
e i t h e r s i d e ) , s l o c k e nt h e f o r k s o n d
them
toword the required centre by the distonce of
the deviotion of the neutrol morking.Then lock
the striking forks in position with screws.
For the striking fork tightening torgue see
Chopter 1.8.
13. Adiust the reverse geor position so thot
there is o gop of obout 2 mm between its teeth
o n d t h e o d i o i n i n gt e e t h , o n d s w i n g t h e s t r i k i n g
fork of the first ond second speedto moke sure
thot it connot foul the teeth.
1 4 . R e i n s t o l lt h e p i n i o n w i t h i t s r e s p e c t i v e
w o s h e r so n d l o c k i t i n p o s i t i o n .S h i f t t h e s t r i k ing fork rods to moke sure thot, for exomple,
o movementoppositeto the requiredone of the
s t r i k i n gf o r k s d i d n o t t o k e p l o c e ,i . e . t h o t t h e
neutrol is midwoy betvr'eenthe engogement
p o s i t i o n so f t h e s y n c h r o n i z i n cg l u t c h e s C
. orrect
o n y e r r o ro n d r e m o v eo g o i n t h e p i n i o n .
Fitting Drive Geors ond Clutch Shqft
1 5 . l n s t o l l t h e o s s e m b l e dd r i v e s h o f t i n t o t h e
h o u s i n go n d s l i p t h e s p l i n e d b u s h o n i t .
Top home the seol ring with its seoling lip
p o i n t i n g o u t w o r d si n t o t h e g u i d e o f t h e c l u t c h
t h r r o w o u ts l e e v e ,o n d s m e o r i t w i t h o i l . T h e n
threod the clutch shoft through the ring to
instoll it into the splinedbush ond put it into
t h e h o u s i n gt o g e t h e r w i t h t h e g u i d e p r o v i d e d
w i t h o c o o t i n g o f s e o l i n g c o m p o u n do n i t s c y l indricol bedding surfoce.Secureboth the shoft
o n d t h e s l e e v ew i t h c i r c l i p s .
lnstoll the sleeveguide with its droin hole
l e v e l w i t h t h e p o r t i n g p l o n e o f t h e h o u s i n go n d
f o c i n gt h e p i n i o n .
F o r t h e s p e c i o l s e o l i n g c o m p o u n ds e e t h e
note in Chopter 10.1.
16. Put the pinion with geors into the housing
ond oil oll synchronizing
r i n g s .F i t t h e M P 5 - 1 0 4
iig for setting the crown wheel bocklosh into
the bore of the differentiol beoning ond the
fitted cover, fit the ossembleddifferentiol in it,
o n d c l o s e t h e h o u s i n gw i t h t h e o t h e r h o u s i n g
holf ofter hoving cooted the seoling surfoces
w i t h o s e o l i n gc o m p o u n d .
F i t o r u b b e r r i n g i n t h e r e c e s so f t h e b o s s
beside the stud bolt ond put o spring wosher
under the nut. Tighten the remoining nuts
without ony woshers (the stressof the bolts
ofter the tightening of the nuts provides for'
t h e i r s u f fi c i e n t s e c u r i n g ) . T i g h t e n t h e n u t s
m o d e r o t e l yf o r t h e t i m e b e i n g .
For the speciol seoling compoundrefer to the
note in Chooter 10.'1.

80

17. Proceedingthrough the bore of the differe n t i o l b e o r i n gi n t h e u p p e r h o l f o f t h e h o u s i n g ,

fit another iig, the MP 5-104,on to the different i o l w i t h f l o n g e sc l o m p e ds o o s t o f i t i n t o t h e
topered roller beoring cover, locote the cover
pocking,ond fosten the cover by meonsof three
n u t s . l f t h e c l o m p i n go r d r o w i n g c l o s e o f t h e
f l o n g e s o f t h i s j i g p r o v e s i n o d e q u o t e ,i t i s
necessoryto drow close the flonges olso of the
f i r s t , p r e v i o u s l yi n s e r t e di i g .
18. Drive the guide of the clutch throwout
s l e e v ei n t o t h e h o u s i n gu s i n gt h e M P 3 - 1 0 3d r i f t ,
top home the drive shoft, ond insert two odi u s t i n g w o s h e r su n d e r t h e c o l l o r o f t h e p i n i o n
s h o f t b o l l b e o r i n go n b o t h h o l v e so f t h e h o u s i n g
ofter hoving determined their thickness by
meosuring.
Using o wire needleinsertedinto the holes of
the tobs of the woshersorrongethe woshers so
thot they do not overlop the porting plone of
t h e h o u s i n g ,t h e n i n s t o l l t h e c o v e r o n d s p r i n g
r .8).
wosherso
, nd tightenthe nuts(seeChopte1
1 9 .F o s t e nt h e h o u s i n gb y t i g h t e n i n gt h e n u t s
( s e eC h o p t e r1 . 8 ) o n d l o c k i n p o s i t i o nt h e g u i d e
of the clutch throwout sleeve with the respecti v e c l i p u s i n g t h e s p r i n g w o s h e r u n d e rt h e c l i p
nuts.

4 . 3 A S S E M B L I N GF I N A L D R I V E

from the
Determir
swivelli
To rotr
iig with
tiol stor
21. Ins
on the b
rotote th
the diol
ible to th
Retoin
ogoinst 1
cover. Tl
teeth chc
losh on t
of the ho
wheelsic
fied volu
the hond
fully its c
( preferob
wheel). I
opened f1
respectiv
of the iig
Now tl"
iusted on
flongeso
topered r
This situc
trot i o n.

Refitting Differentiol
20. Turn the housing into the horizontol position. Rotote the ends of the knurled hondles
of the inserted iigs MP 5-104to move the rei n s t o l l e dd i f f e r e n t i o l ( s e e p r e v i o u sp o r o g r o p h s
16 ond 17) until the crown wheel withdrows

q,

ry

Fig. a3fi
for tc
1

F i g .4 . 3 1 1 -A d i u s t i n g B e v e lG e o rB o c k l o s h
1 - MP 5-104iig, 2 - M P 5 - 1 0 1i i g ,
3 - M P 5 - 1 0 6i i g , 4 - Screwdriver

22. Rem
side (turn
withdrow
dimension
hos to be
roller beor
Measuring
23. Unsc
the topere
locote it o

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F
I
t

i
!
I

4.3-4.4

lf the shims connot be set up exoctly to the

colculoted thickness, determine o thickness
which would result in o prelood due to on
overoll increose of 0.03 to 0.07 mnr of the dir n e n s i o no f t h e s h i m s .
27. Ploce the topered roller beoring on the
respective bore, bolt the other MP 5-107iig on
the housing ond rotote the centre bolt to press
the beoring into the housing os for os it will go.
R e m o v e t h e i i g , f i t t h e s h r u n k - o nr i n g o n t h e
stor pinion,and lock the ring in position using
o c i r c l i p . L u b r i c o t et h e b e o r i n g w i t h o i l , f i t t h e
respectiveshims on the beoring ond the gosket
on the cover, ond bolt down the cover.
T u r n o v e r t h e h o u s i n g o n d p r e s s - i nt h e o t h e r
beoring in the some monner (the press-fitting
iig is olreody in position), instoll the preporred
shims, ond bolt down the cover with its gosket.
28. Meosure how deep is tlre drive shoft
beoring below the level of tlre housing surfoce
ond compensote the difference with shims up
t o o m o x i m u m p r o t r r r s i o no f 0 . I m m - F 0 . 0 5r n n r .

S e t t i n g :P r e l o a dO . O b- O . 1 0 m m
1. Before assembling Transmissioncasing
removeouter crown wheel bearing races.Leave
t h e b e a r i n g so n t h e d i f f e r e n t i ahl o u s i n g .
2. Assemble transmission.DO NOT carry out
operation17 above.
3 . F i t t h e o u t e r r a c e si n t o c a s i n gp r e s s i n gi n t o
place using coned cover. Do not forget to fit
gaskets.On the SelectorShaftside (side B) of the
c a s i n g f i t a p p r o x i m a t e l yO . 6 0 m m o f s h i m s
betweenthe coned coverand outer races.Ensure
there is backlash between crownwheel and
p i n i o n ,i n c r e a s et h e s h i m t h i c k n e s si f r e q u i r e d .
4 . F i t D i a l t e s t g a u g e s o t h a t p o i n t e rr e s t s o n
t h e d i f f e r e n t i aal s s h o w n i n f i g . 4 . 3 / 1 A .

F i s .4 . 3 / 1 A

5. Lift Crownwheel assembly to determine

clearance
b e t w e e nb e a r i n g s( a ) . . . l f t h i s e x c e e d s
O . 2 Om m d e c r e a s et h e c l e a r a n c e
t o b e t w e e nO . O 1
a n d0 . 2 0 m m b y f i t t i n gs h i m st o N o n - s e l e c t osri d e
o f c a s i n g .( b ) . . . W h e n t h e c l e a r a n c ei s b e t w e e n
0 . 0 1 a n d 0 . 2 0 m m t a k ea r e a d i n gA
. ddtothis0.OS
t o 0 . 1 0 m m . M a k e a s h i m p a c kt o t h i s t h i c k n e s s
and fit to non-selector
side(sideA) of transmission
casingC
. h e c ks o m e b a c k l a s hs t i l l e x i s t sb e t w e e n
t h e C r o w n w h e ea
l nd pinion.

F i g . 4 . 3 / 4 - P r e s s - ift t i n g o f D i f f e r e n t i o l T o p e r e c l
R o l l r : rB e o r i n g s U s i n g M P 5 - 1 0 7J i g

Shims 0.1 nrm to 0.2 mm thick ore ovoiloble.

Fit the gosket ond the ossembledcover on the
housing ond fosten it with nuts ond spring
woshers (for the cover refer to Chopter 4.5).
Swing down the beoring with the speedometer drive geors in the cover into engogen r e r r tw i t h t h e p i n i o n d r i v e g e o r o n d l o c k t h e
beoringin position by tighteningthe nut of the
b e o r i n gc l i p .
Adjusting crownwheel

{.3-4.4

6. Remo
b) Crownw
Tools

Settin
not le
1. Insta
one of the
Glave Cyli
that the p
pendicula
2. Lock
between tl"
cover.
3. Using
back and
c l e a r a n c eI
teeth. This
gauge, anc
wheel(see
legible the
O . 1 8 m mb i
4. lnsuff
wheel is tc
increase tl
from the nc
the equiva
This will p
increaseth
Excessc
thickness
Selector S
To worl
shims to n
(a) Bac
(b) Act

To
(a) O.3
(b) o.2

Example
1 s t D i a l r e a d i n g0 . 3 O m m
0.20 mm Shim fitted on non-selectorside.
2 n d D i a l r e a d i n g0 . 0 7 m m
Shim pack requiredbetween
0 . 0 7+ O . O 5= O . 1 2 m ma n d 0 . O 7 m m
*O.1Omm
= 0 . 1 7m m
S h i m s i z e sa v a i l a b l e .
0 . 0 8 , O . 1 4 ,O . 2 Oa n d O . S O m m
S h i m s i z e s e l e c t e dO . 1 4 m m .T h i s w i l l g i v e
O.07mm preload tension to crownwheel
b e a rni g s .
The Crownwheelshould now turn freely with
little drag.

Bearing

Alternative Method
a) Crown Wheel Bearing Preload.
Tools Dial Test Gauge and Stand

M P s- 1 O Gl e v e r

82

Refitting C
Assembly

29. Instc
ond the re
it with nut
-looded brc

t8
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(q)
(e)

Lurugt'O qsellceq lenlcv (q)

ururgl'O parrnberqsellceg {e)
-:elntlJol 0urilrro;;o1
eql esn anour ol surtls
)Jorlt 01
lo ssoulcrql aleuirxorddeaql lno
'aprs
rolcal0s
-uou oql ol eprs lolcelos eql uloll sseulc!tll
urqs Burnou lq palceroo sr eouereelcssacx3
'qsellseq aql asearcul
pue esec ssoJceloaq/lAuMorc
s!t{I
aql qsnd ll!/v1
'oprs rolcolas aqr uo ssaulcil.ll luele^rnba
atll
aceldpue 6ursecoqllo oprsroloalas-uouaql uroJl
ssaulcrql urqs e^ourer ocueJealcaql osPolcul
o1 'uorurdaql qtrm tlsoul ut Aldaapool st leeqm
- u M o r cl e q l s e l e c r p u ar c u e l e o l cl u e l c l # n s u'lt
' q s e l ) c e qu L u S
l'0
- tt'O uaaMlaq salnBrleql asn ueqt agqr6e;
'(zuarl
lou sl slqlll
L / 8 ' v ' 6 l J 7 9 a 6 e de a s ) l e a q m
uMoJc oq] uo uaurlM se eq plnoqs pue 'a6ne6
'ql00l
letp aql ulorl peor aq uec luouanotu srql
uorurdpup looqruru^ olc aql uaamlaq scuelealc
lo lunoure eql aurruJalapol tluol pue lceq
leaq^^u^/\orceql elelor gOt - gdt^ Uu'tlr"io,
6urureleu
r o r u r de q l p u e l n u u o t u t da q l u o e m l o q
J o ^ a l e l q e l r n se 6 u r s n A q u o r u t d a q l I O o l ' Z
'qlool
oql ol elqrssodse le;nctpuad
laaqlr,rr
-led se sr rolecrpur lerp or.ll ;o lutod aql leql
eql oleloJ uaql 'lapullA3enel9
os loaLl^/\u^/\orc
qslnlc aql oururelaltol pasn spnls aql lo ouo
q l r / ' / lr0\ l - 9 d t / \ l l o o l l l e l s u l' l
uorolecrpur
' rluerrupg ; ou
l ' O t ! ' O o s n a ; q t B e1
'leoq^^uMorJuo
paUtcodssV :s6ulgag
+l
'uorutd
lool ol Ja^el
9 0 t - 9 d 1l
to t- gdt^ :slool
'qsellcPq
(q
uotutd
' e O n e D ;aaqlrrunrrol3
l e r Oe ^ o r u a U ' g

uaa^l
uorss
sseul
90'0 s
uoa^l
aprslo
[0'0u
spaec
autuJ

v L/t'

uo slse
'pelrn
pue la
o r n s u l'
sr!rqs l
aql lo (
lll ol lo
olur6ur
lno fule
'
a^eal 's
6ursec

tt-et

R e m o v et h e c l i p o f t h e c l u t c h t h r o w o u t b e o r i n g g u i d e ,i n s e r tt h e M P 3 - 1 0 2i i g i n t o t h e g u i d e ,
open its iows, ond withdrow the guide.After
h c v i n g r e n e w e dt h e s e o l r i n g , d r i v e h o m e t h e
g u i d e u s i n g t h e M P 3 - 1 0 3d r i f t . T h e d r o i n h o l e
in the guidemust foce downword.
The lotest desing of the extroctingiig hos
t h e t y p e d c s i q n o t i o nM P 3 - 1 1 2 .S c r e w t h e i i g
b o l t i n t o t h e i i g n u t i n s e r t e di n t o t h e m e c h o n i s m t h r o u g h t h e h o l e c l e o r e db y t h e r e m o v o l
o f t h e c l u t c h r e l e o s ec y l i n d e r .J e r k t h e i i g t o
d r i v et h e g u i d eo u t o f t h e h o u s i n g .
Dismontling the Power Pock
F o r c o m p l e t ed i s m o n t l i n go f t h e p o w e r p o c k ,
remove it from the cor - see Chopter 4.-1,
" R e r n o v oo
lf
Power Pock from the Cor". Then
p r o c e e do s f o l l o w s :
1 . R e m o v et h e f r o n t c o v e r o n d t h e c o v e r o f
t h e p i n i o n b o l l b e o r i n g ,t h e c l u t c h r e l e o s e
m e c h o n i s mo, n d t h e c l i p o f t h e g u i d e o f t h e
clutch throwout sleeve, i.e., oll component
p o r t s o t t o c h e dt o b o t h h o l v e so f t h e h o u s i n g .
2 . R e m o v et h e c o n n e c t i n gb o l t s o f t h e f l o n ges. Force oport the f longesusing o screwdriverr
i n s e r t e di n t o t h e c h o m b e r so f t h e f l o n g e f e e t
( l u g s ) . L i f t i n g o w o y o l l c o m p o n e n tp o r t s o n e
b y o n e i s t h e u s u o l p r o c e d u r eo f d i s m o n t l i n g .
Toking oport of lorger units (pinion, etc.) is
d e s c r i b e di n d i v i d u o l l yi n t h e f o l l o w i n gc h o p t e r s .
3. Press out the beoring cups which hove
r e m o i n e di n t h e h o u s i n go f t e r i t s h o l v e s h o v e
been seporoted.Use the MP 5-107iig supported
b y t h e M P 5 - 1 0 8i i g .

Assembling Front Cover

1. Slip the rubberseol ring on the speedom e t e r b e o r i n g o s s e m b l y( b e o r i n g w i t h g e o r s )
o n d p u s h c o r e f u l l y t h e b e o r i n g , p r e f e r o b l yb y
o steody rotory motion, into the cover iust for
enoughto be oble to instoll the key without
d o m o g i n gt h e s e o l r i n g b y t h e s h o r p e d g e o f
the keywoy.
F o r t h e s o m er e o s o n c, h o m f e rt h e e d g e o f t h e
beoring bore before instolling the beoring in
o new cover.
2 . L o c k t h e b e o r i n gi n t h e o x i o l d i r e c t i o n b y
i n s t o l l i n gt h e k e y o n d s p r i n g w o s h e r s ,o n d b y
s c r e w i n gd o w n t h e n u t . S l i p t h e c l i p o n t h e
p r o t r u d i n gp c r t o f t h e b e o r i n g o n d l o c k i t o l s o
i n t h e o x i o l d i r e c t i o nw i t h o b o l t ,s p r i n gw o s h e r ,
ond nut. Do not tighten the nuts fully.
3. Instollthe oiled geor chonge lever in the
c o v e rw h i l e p u s h i n gi t o n l y o s f o r o s t h e g r o o v e
f o r t h e s e o l r i n g . W i t h t h e l e v e ri n t h i s p o s i t i o n ,
i n s e n tt h e s e o l r i n g i n i t s g r o o v e o n d p u s h
f o r t h e rt h e l e v e rt h r o u g ht h e r i n g . S l i p t h e d u s t
boot on the lever ond ottoch it to the cover
w i t h o l e n g t h o f l o c k i n gw i r e .
4 . A t t o c h t h e f o s t e n i n g( m o u n t i n g )l u g s u s i n g
c o p s c r e w so n d s p r i n gw o s h e r s T
. hereis o right- h o n d o n d o l e f t - h o n dl u g , o n d t h e i r s l o t s m u s t
be turned owov from the cover.

FK 1t't4
F i g . 4 . 5 l 1 - F r o n t C o v e ' rA s s e m b l y
Dismontling Front Cover
Fig.4.al2- PressingOut the Cup of the Topered
R o l l e rB e o r i n gU s i n g M P 5 - 1 0 7o n d M P 5 - 1 0 8J i g s

Lift owoy the speedometer beoring ofter

h o v i n g r e m o v e dt h e s l e e v ec l o m p i n g b o l t o n d
the key (helddown by the nut). Thenwithdrow
t h e g e o r c h o n g el e v e r b y s i m p l y p u l l i n g i t o u t .

4.5 FRONT COVER

4.6 PINION WITH GEARS
The front cover ossembly forms o self-cont o i n e d u n i t f i t t e d t o t h e g e o r b o x .F o r b o t h t h e
r e o s s e m b l yo n d d i s m o n t l i n gp l o c e i t o n o w o r k
bench.
84

The pinion with geors forms o self-contoined

unit to be instolled in the georbox.Use o work
bench ond o press fon both its ossembly ond

dismo
wheel
sure t
Only c
wheel
m itted
drive.
4.8.
Whe
olso tl
o new
one is

Assem

1 . P
the pi
the or
thrust
toworc
3-104p
ground
the be
must t
meosu
2.S
collorI
ring ir
the grr
The rir
3.5 to I
th icke
ond pu
speed
3.H
'
it the
selecte
toword
dismo
(by tol
i t i n p
free to
Clon
MP 3.1
Note
innerb
toining
either r
-speed
ports.
4. Tr
groovir
pinion
friction
groove
groove
5. On
ond fit
the nex
sizes3

98
6 u 1 . ra q l ; o a 6 u o q c p u D l D ^ o u l a : p e l o a d a l o I q
p a l s n l p o a q u D c l l p u o r . u u rl O ' 0 + L ' 0 ] o s l l r u r l
aouojelol u!ql!M eq plnoqs ocuDrDalc s!ql
'roa6 eq1
, o e c u D J D a l cl D r x Da q ] e J n s D e u {r 1 1 o u 1 1
p u o ' g q d o . r B o r o dq l l l u r e c u D ! ; d t u o c u r p a ! r ] p u o
'.roe6
p a u l r u J a l a p 6 u r . ro q l l r l t u o ! } ! s o d u r 1 1> 1 c o 1
p e e d s - p u 7e q l l l D l s u t ' e n o o l 6 p a l l t r u o I l s n o l n e l d
e q l o l u ! 7 q d o . r 6 o . r o du 1 p e u o ! ] u e u s 6 u g . r ; o
a 6 u o . ra q l l o 6 u r . rp e l c a l a s A g l r o . r l r q : ou D ] ! J - g
'ep!sD
l ! l n d p u o 6 u 1 . re q l a ^ o u a r
ueql 'ulrrt Z0'0+0 lo eouorDelc D qltM anoolD
aql u! ltl o1 sDrl ll 'sl!ru!l aouDrelol o1 p:o6e-r
tlll/!{ lselc!91 aq1 asn ol puD ssol3 sseulctLll
a u o , o s E u r . r; o l a n a s A r l o ] p a p u e u r u o c e J s ! l l
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6 u 1 . re q l
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s s a u 1 3 tq I
6 u 1 g u o r l c r r J l o u o t l o u ! r u r e l e C- Z l S ' V ' 6 l J

euo sql asn puo ruur gg't puD tg't '09.t sezls
eq16uotuoluo:; 6ur.reql esooqC'anoo.r6
lxeu eql
olu! sapls Llloquo sanoo.r6qllM
Du!J
oql }tl puD
6ur.r
aql JoJanoo:6 6u;rvro11o1
aql r!u,O.S
1co;
'(sep1sqtoq uo senool6
llo qilM 6u1: auo puo apls euo uo sanoorD
pe}il1 eq o1 s6u;t uollct4
uo qrtrt JDI!ujrsor"rr1)
6 u r u g o u r aa: q l l l o o 1 s a r ; d d oe r u D se q l . u o r u r d
eql u! anoorB eq] lcn:lsqo lou saop 6u1noo.r6
eql lo 6op aql loql os Dur.raql urnl .t
'sUod
-.roe6peadsu!-unr Jo] op ll!M llo 6u11ocr.rqn1
- ] s L M e u o . r o ' u o r u l dM e u o ' : o a 6 r v r e uD J o q l t e
6 u r s n u e q M ( e p r q d g n s r pu n u a p q l ; o r , u6 u 1 u r o 1
-uoc) alsod o1Ago61
eLll rlllrlt s.roe6;o eJoqreuu!
eql elDc!rqnl ol
s!
:aloN
ll
PePueuu.tocer
'(u61sep rvrau)e.rn1x!t
LLL-tdhl
ro ggl-t dt/\ eql olu! uorurd aql duolg

puo l1q
lJoM D a

peu!olu

'tno
l! 6
,v\DrPqll
puD lloq
reUD 6u

Al
?t?,t )t{t

sr :oe' eqrr'ql arnsororuor" ;;L?ll.::t;til

l c o l o l ( a : n l . r e d o s l t u r U t r p o q l t r l r rE u r d d o l I q )
qclgd anoor6 o {q 6ur.r aq} ulng '6u1;luDulstp
6 u 1 . r n pp e ^ o L u e r6 u r . rp ; o e q l r o . r o a Ba q l s p J D M o l
sa,roo:6 l!o sll rlll/\,\ 6u1l uotlclJl pelceles
A ; s n o l n a r d e q l l r e s u ! r v r o 1 1' . r o a 6 p a e d s - 1 s ; e q l t !
u o d 3 1 s' l ! o r { 1 M q s n q e q } p s : o o r u s 6 u r n o g . g

-lsLsLrl;o Du11co1
,o, "0,.o'!i?"oo";i;
ronlue^e

anoor6 eql u! lll rq6l] D sr qcrqM euo ]se{crql

aql lcelas 'uur L'0 {q dn peddals uru g'C ol g.t
rlorl sassoulclql rnol u! pel;ddns elo s6uu aq1
'Iypqolns s1; I.r1
o l q s n q o q l p u o e n o o . r 6e q l
1o e6pe eq] uoeMtaq enoo.r6llDqs eql ur 6uir
u o ! l c ! r + e q l l l o l s u ! p u o 6 u r . r o e qa q l p r o M o l r o l l o c
s l ! q l l M q s n q : o a 6 p a a d s . l s 1 -a q ] u o d t t s . z

i6ug:nsoau
,t,o,pasn s! lt aJuls peDotuop eq Je^au lsnul
u o g u g de q l l o a c o ; p u n o . r 6 a q l ' e c o r 6 u u o e q a q 1
u o - 6 u r s s e - r du e q n n u o l u ; d a q l , o a c o ; p u n o r O
a q l l c a 1 o . r do t p o a q t r s n r q l a L l l r { } l M a 1 o 1 d9 6 ; . 6
'lxau pelll,
aq o1 sloa6 sql promol
dn aql esn
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oql ulor+ ionrro 6urr 1snlq1
relno sl! qllM 6ulrDaq eql 1o grod relno eql
11 uo dr;s puD po r{}!M }l roeus .uolugd eqi
uo a3Dr 6ugroeq Jallor Jeuu! eqi sseJd.!

( o p l l t r v rl . r o d d n s p u o e 1 o l d 1 o
a d r t l A u o ' a l q D l ! o ^ D] o u J l : s r D c 0 0 1 o p o l g 1 o )
pDeH lsnrql puD atDld tgL-t 661 6ursn
6 u r . r o a g u o r u ! d ; e n e g u o - 6 u t s s e . t d- L l g ' V ' 6 l J

uo!u!d 6u;lquassy
'uolloredo Isrou esnoc o1 gdo
sl auo
Meu D qlim Dulqsau .roe6 plo uV 'euo.Mau o
qllM UDqs 3^trp eql uo :oa6 6utqsau aLll oslo
a c o ; d a . r ' s r o a 6 a q l ] o a u o s 6 u l r v r a u e Ju o q 6
'8't
l e l d o q 3 a a s 6 u 1 1 t o t uI D O ! J a u n uJ t a q l J o J ' e ^ ! J p
lourl puD xoqloaD euo olu! pel1, aq o] pelllur
-red s1 Jaqtrtnu euos eql ql!rlrr palJotu
leeqm
u M o r o p u o u o l u g d a q l q l ! M . r r o dp e q c l o r u o A 1 u 6
'6ugqsau
lsaq aLll puo ostou lsertrrol aql oJns
-ue ol ,{lquasso e^r}cales Aq paqcloul alo
leeqM
u r v r o : ca q l p u o u o r u r d l g ^ a q e q t ' 6 u r ; l u o u r s r p

lsnu slo
-]t{6!ro s
6 u 1 s ns 6
re^oc eq
]snp eql
qsnd pu
'uo11gs
anoo;6e
aql u! rs
.
'leqsonn
6
oslo 1! Ic
aq1 uo d
Aq puo '
Aq uo;1c
u1 6u1:o
aq1 1o e6
1o a6pa
1noq11 I
.ro; 1sn!.r
{q ilqore
(s.roa6q
-opaeds e

in the other groove. Chose the ring olso with

regord to toleronces cvoiloble in one closs of
the rings os mentioned in the previous Pqrogroph. Check the cleoronce of the geor with
the oid of o diol indicotor.
Then remove the geor including the friction
ring in the second groove of the shoft.
7. Ploce the lock of the 1st' ond 2nd'speed
s y n c h r o ni z i n g c l u t c h o n t h e b e n c h w i t h i t s
teeth downword. lnstoll springs in the clutch
core securing them with greose ogoinst folling
out ond insert the clutclr core with the shorter
side of the inner heod on top in the respective
geor.
Locote bclls (dio. 1ir in.) on the springs,comp,ressthe springs with the fingers or using
o suitoble rod, cnd fit the complete core itrto
the geor.
8. Hoving thus osembled the synchronizing
c l u t c h l o c k , i n s t o l l t h e s y n c h r o n i z i n gr i n g f r o n r
the opposite side of the geor. Now threod the
lock on the oiled shoft with the geor focing
owoy from the shoft.
9. Instoll in position the previously selected
friction ring with its groove focing owoy from
the shoft (toword the geor) ond insert the
synchronizing ring into the fitted lock of the
synchronizing clutch. Slip the oiled geor ond

F i g . 4 . 6 l a- A s s e m b l i n g1 s t ' o n d 2 n d - s p e e d
Synchronizing
C l u t c h - l n s t o l l i n gt h e C o r e
o n d P n e s s i n gi n t h e B o l l s

the previously selected friction ring on the

oiled shoft.
10. Slip on the 3rd - speed geor ond secureit
with on orbitrorily chosen ring from the ronge
o f f r i c t i o n r i n g s i n c o m p l i o n c ew i t h t h e p o r o groph 2. Meosurethe oxiol cleoronceond odiust
it to 0.1*0.07 mm by o repeoted exchonge of
the frictionring.
N o w r e m o v et h e g e o r , l u b r i c o t ei t , s l i p i t o n
t h e o i l e d s h o f t o n d l o c k i t i n p o s i t i o nw i t h t h e
ring with the oil groove focing the geor.
11. Proceeding occording to porogroph 2,
insert on orbitroryfriction ring into the lost
groove,slip on the 4th-speedgeor ond tighten
t h e p i n i o n n u t o v e r o p i l o t c o l l o r r e p l o c i n gt h e
beoring (for exomple of dimensions dio.
25.5/38x26with edges of the inner bore chomf e r e d t o 1 x 4 5 o ) .M o r k t h e s i d e o f t h e p i l o t c o l l o r w h i c h w i l l b e t u r n e dt o w o r d t h e n u t s o t h o t
the side focing the geor connot be domoged by
impression.Adiust the cleoronce of the geor
to 0.1+0.07mm by o repeoted trying on (exc h o n g e ) o f t h e f r i c t i o n r i n g s . T h e n r e m o v et h e
geor ond the ring from the shoft.
12. Assemblethe 3rd- ond 4th-speedsynchonizing clutch using the some method os when
hoving ossembled thot of the 1st ond 2nd
speed. lnsert the synchronizing ring into the
clutch ond slip the clutch on the oiled shoft
with the short side of the lock first.
13. Instoll the selected friction ring in the
locking position into the groove with its oil
groove focing owoy from the shoft. Push or top
home the key into the spline of the shoft so
thot it possesthrough oll friction rings ond its
end is ot leost flush with the splined shoft end.

F i g . 4 . 6 / 3- L o c k i n g 1 s t - s p e e dG e o r i n P o s i t i o n
( t u r n i n gt h e r i n g w i t h o d r i f t ) w i t h t h e P i n i o n
C l o m p e ciln M P 3 - 1 0 5o r M P 3 1 1 1 J i g
86

1 -

Fig. 4.

L8
r u l " r u t ! x D r uD ( ) 1 l l p u l J 6 ' , 6 u l J D a ql e l l o J a q l , o
a c D l J e u u t e q l e ^ o u l e j o l A l D S S o c e us ! l l J l . Z
' s J D a 6a q l u o l l r s o d u g 6 u r 1 c o ; s 6 u 1 - r
uottctJl aql
{ 1 1 q D r 16s u 1 u . r n p1 u o ( t L q d o : B o r o d a a s ) i e 1 e q 1
6 u 1 r , r o . r p q 1 1rMe U D l l o q s a q t ] l o u e q l 6 u r d d r g s
Aldurls iq penoruel eq ol Apoe: puD posDelor
erD seqolnlc 6urzluo:qculs puo sloe6 ;;o *o[u,

6tf lli-e dn ro
'6!l
S g L - t c J t Au ! 1 r N u o r u r d 6 u r u a 1 q 6 r -1 g / g ' t

'pue
l
sl! p
os u
do1 .r
lto st
eql u
uDqs
eql o
Puz
ueq
-uor.l

- J D e qe q l e l o u e r o ] l l o q s l ! a l D l o J p u o 6 u r . r o e q
e q l u o r e 1 1 n d8 0 1 - t d 6 a q ] l ! J ' l n u s l ! l l o M a r c s
puD (tig'V puo 979'y s6;3 u! uo!lDrlsnlr slt
e a s ) 6 1 19 0 1 - ed r u o q l u ! u o 1 u 1 de q l d L u D l C' !

all] e

A;quessos;O uo!u!d

-xe)
.ioe6
Aq pa

'ruru g'0 ol
0 jo esuDJoolcD e^Del ol lnq euoq
A 1 1 n ;r o e 6 e q l s s a . r d o l l o u p e p u e t u t u o o o r s ! ] l
'uo1u;d eql puD ssa.rd
eql ueeMleq 11 ezeenbs
o l l o u s D o s A ; 1 n 1 a r o c: o e 6 o q l u o - s s e J d
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aql u

L l s l n l c6 u t z t u o l q c u r {pse a d s - q l t p u D - p J e- g ' r l c } n l c 6 u r z r u o : q c u ^ sp e a d s
- p u Z p u o - l s L - g ' : o e 6 p e a d s - r l ] t - y ' ; o a 6 p a a d s - p r t '-.er o e 6p e a d s - p u Z - 7 ' n a } p e a d s - 1 s 1 - - ; _
u o r u r d p e l q u a s s v A ; e 1 a ; d u o 3- S / g ' t ' 6 ! J

eJo
p30

length ond depth ond strike it off while still

hot from grinding.
Co u t io n ! The iig used for other types of
S k o d o c o r s c o n n o t b e u s e d f o r r e m o v i n gt h i s
roce!
Although the ports ore identicol ot f irst sight,
the teeth of the pinion ore lorger ond they
w o u l d n o t p o s s w i t h o u t o d o m o g et h r o u g h t h e
iig.
W h e n d i s m o n t l i n g t h e s y n c h r o n i z i n gl o c k s ,
support the clutch core with on obiect obout
2 0 m m h i g h , t o k e t h e l o c k b e t w e e nt h e p o l m s
o f b o t h h o n d s ,o n d p u l l i t o f f t h e c o r e .T h e b o l l s
c n d s p r i n g se i e c t e d f r o m t h e c o , r ew i l l f o l l i n
yourpolms.

Dismontling Drive Shoft

1 . C l o m p t h e s h o f t i n o v i c e o c r o s st h e f o c e
of the 4th-speedgeor ond screw off the nut.
I n s t o l lt h e s h o f t i n t h e M p 3 - 1 0 6s u p p o r tb y t h e
outer beoringroce ond press off the beoring.
2. Press the shoft out of the beorings by
p l o c i n g t h e s u p p o r ts u c c e s s i v e l yu n d e r t h e i n dividuol geors ond the second beoring. protect
the shoft sphericol end - use the buttress plote
for pressing off- see porogroph2 of the previous section.

4.8

Generr

The
i. e., th
ferenti,
togethr
checke
(mesh
on the
Only
crown '
con be
Bevel (

4.7 DRIVE SHAFT C/W GEARS

Spor
with n
trotion
The ;
( 175) v
like the
first po
froction
the pini
crossin
port of I
in hund
missing

L i k e t h e d r i v e n s h o f t ,i . e . t h e p i n i o n w i t h
g e o r s ,t h e d r i v e s h o f t w i t h i t s g e o r s f o r m s o
u n i t t o b e i n s t o l l e di n t h e g e o r b o i . F o r o s s e m b ling the drive shoft,use ogoin the work bench
o n d - o p r e s s .W h e n r e p l o c i n go n e o f t h e d r i v e
shoft geors with o new one, it is necessoryto
r e n e w o l s o i t s m e s h i n gg e o r o n t h e d r i v e ns h o f t
(pinion).
AssemblingDrive Shoft
1 . U s i n g o g r i n d s t o n ec, h o m f e rt h e s h o r p e d ges of both geors ot the point of their inner
cylindricol bores ond the loterol chomfer of
these bores.
2. H,ug-tup the 3rd-speed geor to o tempero_
.
ture of-80 up to 100oC,insert it with the longer
side of the inner heod first into the Mp 3-106
s u p p o r to n d s h r i n k -ift t h e s h o f t . ' U s et h e o t h e r
port of the support, the buttress plote, slipped
o v e r t h e s p h e r i c o le n d o f t h e d i i v e s h o i t ' o s
o thrust pod between the shrink-fitted shoft
o n d t h e p r e s ss p i n d l e .
3. Heot up the 4th-speedgeor like the previ9t1;.geor ond shrink-fit it on the shoft _ see Fig.
4.7t2.
4. Pressthe boll beoring with its outer thrust
ring owoy from the shoft to the th-speedgeon,
ond onother boll beoring to the 1st-sireed
[eor.
Use the other holf of the Mp 3-106supporl
for
pressing-on
the beorings.
.5. Clomp the shoft in o vice (providing the
v.iceiows with sheet linings) Uy'the floriks of
the 4th-speedgeor ond tighteh the nut. Hommer
down the nut neck into the shoft qroove.
Use o new nut if the neck of thle old one is
domoged.
E l i m i n o t eo n y s t r e s sr e s u l t i n gf r o m s h r i n k i n g
on the geors by topping the geors ond the shofl
willr o mollet.
88

Adjustir

Fig. 4.711- Shrink-fitting of Geo,rs on Drive

Shoft Using MP 3.106 Support (two-port iig
c o n s i s t i n go f t h e s u p p o r tp r o p e r o n d t h e b u t t r e s sp l o t e )

Fig.4.712- Drive Shoft c/w Geors

- 1st-speedgeor,2- reversegeor,3 - 2nd-speed
geor, 4 - 3rd-speedgeor, 5- 4th-speedgeor

To od
set the ,
the oxis
the flon
the MP I
1. Fos
the diol

1- MP

68
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4 . 9 - 4 r. O

pointer ofter pushing the pinion into the

h o u s i n g i s t h e m e o s u r e( t h i c k n e s s ) o f t h e
shims.

3. To evoluotethe doto obtoinedfrom the diol

indicotor reoding ond the doto of the geor set,
odopt the following procedure:
The setting distonce of the gouge- 60.00mm
- is morked on the gouge orm; the reoding of
the diol indicotor hos shown o deviotion of e. g.
plus 66 divisions, i. e. 0.66 millimetres (plus
m e o n s t h o t t h e t i p o f t h e g o u g e i s p u s h e di n word from the set zero position ond the indicotor reoding is higher; o reverse deviotion m i n u s r e o d i n g- c o n n o t p r o c t i c o l l y o c c u r ) . B y
subtroctingthis deviotion from the meosureon
the gouge, the octuol distonce between the
pinion ground foce ond the geor cross oxis will
be obtoined, i. e. 60.00 mm minus 0.66 mm :
59.34mm.
The meosureon the crown wheel indicoting
the ossembly distonce of the pinion is, foi
exomple,59.60.Accordingly,the pinion must be
m o v e ds l i g h t l y o u t o f t h e h o u s i n g0 . 2 6m m , i . e . ,
by the differenceof the two meosurings(59.60
minus59.34:0.26 mm).
4. Preporeodiusting sirims 0.30 mm thick to
be insertedunder the flonge of the pinion beoring on further ossemblyof the housing.
Shims 0.14, O.2, 0.3, ond 0.5 mm thick ore
ovoiloble.lf the requiredoccuroteoutword shifting of the pinion connot be ochievedwith shims
o f o n y o f t h e s p e c i if e d t h i c k n e s sc, o m b i n et h e m
to obtoin the next higher volue.

^ l ;
e

e l l
;

\l-

4.9 DIFFERENTIAL
Assembly
1. Instollthe sun geor (plonet) without the
friction wosher,the two stor pinions (sotellites),
ond the pilot pin for the stor pinions into the
left-hondholf of the differentiol cose (with the
flonge for the crown wheel). The originol differentiol pinion shoft pressed into the cose
must be reploced tempororily by the pilot pin
to focilitote hondling.
2. Push the sun geor from outside into engogement with the stor pinion teeth ond use
o depth gouge to meosure the dimension by
which it protrudesfrom the housing.Then, proceeding from inside, push the sun geor into the
obutment surfoce of the differentiol cose ond
meosureogoin by how much lt protrudesfrom
the housing.The difference of both meosurements determinesthe gop for the sliding ring.
The rings ore suppliedin thlcknessesof 1.8, 1.9,
2 , 2 . 1 , 2 . 2 ,o n d 2 . 3 m m . S e l e c tt h e r i n g w h l c h i s
0 . 1 m m t h i n n e r t h o n t h e c o l c u l o t e dd i m e n s i o n
of the gop.

I
((

Fig.

Note:
The thickness of shims required for the odi u s t m e n to f t h e p i n i o n c o n b e o l s o c o l c u l o t e d
in the followingwoy:
o ) S e t t h e d i o l i n d i c o t o ro f t h e M p 5 - 1 0 3g o u g e
o s i n p o r o g r o p h1 o f t h e p r e c e d i n gt e x i i . 6 . ,
with the gouge odiusted on the meosuring
contoct, the reoding of the diol indicoto-r
w i l l b e 1 . 0 0m m .
b)
. S w i n gt h e t i p o f t h e d i o l i n d i c o t o r o g o i n s t
t h e p i n i o n g r o u n df o c e o n d p u s h t h e
iinion
by meons of the Mp 5-102 beorinq retoiner
i n t o t h e h o u s i n gt i l l t h e d i o l i n d i c i t o r r e o d s
1.00mm.
c ) P u s h ,t h e p i n - i o nf u r t h e r i n t o t h e h o u s i n g
{while w.otchingthe deflection of the poin-.
ter) until the ossembly meosuringis obtoined (the 59.60 meosure on th; crown
w h e e l ), i . e . , b y t h e d i ff e r e n c e o f t h i s
meosuring from 60.00mm - in our exomple
6 0 . 0 0m i n u s 5 9 . 6 0 : 0 . 4 0 m m .
d ) Without chongingthe position of the
diol
I n d i c o t o r ,p u s h t h e p i n i o n i n t o t h e h o u s i n g
g s f o r o s i t w i l l g o - t h e d i f f e r e n c eo f t h 6
d.iol reoding from the previous0.40 mm is
the thicknessof the requiredshims (0.26
mm). Or, without chongingthe position of
the diol indicotor on tfrJ pinion, trin tf,e
scole to zero (0). The deilection of the

90

,'

l|i

F i g . 4 . 9 / 1 - S e c t i o n o lV i e w o f D i f f e r e n t i o l
The orrow points to the mork indicoting the
side for pressing-on the differentiol pinion
shoft. Any symbol con be used (o figure, o letter) but it must be identicol for both ports of
the differentiol. lt olso indicotes the correct
relotive position of the two differentiol ports.

Fig-

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o f t h e b r o k e m e c h o n i s mo d h e r i n g t o t h e i n s t r u c t i o n so f t h e o b o v e - m e n t i o n ecdh o p t e r , l o '
c o t e t h e b e o r i n gs h i m 0 . 3 m m t h i c k , o n d c o m '
plete the ossembly.
N o t e : T h e 3 m m s h i m s h o u l db e u s e do n l y
w h e n r e p l o c i n gt h e w h e e l h u b o r w h e n e l i m i r r o t i n g o n o s c e r t o i n e ds h o f t p l o y , t h o t i s t o s o y
i f t h e s h o f t m o v e so x i o l l y o n d k n o c k s .H o w e v e r ,
i t i s r e c o m m e n d e dn e v e r t o u s e m o r e s h i m s
thon three.
5 . A d o m o g e ds e o l i n g r i n g c o n b e r e m o v e d
w i t h o h o o k o r o n e e d l e ,o n d o n e w o n e d r i v e n
or pressed-on.The lotter olternotive should be
preferredwith regord to the visuol checking of
t h e p r e s s i n g - o no p e r o t i o n .T h e t i g h t e n i n g f i n
ond spring of the pocking hove to be tunnedinside the holf-oxle.
When driving home the seol ring, slip the
M P 5 - 1 1 4p i l o t t o p e r ( s e eF i g . 5 . 2 1 3o) n t h e s h o f t ,
smeor it with oil, ond move the seoling ring
olong it to drive it finolly into the holf-oxle
u s i n g t l r e M P 5 - 1 1 6d r i f t o s s h o w n i n F i g - 5 - 2 1 2 .
F o r p r e s s i n g - o tnh e s e o l i n gr i n g , u s e t h e M P
5-112iig (see Fig. 5.214)ond the, sleeve with
t o p e r o s p e r F i g . 5 . - 1 l 4P.u l l t h e s h o f t s l i g h t l yo u t
o f ' t h e h o l f - o x l e s, l i p o n i t t h e o i l e d t o p e r o s
s h o w n i n t h e i l l u s t r o t i o n t, h e n t h e s e o l i n g r i n g
o n d f i n o l l y t h e s l e e v e .F o s t e nt h e M P 5 - 1 1 2i i g
s c r e w i n gi t s h e o d o n t h e h o l f - o x l et h r e o d , s l i p t h e s e o l i n gr i n g o n t h e t h r u s t r i n g b y m e o n so f
the sleeve,ond turn the wrench to press the
s e o l i n gr i n g i n t o t h e h o l f - o x l e .
N o w t h e b e o r i n gc o n b e p r e s s e do t t .

F i g . 5 . 1 i 3- F o r c i n g S l r o f t o u t o f B e o r i n g U s i n g
MP 5-113Jigs ond Jirrs os per Fig. 5."1/1
The oxle shoft moy Inove out of the holf-oxle
only to such on extent thot the reor edge of the
beoring thrust ring is flush with the holf-oxle
socket. Otherrwise it is opt to foll out of the
epicyclic geor ond its refitting would require
the removol of the holf-oxle from the georbox
housing.
4. To fit o new boll beoring proceed occording
t o C h o p t e ' r5 . 2 . P u l l o u t o g o i n t h e s h o f t s l i g h t l y
until the thrust ring con be seen,fit the beoring

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F i g . 5 . 1 i 4- S l e e v eo n d T o p e r f o r P r e s s i n g ' o n
H o l f t - A x l eS e o l i n g R i n g ( t o p e r s u r f o c e
s m o o t h e do u t d u r i n g m o n u f o c t u r e )

96

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f l o n g e .T h e i i g o f t h e l o t e s t d e s i g n p e r m i t s i t s
s i m p l e f o s t e n i n gb y e n g o g e m e n w
t ith the holfoxle flonge (fit the iig ond rotote it to lock it
in position).
I n s t o l lt h e l o r g e rl i n e r b e t w e e nt h e b o l l b e o r i r r g o n d t h e i i g h e o d ,o n d p r e s st h e b o l l b e o r i r r g
on the shoft by turningthe iig wrench.
3 . R e p l o c et h e l o r g e r l i n e r w i t h t h e s m o l l e r
o n e ( r e s t i t o g o i n s tt h e i i g b o l t h e o d ) , o n d t u r n
the wrench in the opposite direction to press
t h e b e o r i n g i n t o t h e h o l f - o x l es o c k e t .

5.:

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5-t

Fitting Broke Mechonismond Wheel Hub

4. Instollthe brokebocking plote complete
w i t h t h e b r o k e m e c h o n i s mo n t h e h o l f - o x l e
s o c k e t ,s l i p o n t h e " O " s e o l i n g r i n g o n d t h e
c o p w i t h t h e s e o l i n gr i n g ( w i t h t h e t i g h t e n i n g
f i n f o c i n g t o w o r d t h e h o l f - o x l e ) ,o n d f o s t e n o l l
the porrtswith bolts, spring woshers, ond nuts.
T h e s e o l i n gr i n g s h o u l d b e d r i v e n o r p r e s s e d
i n t o t h e c o p s o t h o t t h e t i g h t e n i n g l i p f o c e st h e
b e o r i n go n d i u s t s o t h o t t h e r e r e m o i n so g o p o f
1 t o 2 m m b e t w e e nt h e p o c k i n g o n d t h e c o p
flonge.
5 . l n s e r tt h e k e y i n t h e s h o f t w i t h i t s b e v e l l e d
end into the runout of the keywoy, smeor the
hub neck with oil so thot it does not drog in
t h e s e o l i n gr i n g , o n d f i t t h e h u b w i t h t h e b r o k e
drum in position. Moke surethot the key did
n o t m o v e f u r t h e ro l o n g t h e s h o f t ( i t s l i f t e d e n d
in the keywoy would couse the hub to burst)
ond tighten lightlythe nut.Sinceo high torque
i s r e q u i r e df o r f i n o l t i g h t e n i n g o f t h e n u t , p u t
off the tightening ond locking of the nut till
o f t e r i n s t o l l o t i o ni n t h e c o r . T h e n t i g h t e n t h e
nut with full torque (see Chopter 1.8),top on
the hub to relieve the possive stress of the
toper, retighten to the specified torque, ond
lock the nut with o cotter pin.

F i g . 5 . 2 l 5- P r e s s i n gB o l l B e o r i n go n S h o f t
U s i n g M P 5 - 1 1 2J i g o n d l t s L i n e r ( s m o l l e r )

DK ?EI

6. Instoll the spocer into the rodius orm, fit

the knurled woshers (with the knurling toword
t h e o r m ) t o e i t h e r s i d e o f t h e e l l i p t i c o l h o l e so f
the rodius orm, ond fosten them with bolts ond
nuts not forgetting the spring woshers. Do not
tighten the connection fully. Threod the bolts
through the bolt holes so thot their nuts foce
into the cor ofter fitting the rodiusorm to the
holf-oxle.
F i t t h e r o d i u sa r m o n t h e p r o t r u d i n gh o l f - o x l e
p i n o n d t h r e o d t h e b o l t t h r o u g ht h e h o l e o f t h e
secrt.Slip spocing tubes on the bolt ond pin
together with sheet shims with rubber liners
ond fosten lightly (without tightening) the
rodius orm to the holf-oxleusing nuts ond lock
woshers.Tighten fully the connection ofter fitting the ossemblyin the cor when odiusting the
reor wheel olignment (geometry).

F i g . 5 . 2 1 6- C o n n e c t i o no f H o l f - o x l e s
w i t h R o d i u sA r m s

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l o r g e r o n d o n e s m o l l e r ,o n d t h e f o r k e d p l o t e ) ,
screw down the iig on the threod of the shoft,
ond use nuts to ottoch it to the holf-oxlesocket

98

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the toe-in of the reor wheels using olso the

M P 8 - 1 5 2g o u g eo r o n o t h e rs p e c i o lg o u g eo v o i l o b l e i n y o u r w o r k s h o p .T o o b t o i n t h e r e q u i r e d
s h i f t o f t h e h o l f - o x l e s( s y m m e t r i c osl o o s n o t t o
d i s t u r b t h e o x l e o l i g n m e n t ) ,s t r i k e o g o i n t h e
h o l f - o x l e sw i t h o r u b b e r m o l l e t o s p e r p o r o groph 2.
4" Retighten the slockened connections
( r o d i u s o r m b o l t s ) o n d , o c c o r d i n gt o t h e p r o g r e s so f t h e r e o s s e m b l yo, l s o t h e n u t s o f t h e
h o l f - o x l es h o f t ( s e e C h o p t e r 5 . 2 , p o r o g r o p h5 ) .
C o m p l e t et h e o p e r o t i o nb y l o c k i n g t h e n u t s .

5.6 HALF.AXLEDUST BOOTS

T o p r e v e n to i l f r o m l e o k i n gt h r o u g ht h e i o i n t
gop between the dust boot ond the joint guord
os well os ony twisting of the boot during
the oction of the rood spring, or its domoge by
contoct with other cor ports, it is importont to
observe its correct position on the holf-oxle.lt
s h o u l d b e l o c o t e dw i t h i t s f l o n g e sf o c i n g r e o r wqrd ond tilted upword ot on ongle of obout
45o.For better occess,ploce the clips fostening
the dust boot to the holf-oxle ond cover with
t h e i r s c r e w s o n t o p . W i t h t h e r i g h t - h o n db o o t ,
screw in the clip screws from the front, with
t h e l e f t - h o n db o o t t h e s c r e w o n t h e h o l f - o x l e
from the reor ond on the cover from the front.
Connect the dust boot flongeswith hollow
r i v e t s u s i n g s u i t o b l ep l i e r s .l f r i v e t i n g p l i e r s o r e
n o t o v o i l o b l e ,b o l t t h e f l o n g e s t o g e t h e ni n s t o l ling odequotely dimensionedploin woshers
u n d e rt h e b o l t h e o d so n d n u t s .
5.7 HALF.AXLESHAFT

F i g . 5 . 5 / 3- C h e c k i n gA l i g n m e n to f R e o r A x l e
w i t h C o r C e n t r e L i n e U s i n g M P 8 - 1 5 8G o u g e

100

T h e t h r u s t r i n g o f t h e b e o r i n g( b e h i n d t h e
s h o f t t o p e r ) i s p r e s s e do n t h e s h o f t . l f i t i s n e c e s s o r yt o r e n e w t h i s r i n g , f o r e x o m p l e o f t e r
repeoted replocements of the beoring (see
Chopter 5.1, porogrroph4), press it on so thot
it is removed76 to 78 mm from the edge of the
toper behindthe shoft threod.

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102

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refer to the proceduresrecommendedby the

monufocturersof the gouges.
The check lood con be formed by blocking the
wishbones with bors occording to Fig. 6.1/5.
Press down the cor with the hond, insert the
bors under the wishbones so thot they beor
ogoinst the oxle brocket,ond releosethe cor to
let the bors be clomped.lf clomping of the bors
does not toke ploce (which con hoppen on on
o l d e r c o r w i t h w e o k e n e ds p r i n g s ) ,c o n s i d e rt h e
c o n d i t i o n o s i f t h e b o r s w e r e c l o m p e d ,i . e ' ,
correspondingto the position of the front oxle
ot check looding.
The words "ot full lood" describe o vehicle
looded so thot the distonce of the rubber deod
stop from the bottom of the lower wishbone
stop is 20 mm (see olso porogroph18) ond the
comber ongle of the reor wheels is 1". Meosure
t h e s e v o l u e so n o l l w h e e l s ( n o t o n l y o n e f r o n t
o n d o n e r e o r w h e e l ) o n d d i s t r i b u t et h e l o o d o s
necessory.
Fig. 6.1/4- Costor Angle
It is imperotiveto set the ongle with regord to
the direction of forword trovel os indicoted
by the orrow

F i g . 6 . 1 / 5 - P r e p o r i nfgr o n t o x l e f o r t h e c o n d i t i o n
of check lood by inserting steel bors of 181 mm
in diometer ond obout 220 mm long

The most importont points from the point of

view of driving ore the toe-in ond the comber
ongle, the odiustmentof which is permitted by
the oxle design.
Adiust first the comber ond then the toe-in
since o chonged comber offects the toe-in.
We refroin from describing in detoil ony
meosuringmethod in view of the lorge number
o f e x i s t i n g g o u g e s .I n s t e o d ,w e o d v i s e y o u t o

104

Toe-in
T o o d i u s tt h e t o e - i n ,s c r e wt h e r i g h t - h o n do n d
l e f t - h o n ds t e e r i n gr o d s s y m m e t r i c o l l y( o c h o n g e
up to 1 mm con be effected by one rod) ot
check lood so thot the distonce between the
w h e e l r i m s ( o r o c r o s st h e m ) b e h i n d t h e o x l e
( A + o ) i s l o r g e rb y t h e t o e - i nv o l u e ( o ) t h o n t h e
distonce between the rims in front of the oxle
(A).
To verify steering symmetry (correct screwing of steering rods during toe-in odiusting),
check the wheel lock position ot the 20" lock
ongle of the neorsidewheel - for the respective
volues refer to Chopter 1.7.
Slocken the steering rod nuts ond rotote the
s t e e r i n g r o d s u s i n g o n o l l i g o t o rw r e n c h ( F i g .
6.1/6).
In oddition to the correct inflotion pressure
of the tyres, poy ottention to severol essentiol
p o i n t s w h e n c h e c k i n gt h e w h e e l o l i g n m e n t :
o ) P l o c et h e w h e e l i n t h e s t r o i g h t o h e o dt r o v e l '
ling direction;
b) The steeringrod ond the trock rod must not
be stressed.The stresscon be eliminoted by
letting the cor swing up ond down in its
suspensionunder the pressureof your honds
(olternotely press down ond releose the
wings)
c ) P r e p o r et h e o x l e o s s h o w n i n F i g . 6 . 1 / 5 ;
d) lf o speciolgouge with o scole for wheel
lock ongle setting is ovoiloble, odiust the cor'
rect length of steering rods in occordoncewith
t h e p o s i t i o no f w h e e l s i n c h e c k l o c k p o s i t i o n s .
Y o u w i l l f i n d t h e r e s p e c t i v ev o l u e s i n C h o p t e r
1 . 7 " S t e e r i n g " .S e t t h e l o c k o n g l e o f t h e w h e e l
on one side to 20' (on o turn-toble) ond screw
the steering rod of the other wheel to odiust

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tentotively ond odiust the direction indicotor

switch - see Chopter 13.17.
4. Using the steering wheel, tunn the wheels
i n t o f u l l l o c k p o s i t i o n st o m o k e s u r e t h o t t h e
l o c k o n g l e i s c o r r e c t l yl i m i t e d b y t h e k i n g p i n
socket stops - see Chopter 6.5, porogroph 36.
5. Adiust the toe-in - see Chopter 6.1.

exomple 50,000km ond more, check the wheel

comber ond prepore suitoble woshers for its
correction.
2. Jock up the cor ond support the body on
both sides to relieve the front wheels, ond
remove the wheels.
3. Proceedingfrom inside the luggoge boot,
remove covers protecting the threods of the
shock-obsorberpiston rods ond screw off the
nuts. Retoin the piston rod by holding its flottened end.

6.4 DISMANTLING FRONT AXLE

b) Operotionsinside the cor

4. Remove the steering wheel, the steering
c o l u m n c o w l i n g , o n d d e t o c h t h e s t e e r i n gs h o f t
from the body - see Chopter 7.8.
c) Operotions from under the cor
5. Removethe bolt of the connection of the
steeringshoftwith the steeringbox ond releose
the shoft sleeve from the connection by pulli n g t h e s t e e r i n gg e o r i n s i d e t h e c o r .
6. Slocken the nuts of the bottom wishbone
pins fostening the front oxle to the brocket on
the body until the woshers of the brockets ore
releosed.
7. Detoch the onti-roll bor brockets from the
body ond disconnect the rubber broke hoses
from the front broke systems. Before disconn e c t i n g t h e h o s e , c l e o n t h o r o u g h l yt h e h o s e
connector ond its surroundings to prevent
foreign motter from getting into the broke
system. For the some reoson,wrop the hose
ends in o cleon rog. Toke the some precoutions
w i t h t h e d i s c o n n e c t e db r o k e p i p i n g .
8 . P l o c e o r o l l - o - c o ri o c k u n d e r t h e o x l e o n d
removethe bolts (two on either side of the telescopic shock obsorber) fostening the oxle to
the body from obove.
9. Compressthe telescopic shock obsorbers,
lower the iock, ond move it with the oxle from
under the cor.

No speciol instructions ore required for dism o n t l i n g m o n y o f t h e s u b o s s e m b l i e sA.c c o r d ingly, only the bosic dismontling procedure
w i l l b e d e o l t h w i t h o n d p o r t i c u l o r sw i l l b e m e n tioned only os fon os they ore necessoryfor the
sequenceof operotionsond the use of iigs.
Ports which con be dismontled witlrout removing them from the cor ore the wheel hubs
a n d b e o r i n g s t, h e b r o k e m e c h o n i s m ss, t e e r i n g
orms, shock obsorbers,ond the onti-roll bor.
l f o n y o d d i t i o n o lp o r t s h o v e t o b e d i s m o n t l e d ,
remove the oxle from the cor ond dismontle it
on the stond.
Dismontling Wheel Hubs ond Beorings
1 . D i s m o n t l e t h e b r o k e m e c h o n i s mo s p e r
Chopter 9.1 ond remove the wheel hub cop
using the MP 6-124drog. When using the MP
6-136pull-off cortridge, the hub cop hos to be
prised off with o tyre lever or o similor tool.
Now removethe costellotednutwith its wosher
o n d p u l l o u t t h e h u b ,o s s i s t i n gt h e r e m o v o lw i t h
l i g h t b l o w s o f o m o l l e t ,i f n e c e s s o r y .
2. Toke out the inner port of the outer beori n g , t h e n t h e s e o l i n gr i n g , o n d ,f i n o l l y ,t h e i n n e r
port of the reor beoring (cone with topered
rollers). Prise out the seoling ring using o
scrrewdriver.Proceed corefully olong the ring
circumferenceto ovoid distorting the ring which

wi
prl
tht
rer

ou
MT
ott
rec

6.3 REFITTINGFRONT AXLE IN CAR

1 . T o r e i n s t o l lt h e o x l e i n t h e c o r , r e v e r s et h e
p r o c e d u r eo f i t s r e m o v o l ,i . e . , b e g i n w i t h t h e
porogroph9 ond proceed to the porogroph 1.
Coot the rubber cup with greose ot the point
of its contoct with the steering shoft.
2 . W h i l e r e c o n n e c t i n gt h e b r o k e h o s e s ,o b servethe utmost cleonlinessond bleed the front
wheel brokes if no other ports of the broke
s y s t e m h o s b e e n d i s m o n t l e d .( l f s u c h o d i s m o n t l i n g h o s t o k e n p l o c e , b l e e d t h e b r o k e so f
o l l w h e e l s o f t e r h o v i n g f u l l y r e c l o s e dt h e b r o k e
circuit).
3. Turn the wheels in the stroight oheod direction before connecting the steering shoft
with the steering box. Fit the steering wheel

.a

Fig

Dis

F i g . 6 . 4 / 1- R e m o v i n gH u b C o p U s i n g
MP 6-124Drog

106

S
bol
6-1C
rub
ovo

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Remove the csstelloted nut ond wosher from

the steering orm, screw down the MP 6-105
cotridge on the threod of the orm, ond drive out
the orm.
Removing Steering Knuckles, Springs,
ond Wishbone Suspension
1. Remove tlre shock obsorber ond fit the
M P 6 - 1 0 6s p r i n g i n s t o l l e r i n i t s p l o c e f r o m o b o v e .
l n s t o l l o h o r s e s h o ew o s h e r o n t h e s p h e r i c o l e n d
of the instoller tie-rod possing tlrrough the coil
spring ond the bottom wishbone, ond compress
portly the spring (for fitting the instollersee
Fig.6.5/4).
2. Screw off the costellqted nuts of the upper
wishbone pin ond the bolt of the lower wishb o n e s u s p e n s i o n ,o n d d r i v e o u t t h e w i s h b o n e

p i n . l f d r i v i n g o u t i s i m p o s s i b l e ,u s e t h e M P
6-107drrog(remover).
Rotote slightly the flonges of the drog to
breok it up in two ports, fit it os o yoke over
t h e u p p e r w i s h b o n e ,c l o m p i t i n p o s i t i o n b y
rototing its heod, ond screw in the centre bolt
t o p r e s so u t t h e w i s h b o n e p i n .
3. Drive out the bolt of the lower wishbone
s u s p e n s i o no n d r e m o v e t h e s t e e r i n g k n u c k l e
from the lowerwishbone.
4 . S c r e wo f f t h e n u t o f t h e k i n g p i n o n d p u l l
o f f t h e k i n g p i n s o c k e tu s i n g t h e M P 6 ' 1 1 1d r o g .
Refer to the following chopters for further
d i s m o n t l i n go f t h e s t e e r i n g k n u c k l e ,t h e k i n g
p i n o n d i t s s o c k e t ,o n d t h e i r r e p o i r s .
H o v i n g r e m o v e dt h e s p r i n g i n s t o l l e r , l i f to w o y
t h e s p r i n g o n d r e m o v et h e w i s h b o n e s .
5 . W h e n r e m o v i n gt h e u p p e rw i s h b o n e ,m o r k
t h e t h i c k n e s so f t h e o p e n ( h o r s e s h o e )w o s h e r s
irrsertedbetween the brocket ond oxle body on
t l r e i n d i v i d u o lb r o c k e t s .T h e w o s h e r so r e 3 m m
o n c t1 m m t h i c k s o t h o t i f t h e r e o r e ,f o r e x o m p l e ,
, ork the
one 3 mm ond two 1 mm woshe'rsm
t h i c k n e s so f 5 m m o n t h e b r o c k e t . A l s o t o k e
i n t o o c c o u n tt h e l i k e l y n e c e s s i t yo f o c o r r e c t i o n
o f t h e w o s h e rt h i c k n e s s- s e e C h o p t e r6 . 2 ,p o r o g r o p h1 .
W h e n r e i n s t o l l i n gt h e u p P e r w i s h b o n e , f i t
w o ; h e r s o f t h e m o r k e dd o w n t h i c k n e s st o s i m '
p l i f y t h e c d j u s t n r e not f t h e w h e e l c o m b e r .

Fig.

Hol
over t
remo!
6.5

The
which
provid

F i g . 6 . 4 1 5- P r e s s i n g O u t P i n s o f S t e e r i n g B c r l l
J o i n t s U s i n g M P 6 - 1 3 8D r o g

F i g . 6 . 4 l 7- P r e s s i n gO u t U p p e r W i s h b o n e P i n
Drog
Using MP 6-'107

F i g . 6 . 4 1 -6 D r i v i n gO u t S t e e r i n gA r m U s i n g
M P 6 - 1 0 5C o r t r i d g e

6. Removethe nuts of the wishbone pin,

c l o m p t h e e y e o f t h e w i s h b o n eo n d b r o c k e t i n
o v i c e ( s e e F i g . 6 . 5 / 3 )o n d u s e o s c r e w d r i v e tr o
push the circlip out of the groove to the nor'
rowed down port of the pin. Sllp the pin out of
the other eye of the wishbone ond push out olso
the other circlip.

108

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Pock with greose the plostic dust cup ond

press it over the nut till it snops home in position on the lever.
Refitting Upper Wishbones
4. When refitting wishbones which hove
been olreody used in the cor ond which ore
rother doubtful (for exomple, o distortion is
suspectedos o result of o crosh), inspect them
corefullyond stroighten them, if necessory.
5. Pressrubber bushesinto the eyes from the
outer side. To focilitote their sliding in, dip
them in petrol or soop woter (suds). Put the
bushesinto the wishbone eyes with their lorger
diometer first ond push them so for thot they
protrude from the eye by the some length on
either side. Blow off the soop woter with comp r e s s e do i r s o t h o t i t d o e s n o o s s i s tt h e s l i p p i n g
of the bush during the next operotion.
6. Slip the spocing tube on the MP 6-122driIt,
dip the drift in petrol or soopwoter, ond,forcing
it through the rubber bush, press the spocing
tube into the bush.
B e f o r ep r e s s i n gi t i n ,t u r n t h e s p o c i n gt u b e s o
thot the ioint of the pockoged bush foces the
top side of the wishbone.
7 . T h r e o dt h e w i s h b o n ep i n t h r o u g ht h e e y e ,
slip on it the cup with its dished port focing
the bush, two wishbone brocketswith the lugs
pointing owoy from the wishbone,ond the other

cup with its dishedport tbword the other rubber

bush, ond threod the pin through the other eye.
8. Push the brockets towords the eyes ond
slip two circlips on the norrowest port of the
pin. To slip them on, hold them with their unconnectedends on the pin ond press down. Use
o screwdriverto move one of the circlips into
the grooveof the pin, ond push the pin with the
circlip in position into the brocket. Clomp the
other brocket with the wishbone eye in o vice
t o c o m p r e s st h e r u b b e r b u s h , o n d s l i p o n t h e
other circlip.
9. lnsert the rubber deod stop into the wish'
bone.

n
v
t
e
t

rl

F i g . 6 . 5 / 3 - I n s t o l l i n gC i r c l i p i n t o P i n G r o o v e
1 0 . R e i n s t o l l t h e t w o o s s e n r b l e dw i s h b o n e s
o n t h e o x l e b o d y . F i t o p l o i n w o s h e r u n d e rt h e
spring woshersof the lug bolts. Instoll, from
'l
obove,one mm or one 3 mm open (horseshoe)
wosher or the previouslyremoved woshers on
the horizontcrlbolts between the brocket ond
the oxle body lug.
First tighten the horizontolond then the verticol bolts.
F i t t h e c u p s o n t h e w i s h b o n ep i n o n d s c r e w
down both nuts.

F i g . 6 . 5 / 2- P r e s s i n gS p o c i n g T u b e i n t o Rubber
Bush Using MP 6-122Drift

Refitting Lower Wishbones

11. Inspectthe wishbonesos per porogroph4.
lnsert rubber bushesin the eyes of the wishbone fnom its inner side. Threod the wishbone
p i n t h r o u g ht h e e y e , s l i p o n i t t h e c u p o s w i t h
the upper wishbone,then two pin holders with
the recesses ot the inner hole focing eoch
other, onother cup, ond complete the operotion
by threoding the wishbone pin through the
other eye.
12. Slip circlips on the wishbone pin ond
lock with them the wishbone brockets in position. Proceedin the some monner os with the
upper wishbone (porogroph8).

110

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l ! p u o ' . r o cp a p o o l 4 1 1 na1q 1 u 1 u o r l g s o ds l l q l l M
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23- Fit the disk broke bock plote on the

s t e e r i n gk n u c k l eo n d f o s t e n i t b y b o l t i n g d o w n
t h e b r o k e b r o c k e t .U s e s p r i n g w o s h e r st o l o c k
the bolts. Drive home the wheel hub on the
s t e e r i n gk n u c k l ew i t h l i g h t t o p s o n d u s e o t u b e
t o t o p h o m e t h e b e o r i n gc o n e .
24. Fit the greose-pockedcone of the outer
beoring on the steering knuckie, locote the
s h i m o n t h e b e o r i n g ,o n d t i g h t e n t h e n u t w i t h
o t o r q u eo f 1 . 5 k p n r ( 1 5 N m ) w h i l e r o t o t i n g t h e
wheel hub.
25. Top the wheel hub ond the broke disk
with o mollet ond rototethe wheel hub to bed
in the beoringsB
. o c k o f f t h e n u t t h r o u g ho b o u t
-180o
ond retighten it with o torque of obout 5 Nm
( 0 . 5 k p m ) w h i l e r o t o t i n gt h e h u b . T h e n b o c k o f f
the nut to the neorest cotter pin slot (ot the
m o s t t h r o u g h3 0 " ) , o n d l o c k i t i n t h i s p o s i t i o n
b y i n s e r t i n gt h e c o t t e r p i n .
26. Check whether the wheel hub rototes
f r e e l y b r - rw
t i t h o u t o n y n o t i c e o b l ec l e o r o n c ei n
t h e b e o r i n g so, n d s e c u r et h e n u t w i t h t h e c o t t e r
pin.

s
I
I

Fittirrg Steering Knucklesond Wheel Hub

into Wishbones
2 7 . H o v i n g t h u s o s s e m b l e dt h e w h e e l , i n s t o l l
i i i n t o t h e l o w e r w i s h b o n e ,f i t o s h i m b e t w e e n
t l - r ew i s h b o n er e o r e y e o n d t h e r e s i l i e n tb u s h i n
t h e k i n g p i n s o c k e t ,t h r e o d i n t h e e c c e n t r i cp i n ,
c i n ds c r e w d o w n t h e n u t w i t h o u t t i g h t e n i n g i t .
28. Press the wheel ogoinst tlre upper wishb o r r eo n d c o n n e c t i t w i t h i t b y t o p p i n g h o m e
t h e w i s h b o n ep i n f r o m t h e r e o r s i d e o f t h e o x l e ,
i. e., from the side of the shorter port of the
k i n g p i n s o c k e t .S l i p t h e M P 6 - 1 0 8p i l o t p i n o n
t h e w i s h b o n ep i n t h r e o d t o f o c i l i t o t e t h r e o d i n g
of the pin throughthe hole in the wishbone.
T i g h t e ns l i g h t l y t h e c o n n e c t i o nw i t h t h e c o s t e l loted nut.

F i g . 6 . 5 / 5- P r e s s i n g - i nB e o r i n g C u p s U s i n g
MP 6-130 Jig

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F i g . 6 . 5 / 5- I n s t o l l i n g S e o l i n g R i n g U s i n g
M P 6 - 1 3 1J i g

Fig. 6.517- MP 6--108Pilot Pin for Upper

W i s h b o n eP i n l n s t o l l o t i o n

112

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Fitting Anti-roll Bor

3 5 . U s i n g o m e o s u r i n gr o d o n w h i c h t h e d i s tonces con be morked with o line, meosurethe

distoncebetween the gouge ploteswhen tunned
forwords ond reorwords (the plotes must be
o p p r o x i m o t e l yh o r i z o n t o l ) . B y t u r n i n g b o t h
s t e e r i n gr o d s ,o d i u s tt h e r o o dw h e e l s s o t h o t t l r e
d i s t o n c eb e t w e e nt h e p l o t e s b e h i n d t h e o x l e i s
3 m m l o r g e rt h o n t h e d i s t o n c e i n f r o n t o f t h e
o x l e , o n d l o c k t h e s t e e r i n gr o d s i n t h i s p o s i t i o n
b y m e o n so f n u t s .

3 9 . S l i p r u b b e r b u s h e so n t h e c e n t r e p o r t o f
the onti-rrob
l l o r ( c l o s eb e h i n dt h e o b l i q u eb e n d )
ond fit on them the holder. After hoving
t h r e o d e dt h e o t h e r r u b b e r b u s h e so n t h e e n d s
o f t h e o n t i - r o l lb o r , i n s t o l l i t i n t h e b r o c k e t so n
t h e l o w e rw i s h b o n e s o
, n d l o c k i t i n p o s i t i o nb y
clomping the rubber bush by onotherholder.
S e c u r et h e b o l t o f t h e h o l d e r w i t h o s p r i n g
wosher.
Reinstolling Shock Absorbers ond Completing
Front Axle Reossembly
4 0 . U s i n g t h e s p r i n g i n s t o l l e rr e l e o s et h e r o o d
s p r i n g o n d t h e n r e m o v et h e i n s t o l l e r . F i t t h e
shock obsorber holder to the shock obsorber
e y e o n d c o n n e c tt h e m w i t h o b o l t w i t h o c o s t e l loted nut.Lockthe nut with o cotter pin.
Threod the shock obsorberthrough the lower
w i s h b o n eo n d t h e c o i l s p n i n go n d f o s t e n i t w i t h
b o l t s o n d s p r i n gw o s h e r s .
41. Fill the wheel hub cop with the recomm e n d e d g r e o s ec n d d r i v e i t h o m e i n t h e h u b .
T h e g r e o s ew i l l p e n e t r o t ei n t o t h e b e o r i n g o n d
l u b r i c o t ei t . U s e t h e M P 6 - 1 2 5 d r i f t t o o v o i d
d o m o g i n gt h e c o p .
42. Screw down o greose nipple on the bott o m b e o r i n go f b o t h k i n g p i n s o n d l u b r i c o t et h e
enti,reoxle with the recommendedgreose.

F i g . 6 . 5 / 1 0- M e o s u r i n gF r o n t W h e e l T o e - i n
36. Rotote the steering screw to check the
correctnessof the steering geor reossembly.
With the wheels in the right-hond ond lefth o n d l o c k p o s i t i o n w h e n t h e s t e e r i n gk n u c k l e
o b u t s o g o i n s tt h e b o s s o n t h e k i n g p i r - rs o c k e t ,
both extreme positions in the steering box
m u s t b e r e s i l i e n t ,w i t h o u t o n y h o r d i m p o c t s .
lf this is not the cose ond there is o hord
impoct, correct the odiustment by shortening
o n e s t e e r i n gn o d o n d l e n g t h e n i n gt h e o t h e r o n e .
3 7 .H o v i n g o d i u s t e dt h e c o m b e ro n g l e o n d t h e
t o e - i n ,r e t i g h t e n
o ) t h e n u t s o f t h e e c c e n t r i cp i n s o n d l o c k t h e m
with cotter pins
b ) t h e n u t s o f t h e u p p e r w i s h b o n e so n d l o c k
them with cotter pins
c ) t h e b o l t s o f t h e u p p e rw i s h b o n eb r o c k e t
d) the nuts of the upperwishbone pins ond
l o c k t h e m b y t i g h t e n i n gt h e t h i n n u t s
e) the nuts of the lower wishbones ond lock
them by tighteningthe thin nuts
f) the nuts of the boll ioint pins (boll pins).

F i g . 6 . 5 / 1 1 -D r i v i n g - o nW h e e l H u b C o p U s i n g
MP 6-125Drift

For tightening torques see Chopter 1.8.

6.6 STEERINGKNUCKLE

38. Recheck the wheel comber,remove the

gouge,ond screw down loosely nuts ond woshers on to the protrudingends of the lower wishb o n e p i n s i n t h e f o l l o w i n go r d e r :t h i n n u t ,s p r i n g
wosher, two ploin woshers, onother spring
w o s h e r ,o n d o t h i n n u t .

The steering knuckle is o unit formed by the

swivel pin, the broke bock plote brocket ond
g u o r d ,s p e c i o l s e l f - l u b r i c o t i n g
b u s h e s ,o n d t h e
spocing tube. The right-hond ond left-hond
steeringknucklecon be identified bythe greose
nipple or nipple hole which must foce forwords.

114

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DimensionolCorrelotionof King Pin ond Bushes

Bush inside diometer

1 8 J0 . 0 1 8

The cylindricol surfoceof the king pin connot

be reconditioned. Grinding or ony other mochining is opt to destroy its speciol surfoce
finish. When worn, the king pin must be reploced with o new one.

pin diometer
Cleoronce of moximum
king pin ond bush weor
6.7 KING PIN
The king pin is formedbodily by the pin cnd
its resilient bush. For pressing the bush in crnd
o u t , u s e t h e M P 6 - - l - 1 2m o n d r e l .

a
a

F i g . 6 . 7 l 1- P r e s s i n g - i n
of King Pin Resilient
B r " r s hU s i n g M P 6 - 1 1 2M o n d r e l

T
C

1211
F i g 6 . 6 i 1 -3 P r e s s i n g i n o n d o u t K i n g P i n
l J u : ; h e sU . s i n g M O 6 1 3 5 P r e s s i n g M o n d r e l

6.8 KING PIN SOCKET

I t c o n s i s t so f t h e s o c k e t i t s e l f o n d t h e r e s i l i e n t b u s h .F o r p r e s s i n gt h e b u s h i n o n d o u t , u s e
t h e M P 6 - 1 1 2m o n d r r eol s i n t h e c o s e o f t h e k i n g
pin bushes.
T h e r i g h t - h o n do n d l e f t - h o n d s o c k e t c o n b e
i d e n t i f i e db y t h e r e l o t i v e p o s i t i o n o f t h e h o l e
f o r t h e k i n g p i n o n d t h e c h o m f e r i n go f b o s s e s
limitingthe wheel lock positions.

sl
a(
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al

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2.

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ler
F i g . 6 . 8 / 1- K i n g P i n S o c k e t

F i g . 6 . 6 i 4- R e o m i n gK i n g P i n B u s h e sU s i n g
M P 6 - 1 - 1R
4 e o m e ro n c l i t s P i l o t T o p e r

1 - l e f t - h o n d 2, - r i g h t - h o n d

116

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5. Turning force of box and column only. The

m a x i m u mp e r m i t t e dt u r n i n gf o r c e o f t h e b o x a n d
c o l u m no n l y ( d r a g l i n k a t t a c h e dt o s t e e r i n gb o x
b u t a l l o w e dt o s l i d e f r e e l ya c r o s si d l e r )i s 1 . 2 k g
2 . 5 l b sw h e n t e s t i s c a r r i e do u t a s i n ( 2 ) .l f t h e f o r c e
i s e x c e s s i v el ,u b r i c a t eu n i v e r s ajlo i n t s a n d c h e c k
t h a t t h ed r a gl i n k a s s e m b l yi s f r e et o m o v e .R e p e a t
t e s t . l f s t i l l e x c e s s i v er e m o v et h e s t e e r i n gb o x ,
w h i c h c a n b e r e m o v e dw i t h t h e t r a c k r o d s t i l l
attached.
T I M EA L L O W A N C E 5 m i n s .
6. Turning force to rotate Steering Box input
'sSh' a f t .W i t h s o m ef o r m o f c o u p l i n g( c o u p l i n gf r o m
t y p e S t e e r i n gB o x ) t e s t t h e f o r c e r e q u i r e dt o
r o t a t et h e s h a f t ;m a x i m u mp r m i t t e dt o r q u e 0 . 16 k g
1 . 1 6 f tl b s .l f u s i n ga n a r m a n d s p r i n gb a l a n c ea s
shown the maximum force required can be
c a l c u l a t e db v
160
1 . 1 6x 1 2
a r m l e n g t hi n c r n
arm length in inches
T h e s e t e s t s s h o u l d b e c a r r i e do u t w i t h t h e
. h e i n i t i a lf o r c ew i l l
w o r m i n t h e c e n t r a lp o s i t i o n T
b e 0 . 2 5 k g % l b g r e a t e rt h a n t h e a v e r a g ep u l l f o r c e .l f e x c e s s i v er,e m o v ei n p u ts h a f tt o p b e a r i n g
cap and adjust the bearing to give 0.OO to
0 . 0 5 m mp r e l o a d .
S h i m P a r tN o . 1 1 O - 5 0 9 6 5 0S t e e lO . 3 m m
1 1 0 - 5 9 O 9 0 OP a o e rO . 2 m m
1 1 0 - 5 9 0 9 0 2 P a p e rO . 7 m m
R e f i tt h e s h i m s a n d g a s k e t sa n d r e t a i n i n gc a p ,
f i t t h e r u b b e sr e a l i n gr i n gd i p p e di n o i l a n d f i t t h e
t h i n d u s t c o v e r .l f t h e d u s t c o v e rs e e m ss t r a i n e d ,
i n s t a l la p a p e rg a s k e tb e t w e e nt h e c a p a n d d u s t
cover.Part No. 1 1O-5909O0.
R e t e s tf o r t o r q u e a n d c h e c k r o c k e rs h a f t e n d
f l o a tw h i c h s h o u l db e b e t w e e nO . 4 a n d O . 5 m m .l f
excessive
a n d u n a b l et o a d j u s t b y t h e a d j u s t i n g
bolt, replace steering box after contacting the
S e r v i c eD e p a r t m e n t .
R e a s s e m b l ec a r a n d c h e c k t h e m a x t m u m
p e r m i t t e df o r c e a t t h e s p o k e i s 2 . 4 k g 4 . 5 l b s .
C h e c k t h a t t h e w h e e l a n d i n d i c a t o rs w i t c h i s
c en t r al i s e d .
R o c k e rS h a f t N u t T o r q u e 1 0 0 N m ( 7 1 l b f t ) .
TIME ALLOWANCE 7O mins. (inctudes
c o s to f a d d i t i o n asl h i m s )
7 . O t h e rp o i n t sw h i c h c a n a d v e r s e l ya f f e c tt h e
t u r n i n gf o r c e o f t h e S t e e r i n gm e c h a n i s m :
a ) e x c e s s i v et e n s i o n o f t h e b a l l j o i n t s .
b ) W o r k s h o p M a n u a l 7 . 5 . 5 . e x c e s s i v et e n s t o n
o f t h e d r a g l i n k a r m s . T h e f o r c e r e q u i r e dt o
m o v et h e a r m s h o u l d b e a p p r o x i m a t e l2yk g o r

LENGTH OF ARM

e.g. wrth length of arm

6 inches max.
permitted force
e q u a l s1 . 1 6 x 1 2
6
= 2.32lbs

DUST
COVER

4 . 6 l b s w h e n a p p l i e dt o t h e i n b o a r de n d o f t h e
t h r e a d e dp o r t i o n .
- O f fV e h i c t e
T I M EA L L O W A N C E
1Omins.
lf problems are experiencedwith wheel
v i b r a t i o no n t h e f r o n t a x l e i t i s n e c e s s a r tyo c h e c k
t h e a m o u n to f w e i g h t a p p l i e dt o o n e h a l f o f t h e
w h e e l r i m w h i c h s h o u l d n o t e x c e e d5 0 g r a m s .
Y o u a r e r e m i n d e dt h a t c h e c k A 1 , k i n g p i n
adjustment,is requiredto be carriedogt at each of
t h e s i x a n d 1 2 , 0 O Om i l e s e r v i c e s .

ADJU S T
UT

2KG {4.6lbs)

118

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SteerlngWheel ond Stcerlng
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5 . P l o c et h e s t e e r i n gb o x w i t h i t s b o t t o m b o l l
b e o r i n gr e s t i n g o n t h e M P 7 - 1 0 2j i g o n d p r e s s
t h e s t e e r i n gs c r e w w i t h b o t h b e o r i n g si n t o t h e
i i g . E x t r o c t t h e b o t t o m b e o r i n gu s i n g t h e M P
6 - 1 1 1k i n g p i n s o c k e t r e m o v e r o n d p u s h t h e
s t e e n i n gs c r e w w i t h t h e t o p b e o r i n go e r to f t h e
steering box. Supportthe beoring by the Mp
7-102iig crndpress it out.

7.3 REASSEMBLINGSTEERINGBOX
1 . P r e s st h e d u s t c u p w i t h i t s s e o l i n g r i n g
i n t o t h e s t e e r i n gb o x w i t h t h e p r e s s e d - i nb u s h
o f t e r h o v i n g t h o r o u c h l yc l e o r r e dt h e b o x . N o w
pfoce the box on the MP 7-102iig oncl press-in
t h e b o t t o m b o l l b e o r i n c tu s i n g t l r e i p r e s s i n g
m a n d r e lM P 7 - 1 0 3 .
2 . F i t t h e l o w e r b e o r i n gc o p s e o l e d o f f w i t h
o poper gcsket ond seoling compound,slip
l p r i n g w o s h e r so n t o t h e b o l t s , o n d t i g h t e n t h e
bolts with o torque os per Chopter t.6. f it the
w o s h e r o n t h e s t e e r i n gs c r e w w i t h i t s d e f l e c tion focing the screw threod ond press the
t o p b e o r i n go n t h e s c r e w u s i n g t h e M p Z - 1 0 3
p r e s s i n gm o n d r e l .
3 . T h e n p l o c e o g o i n t h e s t e e r i n gb o x o n t h e
M P 7 - 1 0 2i i g o n d p r e s si n t o i t o n d i n t o t h e b o t tom beoringthe steeringscrew with the pnessed- o n t o p b o l l b e o r i n g ,u s i n g o g o i n t h e M p 7 - 1 0 3
p r e s s i n gm o n d r e l .F o r f u r t h e ro s s e m b l y u
, sethe
v i c e o n d t h e d u m m yb r o c k e t .

4 . M e o s u r et h e h e i g h t o f t h e b e o r i n g p r o t r u d i n g f r o m t h e s t e e r i n gb o x o n d o d i u s t i t b y
f i t t i n g s h i m s i n t e r s p o c e dw i t h p o p e r g o s k e t s
c o o t e d w i t h o s e o l i n gc o m p o u n d .F o s t e n d o w n
the cop by tightening the bolts. Check the
steeringscrewfor free rototion ond the obsence
o f p l o y . T h e b e o r i n gs h o u l d b e w i t h o u t o c l e o r once or there hos to be o prestress of up to
0.07 mm.
5 . R e m o v et h e b o l t s o f t h e c o p , s l i p t h e r u b b e r s e o l i n gr i n g d i p p e d i n o i l o n t o t h e s h o f t ,
ond fit the dust cup on the cop. lnstoll spring
w o s h e r so n t h e b o l t s . S h o u l d t h e c u p b e o v e r stroined due to the toleronce of the recess for
t h e s e o l i n gr i n g o r t h e r i n g i t s e l f, i n s t o l l o p o p e r
g o s k e tu n d e ri t o s u n d e rt l r e c c r p .
6 . L o c o t e t h e s t e e r i n gn u t o n t h e s c r e w f o l lowecl by the rocker shoft with pin, spring,
spring pin, ond the licl gosket cooted with
o s e o l i n gc o m p o u n d ,o n d f i t t h e l i d w i t h b u s h
in positionto close the steeringbox. Instoll
s p r i n gw o s h e r su n d e rt h e b o l t s o r r d t i g h t e n t h e
bolts with o torque os per Chopter 1.8. Screw
the set screw into the lid ond rnove the steering geor so thot the drop orrn is swivelled
throughobout one holf of its trovel from the one
or the other extreme lock position.Witlr the
drop ornr in this position, screw down the set
screwos for os it will go ond then bock it off
through obout 95 to '120'.This will provide for
on odequote cleoronce of the steering geor.
[.ock the set screw in position with the respective nut.
7. Drive the key on to the rocker shoft cone,
fit the drop orm ond hold it down lightly with
the nut. Clomp the drop orm in o vice, tighten
fully the nut (for the tightening torque see
C h o p t e r 1 . 8 ) , o n d s e c u r et l r e n u t w i t h o c o t t e r
p in .
8 . C l o m p o g o i n t h e s t e e r i n gb o x b y m e o n so f
t h e d u m m yb r o c k e to n d m o k e s u r et h o t t h e d n o p
orm con swivel from one extreme lock position
to the other.A certoin resistonceshould olwoys
be present, but if the resistonce is too greot,
decreoseit by o slight slockening of the set
screw in the lid. The rototing resistonceof the
shaftshouldnot exceed20 Nm (O.2kpm).Referto
page 117/118 for testingprocedure.
9. Set the ossembledsteering box in its fitt i n g p o s i t i o n ( i n c l i n e d b y o b o u t 4 0 o )o n d p o u r
i n o i l t h r o u g ht h e h o l e i n t h e b b x l i d ( c o v e r )
till the oil level reochesthe bottom edge of the
f i l l i n g h o l e .T h e n s c r e w d o w n t h e t o p e r e dp l u g .
7.4 RELAY (TDLER)LEVER

F i g . 7 . 3 1 1- P r e s s i n g - i nB o t t o m B e o r i n g
o n M P 7 - 1 0 2J i g ( s u p p o r tp l o t e ) U s i n g
M P 7 - 1 0 3P i r e s s i n q
Mondrel

F o r i t s i n s t o l l o t i o n( o n d r e m o v i n gi n r e v e r s e
order) ond ony pertinent porticulors see the
Chopter 6.5, porogrophs2 ond 3.

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o d i u s t ,i f n e c e s s o r yt,h e d r i v i n g d o g o f t h e d i rection indicotor switch - see Chopter 13.17.

Refit the steering wheel so thot its spokes
o r e h o r i z o n t o l ,l o c k i t i n p o s i t i o n w i t h t h e n u t
(for tightening torque,see Chopter 1.8), ond
bolt down the spoke shroud.
7 . 8 S T E E R I N GW H E E L S H A F T A N D S H A F T
BEARING
T h e s t e e r i n gw h e e l ( c o l u m n )s h o f t i s b u i l t u p
of two ports with the beoring in the uPPerport.
Usuolly, it is not necessoryto disconnect the
two ports of the shoft or to removethe beoring
ond steering lock. lt con be removed from the
cor os o unit.
Removol
1. Removethe steering wheel - see Chopter 7.7.
2. Remove the screws on the lower port of
t h e s h o f tc o w l i n g o n d p u l l t h e c o w l i n go f f . A f t e r
removing two bolts, detoch the cluster switch
on the shoft from the upper port of the shoft
cowling.
3. Removetwo front screws of the upper Port
o f t h e c o w l i n g o n d r e m o v et h e c o w l i n g .
4. Disconnect the leods from the switches
ond the switch box.
5. From under the cor, remove the bolt of the
c o u p l i n gc o n n e c t i n gt h e s t e e r i n gc o l u m n s h o f t
to the steering box ond detoch the dust boot
f r o m t h e f l o o r . R e m o v et h e b o l t s o f t h e s h o f t
beoring (from under the shoft) ond the bolts of
t h e s t e e r i n gl o c k ( f r o m t h e f r o n t ) f o s t e n i n gt h e
s h o f t t o t h e b o d y ,o n d p u l l o u t t h e s h o f t .
Refitting
T o r e fi t t h e s t e e r i n gc o l u m n s h o f t i n t h e c o r ,
. hile reinstolr e v e r s et h e r e m o v i n gp r o c e d u r eW
ling the steering wheel (Chopter 7.7), do not
forget to check the direction indicotor switch
for correct function.
U s e p l o i n o n d s p r i n g w o s h e r su n d e rt h e b o l t s
o f t h e s t e e r i n gl o c k b r o c k e t .R e i n s t o l lt h e s h o f t
b e o r i n gu s i n g s p o c i n gt u b e s ,r u b b e rb u s h e so, n d
p l o i n w o s h e r s ,o n d s e c u r et h e b o l t o f t h e c o u p l i n g , c o n n e c t i n gt h e s t e e r i n gc o l u m ns h o f t w i t h
t h e s t e e r i n g b o x , w i t h o s e l f - l o c k i n gn u t ( f o r
t i g h t e n i n gt o r q u e ,s e e C h o p t e r1 . 8 ) .
To DisconnectShofts
R e m o v et h e b o l t o f t h e c r o s s - p i ni o i n t c o n nection.
Connectingof Shofts
F i t o f o s t e n i n g s l e e v eo n t h e t u b e w i t h t h e
s h o f t ,d i p t h e r i n g i n o i l o n d s l i p i t o n t o t h e

s h o f t e n d w i t h i t s w e d g e - s h o p e dp o r t t o w o r d
t h e b e o r i n g ,i n s t o l l t h e s p r i n g o n d t h e i o i n t
socket of the shoft bottom port. Tighten the
c o n n e c t i o nw i t h t h e b o l t w i t h s e l f - l o c k i n gn u t
( t i g h t e n i n gt o r q u eo s p e r C h o p t e r 1 . 8 ) .
T h e s l e e v em u s t b e f i r s t b u i l t u p i f t h e s h o f t
is refitted for the first time. Locote both holves
of the sleeve on the tube ond fosten them
l i g h t l y t o g e t h e rb y b e n d i n gt h e t o b o f o n e h o l f
of ttre sleeve over the other. The sleeve must
o n n o o c c o u n tc l o m p t h e t u b e t i g h t l y .

;
(

Bottom Port of Steering Column Shoft

(
t

T h e s h o f t i s p r o v i d e dw i t h c r o s s - p i n i o i n t s
o n d c o n n o t b e d i s m o n t l e d( t o k e n o p o r t ) . B e f o r e
f i t t i n g t h e s h o f t d u s t b o o t , s m e o ri t w i t h o i l t o
f o c i l i t o t ei t s s l i p p i n go v e r t h e p c r r t so f t h e j o i n t .
F o r t h i s p u r p o s e ,i t i s c l s o o d v i s o b l et o w r o p
the joint in o plostic foil or to moke o sleeve
with o pilot cone.
Top Port of Steering Column Shoft - Beoring
Removol
1 . l - i f t o w o y t h e f o s t e n i n gs l e e v e o n d c h e c k
whether the shoft rototes freely in the tube. lf
i t i s n o t t h e c o s e ,u n l o c kt h e s t e e r i n gl o c k o n d
press out the shoft proceedirrgfrom the side
o f i t s s p l i n e de n d .
2. lf necessory,
removethe circlip of the shoft
ond lift owoy the beoring. The other beoring
hos to be driven out by topping it corefully
t h r o u g ht h e c u t - o u t si n t h e t u b e t o o v o i d d o m o g ing it.
3. Removethe brocket with the steering lock
- see Chopter 7.9.

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R e fi t t i n g

1 . S l i p t l r e b e o r i n gp o c k e d w i t h g r e o s eo n t o
t h e u p p e rp o r t o f t h e s h o f t , t h e n t h e r i n g w i t h
its wedge-shopedport focing the beoring, ond
lock both ports in position with the circlip.
Press the shoft into the tube ond press-inthe
b e o r i n g ( o g o i n p o c k e d w i t h g r e o s e )f r o m t h e
other end.
2 . l n s t o l l t h e b r o c k e tw i t h t h e s t e e r i n gl o c k s e e C h o p t e r7 . 9 .
Shoft Beorings
They hove to be thoroughly lubricoted first,
since ofter their reossemblywith the shoft odd i t i o n o l l u b r i c o t i o ni s n o t p o s s i b l e .l f t h e r e i s
ony doubt concerning the greose pocking, remove the circlip f rom the inner port of the
beoring, toke the beoring oport, cleon it, ond
r e o s s e m b l ei t o f t e r h o v i n g p o c k e d i t w i t h t h e
r e c o m m e n d e dg r e o s e ,i . e . , b r o n d N H 2 o f C z e choslovok provenience or one of the bronds
s p e c i if e d i n C h o p t e r7 . 5 , p o r o g r o p h3 .

124

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UU 9I

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SONIUcIS UV:IU

'adA] crdocsalal pLrD

s r l n o J p A qe q l l o e r o s r e q r o s q o l 3 0 q s o L l l ' e j r M
u o r l c a s - p u n o rl o p a p o c e r o s 6 u t . r d sp D o J a r l l
u o ; 1 d ! J c s a Cl o s r u q c a l

Z'8

er-i s

8.3 SHOCK ABSORBERS

The shock obsorbers ore of the hydroulic,
telescopic,double-octingtype of the PAL moke.
The dompingeffect dependson the speedof the
relotive movementsof the oxle ond body. Doto
required for testing ond odiusting the shock
obsorbersore given in the following Tobles.
Front Shock Absorber - see Fig.8.3/1
type PT 26x110, Ser. No.443.621-215.000
Maximum stroks
Damping torce during
down stroke (comprssion
Damping force during
upward stroke (expansion)
Filling capacity

1977-74

19 7 8 o n

llO mm

110 mm

470N

500N

loSN

1300N

lOO cc

1OOcc

19 7 8 o n

175 mm

175 mm

Damping force during

down stroke (compresston,

470N

500N

Damping force during

upward stroke {expansronl

950N

r 200N

160 cc

160 cc

Maximum stroke

Filling capacity

Removingond Refitting

Sh

C
cle
the
1
fittr
bor

(Im(

When removingor refitting o shock obsorber,

retoin the piston rod (upper fostening) by holding the flottened end of the threod in o sponner.
In the cose of the reor shock cbsorber, retoin
the piston rod in the bottom port by holding the
heod of the bolt connecting it to the shock
obsorbercylinder.
The ossembly of the rubber bushes of the
respectiveshockobsorbermounting con be seen
in Fig.8.3/1.
'the
Access to the upper mountings of
front
shock obsorbers is from the luggoge boot
(under the floor). The threod is protected by
o cop nut. The mountings of the reor shock
obsorbersore occessiblefrom the reor luggoge
comportment behing the reor seot bockrests
ofter folding owoy the upholsteryon the wheel
orch. The mounting is in the cyllndricol extension piece in the scuttle of the reor dosh.

Reor Shock Absorber

type T 26x175; Ser. No. 443.621.247.OO1
1977-78

Both types of shock obsorbersore of similor

design, only their bottom fostening is different
(the front shock obsorberhos o fostening eye,
the reor shock obsorber hos o bolt ond locks
the outer protective tube). They hove o different stroke,domping force, ond filling copocity.

2
wit
woI

pis
wor
the
loc<
(11
3.
obo
(M(
I nst
rod
the
oil'
into
4.
witt
Con
prot

Shock Absorbor Dismcntling

*) At o temperotureol 25 to 30oC, o frequency

of 100 strokes per minute, ond o stroke of
100 mm.

D i s m o n t l i n gi s o r o u t i n ep r o c e d u r eb e g i n n i n g
with screwing out the plug (1) ofter the protective sleeve (tube) hos been removed.Never
dismontlethe piston volves since there is o risk
of impoiring the domping force by mixlng up
the volves.

Inod
On f(

Inod
oll c(

Fig.8.3/1- Front Shock Absorber- Sectionol View

130

Exce
on c(

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Remedy

Defect
Airlock obove plston

Flll shock obsorber correctly

wlth oil

Oil leokoge due to domoged

piston rod

Renew piston rod ond lobyrinth

seol - check shock obsorber
mountlng on cor

Plug worked loose - oil leoks

post the threod

Reflll oil ond tighten plug

correctly

Suction volve does not closc,

oil is forced Into reservetube oir is sucked in obove the plston

Remove foreign motter from

suction volve - renew suction
volve body lf volve seot
is domoged

Domping force increoses

on compression

E x c e s s i v eo i l f i l l i n g

Adiust to specificotio.ns

Shock obsorberknockswhen
exponslonstorts. Domping
force poor ot first. loter rises
to normol

Volve obovepiston sticking

Removecouseof stlcklng, or
chlps- renewvolve,reflll shock
obsorberwith oll

Jerky upword stroke

Check shock obsorbersfor correctoperotlondirect in position in the cor uslng o diognosticoppor'

otus or, ofter removol,on o test bench in comploncewith molntenonceinstructlons.

132

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r
I

F i g . 9 . / 1 - H y d r o u l i cB r o k e S y s t e mD i o g r o m
'l Broke f luid tonk
2 - M o s t e rc y l i n d e r
3 - Broke booster (on SfOOn 120 LS cors)
4 - M o s t e r c y l i n d e ns u p p l y l i n e
5 - Moin front-brokecircuit line
6 - Front brake distribution system
7 - Front broke mechonism
8 - Moin reor-brokecircuit line
9 - Reor broke distribution system
10 - Reor broke mechonism
I on cors fitted
11 - Broke booster vocuum line I with broke
J booster
1 2- S u c t i o n l i n e c o n n e c t i o n

F i g . 9 . 1 / 1- R e o r B r o k e A s s e m b l Y

134

s
l

r
I
(
\

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Broke Shoes ond Broke Drums

T h e l o w e s t l i m i t o f t h i c k n e s so f o s t i l l u s o b l e
b r o k ed i s k i s 6 . 5 m m . T h e m o x i m u mp e r m i s s i b l e
r u n - o u to f t h e f r i c t i o n s u r f o c ei s 0 . 1 5m m .
1. After hoving lifted owoy the broke oss e m b l y ,r e m o v e t h e w h e e l h u b o n d t h e n t h e
b r o k ed i s k .
2 . R e o s s e m b l teh e b r o k e d i s k w i t h t h e w h e e l
h u b u s i n g c o p s c r e w sw i t h s p r i n g w o s h e r s .
3 . T o p r r po r c h o n g et h e l u b r i c o n ti n t h e w h e e l
h u b b e o r i n g so n d r e i n s t o l lt h e b r o k e o s s e m b l y

W h e n r e f i t t i n g o b r o k es h o e w i t h o p o r t i o l l y
worn lining moke surethot it hos o thickness
sufficientto lost till the periodic inspection
(ofter every 20,000kilometres).The new lining
is 5 mm thick. When it is worn down to 1.5
'l
to mm (4 to 3.5 mm when meosuredwith the
s h o e ) , t h e b r o k e s h o e h o s t o b e r e p l o c e dw i t h
o n e w . o r o r e c o n d i t i o n e ds h o e w i t h g l u e d - o n
n e w l i n i n g . B e s u r e t o r e p l o c et h e r e s p e c t i v e
broke shoes in both wheels to preserveo uniform broking effect.
S p e c i o l g l u e s o r c e m e n t s o n d h o r d e n i n go t
h i g h t e m p e r o t u r e so r e r e q u i r e d w h e n r e l i n i n g
t h e b r o k es h o e ss o t h o t t h i s i o b c o n b e d o n e i n
s p e c i o l i z e dr e p o i r s h o p s o n l y . F o r i n f o r m o t i o n ,
opply to the broke monufocturer- Autobrzdy
N o t . C o r p . ,J o b l o n e cn o d N i s o u .
B r o k ed r u m sa r e g r e y c o s t - i r o nc o s t i n g s .T h e i r
u n e q u o lw e o r c o n b e r e c t i f i e d b y m o c h i n i n gt o
o 2 3 1 m m d i o m e t e r .N o t o o l m o r k s m u s t b e l e f t
on their surfoce which hos to be perfectly
s m o o t h . T h e o l i g n m e n td e v i o t i o n o n d m o c h i n i n g t o l e r o n c es h o u l d n o t e x c e e d 0 . 1 m m . T h e
m o x i m u mp e r m i s s i b l ew e o r i s u p L o 2 3 2 m m i n
diometer.
O n l y b r o k e d r u m s w i t h o n i d e n t i c o ld i o m e t e r
ore permitted to be mounted on one ond the
s o m eo x l e .

ReplocingBroke Pods
The overoll thicknessof o broke pod with
new lining is 15 mm.When worn down to 7 mm
(with the lining 1.5 mm thick), the pod is
unusoble.
Alwoys reploce broke pods on both ends of
t h e o x l e o f t h e s o m et i m e s o t h o t t h e i r w e o r i s
u n i f o r m .W i t h r e g o r dt o t h e c o e f f i c i e n to f f r i c tion, they hove to be of the some type ond
rnoke.
1 . S u c k o f f t h e h y d r o u l i cf l u i d f r o m t h e t o n k
so thot it is only holf filled.
2 . R e m o v ec o t t e r p i n s o n d l i f t o w o y t h e b r o k e
lining cover.
3 . R e m o v et h e f r i c t i o n p o d , c l e o n t h o r o u g h l y
t h e c o v i t i e so f t h e y o k e s ,p i s t o n p o r t s ,o n d d u s t
boots.
4. Fit the MP 6-134 force-off lever over the
broke disc ond drive the pistons into the
cylinder bottoms by the presswe of levers.
5. Ploce o new friction pod into the broke
o s s e m b l ym o k i n g s u r e t h o t t h e c l o m p o f t h e
thrust plote fits into the collor of the piston
foce.

9.2 FRONT BRAKEASSEMBLY

Disnrontlingond Reossembly
1 . D e t o c ht h e b r o k e f l u i d s u p p l yp i p i n g f r o m
the broke. Absolute cleonliness is o must.
O t h e r w i s ed i r t o n d f o r e i g nm o t t e r w i l l p e n e t r o t e
into the piping.
2 . R e n r o v eb o l t s l r o l d i n gd o w n t h e b r o k ey o k e
c r n dl i f t o w o y r l r e b r o k e o s s e m b l y .
3. Use the MP 6-132 gouge to set correctly
t h e b r o k e ( n e w o r r e p o i r e d )o n r e i n s t o l l o t i o n .
4 . S e l e c t t h e s h i m s r e q u i r e dt o f i l l t h e g o p
between the end of the gouge ond the foce of
t h e f o s t e n i n g l u g . T o p o s i t i o n c o r r e c t l yt h e
b r o k e ,i n s e r t s h i m s b e t w e e nt h e f o s t e n i n gl u g s
cnd yokes. You con, however, meosure direct
t h e d i s t o n c eb e t w e e nt h e f o s t e n i n gl u g o n d t h e
t r r o k ed i s k o n d s e t t h i s d i s t o n c ei n c o m p l i o n c e
w i t h F i g .9 . 2 1 1b y o d d i n g p o c k i n gp i e c e st o t h e
shim pock.
5. Using the respectivecopscrewsond spring
'.^roshers,
bolt down the yoke to the lugs.
6. Attoch the supply hoses ond bleed the
broke.
Replocingthe Brake Disk
A w o r n b r o l < ed i s k c o n b e r e c o n d i t i o n e db y
g r i n d i n gi t t o o t h i c k n e s so f 7 . 5 m m . l f n e c e s s c r y , r e p l o c ei t w i t h o n e w o n e 9 m m t h i c k .

tr
c

\
c'
p
r
o
1
tt

pl

tt
r

ol

ot

iu

ol
dt
is
ol
sl
Fig.9.2l1-Front Wheel Broke Mechonism
o n d M o u n t i n g( s e t t i n g ) D i m e n s i o n s
1 - B r o k ed i s k
2 - Broke
3 - Shims
A - B r o k e s e t t i n g c l i m e n s i o -n 1 8 . 7 + O . 2

136

Rr
ot

th
th
c0
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ap1n6 eql olul 6ug.r6ugu1ola.r
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ralsD[AlelDrg ]o tl,ralnlDuoltceS- L/e'6-6ll

Reossemblethe pressure-reliefv o l v e i n t h e
f o l l o w i n g o r d e r : d u s t c u p , s p r i n g ,s p r i n g p l o t e ,
ond seol.

Nicks ond burrs ore opt to domoge the dust

boot ond prevent its perfect odhesion to the
cylinder. Every boot must be odequotely prestressed(topered) so thot its seoling edge con
be in permonentcontoct with the cylinder surfoce. A decreosedprestresssignols excessive
weor of the dust boot or its fotigue. For the
c l e o n i n g o n d l u b r i c o t i o no f w o r k i n g p o r t s , s e e
t h e i n s t r u c t i o n si n C h o p t e r 9 . 3 .
9.5 FRONT BRAKEWHEEL CYLINDERS
Wheel cylinders ore ossemblies formed by
o n e c y l i n d e r w i t ht h e y o k e o n d o n o t h e rc y l i n d e r
w i t h t h e f l o n g e o n d o c c e s s o r i e s .F i g . 9 . 5 / 1
shows the loyout. For cieoning ond lubricotion
o f t h e w o r k i n g s u r f o c e s ,s e e t h e i n f o r m o t i o n
i n C h o p t e r9 . 3 .

Fig. 9.312- SecondoryPiston Cup Mounting

F i x t u r ef o r d i o . 1 2 m m M o s t e r C y l i n d e r
( 1 - g u i d e b u s h , 2 - c l o m p i n gr i n g )

Dismontling
1. After hoving removed the broke pods,
d i s c o n n e c to n d l i f t o w o y t h e i n t e r c o n n e c t i n g
p i p i n g , c n d t h e n r e m o v e fo u r c o p s c r e w s t o
s e p o r o t et h e c y l i n d e r w i t h t h e y o k e f r o m t h e
f l o n g e dc y l i n d e r .
2 . P u l l o f f t h e r e t o i n i n gr i n g o f t h e d u s t b o o t
o n d l i f t o w o y t h e d u s t b o o t .C o n n e c to c o m p r e s s e do i r s u p p l y( o r t h e b r o k em o s t e rc y l i n d e r )
ond use it to force the piston out of the

F i g . 9 . 3 / 3- S e c o n d o r yP i s t o n C u p M o u n t i n g
F i x t u r ef o r d i o . 2 2 m m M o s t e r C y l i n d e r
( 1 - g u i d e b u s h , 2 - c l o m p i n gr i n g )
9.4 REAR BRAKEWHEEL CYLINDER
'l-he

w h e e l c y l i n d e r r e q u i r e sp r o c t i c o l l y n o
s e r v i c i n gW
. h e n e v e rr e m o v i n gt h e b r o k ed r u m s ,
e x o m i n et h e r u b b e rd u s t b o o t s . T h e yh o v e t o b e
p e r f e c t l yt i g h t , f l e x i b l e ,o n d u n d o m o g e dW
. hen
r e p l o c i n gt h e m , e x o m i n e t h e i n n e r s u r f o c eo f
t h e w h e e l c y l i n d e ro n d t h e s u r f o c eo f t h e p i s t o n .

F i g . 9 . 5 / 1- F r o n t B r o k e W h e e l C y l i n d e rc / w
BrokePods

F i g . 9 . 4 / 1- S e c t i o n o l V i e w o f W h e e l C y l i n d e r

138

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fold ot the moment of the opplicotion of the

brokes,ond led through o rubber hose (tube) to
the booster.

press button so thot it iust touches the lower

flot port of the fixture spindle.
2. lf it is necessoryto level the broke pedol
with the clutch pedol, odiust the length of the
contnol volve press button lug.
Remove the broke booster from the pedol
brocket, slip off the collor (cup), connect the
booster with the pedol, ond refit it tempororily
to the brocket. Now rotote the hexogon on the
threodsof the lug till both the clutch ond broke
pedol ore level. Removeonce more the booster
from the pedol ond pedol brocket,neinstoll the
c o l l o r ( c u p ) ,o n d c o m p l e t et h e f i n o l r e o s s e m b l y .

Removol ond Refitting

The broke booster is held down on the pedol
brocket by nuts ond spring woshers.The lug of
the control volve press button connects it with
the broke pedol, on which it is securedby o retoining ring. These mounting ports or the connections of the vocuum supply ore to be hondled only when removing or refitting the broke
booster.
However,we odvise you to hove this iob done
in o speciolizedrepoir shop properly instructed
by the broke monufocturer.All rubber ports (in
the terms of current mointenonce, this is
procticolly the seol of the press button controlling the moster cylinder) must be protected
from the effects of the broke fluid or other
lubriconts. Use petrol for cleoning the rubben
ports.

9.7 BRAKEFLUID TANK, PIPING AND HOSES

Tonk ond Filling Hose
T h e b r o k ef l u i d t o n k i s h e l d i n p o s i t i o n i n i t s
brocket by o slip-over clomp. Speciol rubber
hoses connect it with the broke ond clutch
moster cylinders.Hose clips ore used to secure
the hoses on the tonk outlet sockets. Both the
side ond centre outlet of the tonk ore connected to the bnoke moster cylinder, the third
outlet being connected to the clutch moster
cylinder (see Fig. 12.111).

Adiustment
1. Adiust the cleononcebetween the broke
booster press button ond the cylinder piston
whenever the moster cylinder or the'broke
booster ore reploced, or whenever there is ony
doubt concerning the correctness of the ossembly of the moster cylinder with the broke
booster. Meosure the distonce between the
cylinder bottom recess ond the cylinder flonge
nroting surfoce os well os the length of the
press button protrudingover the moting surfoce
of the booster. Compore the meosuringsond
odiust the length of the pressbutton by rototing
its threoded end to obtoin o cleoronceof 0.5 to
1 mm between the press button ond the piston.
Still better, you can use special tools Mp6.
'14'lA.
Fit it on the moster cylinder, push
i t s s p i n d l ei n t o t h e c y l i n d e rt i l l i t s r o u n d e de n d
rests ogoinst the piston, ond lock it in this positio-nwith the respectiveretoiningscrew.Apply
the fixture to the booster ond rotote the boostei

PressurePiping ond Hoses

The rigid port of the hydroulic line consists
of speciol steel pipes. Their connections with
other ports of the line ore seoled off by clomping on the conicol surfoceslf these conicol surfocesbecome domoged,
removethem ond form new ones by floring the
pipes.To do this, use the coulking holder, type
M P 9 - 1 5 1C
. l o m p t h e p i p e i n t h e h o l d e rs o t h o t
it is level with its upper edge ond flore the pipe
w i t h c c o u l k i n gc h i s e l .T h e h o l d e r i s d e s i g n e d
to be clomped in o vice.
The holder hos two drilled holes of 5 ond
6 mm in diometerso thot it con be used olso for
repoirs of pipes of the clutch line. For dio.
5 mm holes,use the MP 9-152ond for dio. 6 mm
holes, the MP 9-153coulking chisel.
The flexiblepqrt of the hydroulicline consists
of speciol hoses.When fitting them to the reor
wheel cylinders,turn them in o position which
will prevent their contoct with ony ports of the
cor in both extreme positions of the cor suspension. This is why the nipples ot the reor
wheels ore inclined downword through on
ongle of 30 degreesfrom the horizontolplone.
9.8 HAND BRAKE

tx r5?2

Fig. 9.612- Broke Booster Press Button

Adiusting Fixture
MP6141A

The hond-brokelever between the front seots

controls the tie-rod which octuotes the rocker
(see Fig.9.8/1).Cobles connectedto the rocker

140

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r0 . 3 - t 0 , 5

I h e p e r m i s s i b l eo u t - o f - b o l o n c m
e ust not exceed 50 grommes on the rim rodius. Every new
t y r e i s p r o v i d e dw i t h o c o l o u r e dd o t o n i t s s i d e ,
i n d i c o t i n gi t s l i g h t e s t p o i n t . F i t t h e t y r e o l w o y s
with this dot focing the tube volve. ln this
p o s i t i o n t, h e v o l v e o c t s o s o n o d d i t i o n o lw e i g h t
c o m p e n s o t i n gt h e w h e e l o v e r o l l u n b o l o n c et o
o consideroble xtent.
lf dynomic boloncing of the wheel is not
p o s s i b l e ,b o l o n c et h e w h e e l s t o t i c o l l yw i t h t h e
g r e o t e s tp o s s i b l eq s s u r o c | . B o l o n c i n gw e i g h t s
of 30, 50, 75, ond 100 grommesore ovoiloble.

10.4 TUBED TYRES

F o r m o u n t i n g , d i s m o u n t i n g ,o n d r e p o i r s o f
c o n v e n t i o n o lt y r e s w i t h i n n e r t u b e s ( f o r p o r t i c u l o r s ,s e e t h e p r e c e d i n gC h o p t e r s ) ,t h e u s u o l
p r o c e d u r e so r e o p p l i c o b l e .T h e p e r m i s s i b l er u n o u t ( u n t r u er u n n i n g ) o f t h e r i m i s t h e s o m e o s
f o r t u b e l e s st y r e s ( C h o p t e r 1 0 . 5 ) .

10.5 TUBELESSTYRES
The oir-tightseolingof these tyres requires
m o r ec o r e o n d o d i f f e r e n th o n d l i n gt h o n t h o t o f
t h e t y r e sw i t h i n n e r t u b e s .

F i g . 1 0 . 5 / 1- P u l l i n gT y r e V o l v e i r r t o W h e e l R i m
Mounting the Tyre
F o r m o u n t i n gt h e t y r e , u s e s p e c i o l m o c h i n e s
o n d p r o c e d u r e sd, e p e n d i n go n t h e t y p e o f t h e
n r o c h i n e l.f s u c h o m o c h i n ei s n o t o v o i l o b l e ,i n s t o l l t h e t y r e u s i n g s p e c i o l t y r e l e v e r s .E n s u r e
t h o t t h e b o l o n c i n gd o t i s n e x t t o t h e v o l v e .
Tyre leverrsfor fitting tubeless tyres differ in
s h o p e f r o m c o n v e n t i o n o l e v e r s .T h e y o r e t h i n . sethem coren e r ,w i t h o u t e d g e s o
, n d p o l i s h e dU
f u l l y i n o r d e r n o t t o d o m o g et h e b e o d s e o l i n g
rubber bose. Insert the levers under the beod ot
short distoncesond refroin from using force. To
f o c i l i t o t es l i d i n g o f t h e t y r e c o s i n g b e o d so v e r
the rim shoulderm
, o i s t e nt h e m w i t h w o t e r o n d
top them with o rubber mollet when eosing
t h e m o v e r t h e r i m s h o u l d e rI.n f l o t e t h e m o u n t e d
tyre immediotely. Check the tyre for propei'
bedding in the rim ond squoreseoting on it.
H o l d i n g t h e w h e e l p e r p e n d i c u l o r l y s, t r i k e i t
severoltimes ogoinst the f loor ot severolpoints
to force the tyre beods to bed correctly on the
bcad seots.

Preporotlonof Rirrr
1 3 e l o r em o u n t i n gt h e t y r e , i n s p e c tt h e r i m f o r
o n y t e c h n i c o ld e f e c t s T
. h e p o i n t st o b e c h e c k e d
ore the rim shoulder ond the moting foce for
t h e t y r e b e o d s ,i n o d d i t i o n t o t h e o v e r o l l c o n d i t i o n o f t h e r i m . l f o n y d e f e c t so r e f o u n d , t h e
r i m m u s t b e r e c o n d i t i o n e d .A s o t i s f o c t o r yr i m
n r u s tc o m p l y w i t h t h e f o l l o w i n g c o n d i t i o n s :
o ) T h e r i m s h o u l d e ro n d t h e t y r e v o l v e h o l e
must not be distorted; there must be no
s h c r p e d g e so r p r o t r u s i o n sl i k e l y t o d o m o g e
t h e t y r e b e o d . M i n o r u n e v e n n e s s ecso n b e
h o r n m e r e df l o t o n d s m o o t h e dw i t h o f i l e .
T h e m o x i m u m e c c e n t r i c r u n n i n go f t h e r i m
s i d e m u s t n o t e x c e e d1 . 5 m m .
b) The moting surfoces must be obsolutely
c l e o n ( f r e e f r o m s t u c k - o nr u b b e r ,r u s t , e t c . ) .
C l e o n t h e m w i t h e m e r yp o p e ro r o w i r e b r u s h
ond coot them with point.
lnstolling of Tyre Volve
C l e o n t h e r i m w i t h o d r y r o g . P u s ht h e r u b b e r
volve into the hole in the rim or pull it in by
i t s t h r e o d u s i n g , f o r e x o m p l e ,o l e v e r o s i l l u s troted in Fig.10.5/1.

lnf lotion
R e m o v et h e v o l v e c o r e t o i n c r e o s et h e d i o m eter of the hole for oir inlet (oir should be
iniected in quick shots to force the beods on
to the beod seots) ond inflote the tyre. Use
o compressorwith oir receiver,the compressed.oir line of the workshop, or compressed-oirr
c y l i n d e r sT
. h e r e l i e fv o l v e sh o v et o b e o d i u s t e d
to o pressureof 350 kPo (3.5 kg/cmz).
N e v e r o l l o w t h e i n f l o t i o n p r e s s u r et o r i s e
unnecessorily.As soon os the tyre hos snopped
i n t o p o s i t i o no n t h e r i m o n d i s f r e e f r o m l e o k s ,
odiust the pressureto 250 - 350 kPo (2.5- 3.5
kg/cmz). lf the tyre refusesto bed properly on
the rim, for exomple due to distorted beods or
beods compressed due to incorrect storoge,
press the tyre circumference inword to open
wide the beods which will then bed properly
on the rim. Use either o length of rope or
o speciol tightener. Slip the rope over the tyre
circumferencewith o certoin cleoronce, insert
o stick between the tyre ond the rope, ond
twist the rope.
Adiust the tyre pressureto specificotions ond
submergethe wheel in woter to check the tyre
for oir leoks.

146

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Fig. 1111-Cooling ond Heotlng System

Diogrom
1 - Engine, 2- Coolont pump, 3 - Thermostot,
4 - Coolont tonk, 5 - Screw cop, 6 - Roidotor,
7 - Rodiotor fon, 8 - Fon thermoswitch, g Heoter, 10 - Heoter fon, 11 - Heoter reguloting
volve, 12-Woter line to rodiotor, 13-Woter
line to heoter, 14 - Filling line, 15 - Bleed
vofve, 16 - Bleed pipe, 17 - By-poss pipe, 18 Droin screws, 19 - Droin hose

150

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11.4-11.5

Removol

on to the coolont tonk. Hose clips ore formed

either by metol strips or lengths of wire. When
tightening the wire clips, toke core not to
domogethe rubber of the hoses.

T o m o k e t h e u n d e r b o d yo c c e s s i b l ef o r h o n d l i n g t h e p i p e s ,p l o c e t h e c o r o v e r o f l o o r p i t o r
o n o r o m p . T h e m i n i m u mr e q u i r e dc l e o r o n c ei s
obout 650 mnr.
1. Remo.rethe guords of the pipes ond the
f u e l t o n k , l i f t o w o y t h e s p o r ew h e e l ,o n d l o o s e n
the yokes holdingthe pipes to the floor.
2 . R e m o v ed r o i n s c r e w s t o d r o i n t h e c o o l o n t
f r o m t h e p i p e s- s e e t h e i l l u s t r o t i o n i n C h o p ter 15.'13.
3 . R e m o v eo n e h o s e c l i p i n t h e m i d d l e o f t h e
c o r t o d i s c o n n e c tt h e p i p e s ( o t t e n t i o n - t h e
remoining coolont will flow out), ond diso s s e m b l et h e l i n e .
4. Disconnect he pipe ends from the hoses,
ond detoch the pipes from the floor or other
ports of the cor.
5 . P u l l o u t t h e r e o r p i p e s p o s s i n gt h e m c o r e fully oround the voriouscor ports.
6. Pull out the front pipes. Turn the front
w h e e l s i n t o t h e i r l e f t l o c k p o s i t i o n ,d i s c o n n e c t
the steering linkoge from the steering reloy
lever ond the steering knuckle orm of the righth o n d w h e e l , o n d p u s h t h e l i n k o g eo g o i n s t t h e
oxle body.While removingthe pipes, rotote the
l e f t - h o n dp i p e c l o c k w i s e( w h e n v i e w i n g t h e c o r
f r o n t e n d ) , o n d t h e r i g h t - h o n dp i p e o n t i c l o c k wise.

To Fosten Pipes ond Hoses

A correct winding of the strip is importont
t o e n s u r eo s e l f - l o c k i n gc l o m p i n g o f t h e s t r i p
clips - see Fig.11.411.

F i g . 1 1 . A l 1 -D i o g r o m s h o w i n g t h e t h r e o d i n go f
the clip strip through the clip closp ond the
direction of rototion of the tightening cotter
p i n - t h e d i o g r o m h o s g e n e r o lo p p l i c o b i l i t y
1 - S t r i p c l i p , 2 - C l o s p ,3 - C o t t e r p i n

Reinstollotion

T h e m o i n p i p e l i n er o u t e d u n d e r t h e c o r f l o o r
consists of front ond reor pipes. They ore embedded in o chonnel moulded in the floor
b o o r d so n d r e s t o n o n i n s u l o t i n g( p o l y s t e r e n e )
podding. From below, they ore protected by
o guord, the copscrewsof which ore locked in
p o s i t i o nb y s p r i n g w o s h e r s .
U s e p i p e h o l d e r s( y o k e s ) t o f o s t e n t h e p i p e line to the floor. In the front ond reor port of
the cor, tighten the pipes over the insulotion
l r o d o n d i n s e r t s p r i n g o n d p l o i n w o s h e r su n d e r
t h e n u t s . D o n o t u s e i n s u l o t i o np o d s f o r b e n d s
forming the tronsition from the front ond reor
lower flot ports. Use spring woshers under the
heods of copscrews.
B e f o r e i n s t o l l i n gt h e p i p e s ,p r e p o r eo u x i l i o r y
yokes (or use lengths of wires ottoched to the
provisionollyscrewed-incopscrewsof the pipeline guord) to liold the pipes in the moulded
c h o n n e l i n t h e f l o o r b e f o r et h e f i n o l f o s t e n i n g
of their guord.
The woter line runs under the cor together
w i t h o t h e r l i n e s ,p u l l - r o d se, t c . F o r t h e i r m u t u o l
refotive orrongementsee Chopter 12.7.

R e v e r s et h e d i s m o n t l i n gp r o c e d u r ew h e n r e i n s t o l l i n gt h e w o t e r l i n e . W h i l e c o n n e c t i n gt h e
s t e e r i n gl i n k o g e ,p o y o t t e n t i o nt o t h e c o n d i t i o n
o f b o l l p i n s e o l i n gc u p s ( f i t n e w c u p s i f t h e o l d
o r e d o m o g e d ) .F i l l i n t h e r e c o m m e n d e cd o o l o n t
ond bleedthe coolingsystem.
11.5 COOLANT TEMPERATURECONTROL
Throughflow Thermostot
This thermostotshuts off the inlet of the
coolont into the rodiotor during the engine
h e o t i n g - u pp e r i o d .l t i s m o u n t e do n t h e e n g i n e
- see Chopter 2.3, por. 30.
T h e t h e r m o s t o to p e r o t e sw i t h i n t h e f o l l o w i n g
volues:
i t b e g i n st o o p e n o t
it is fully open ot
its lift ot full opening

When closed, it is permitted to let poss

o n r o x i m u mo f 0 . 5 l i t r e s o f c o o l o n t p e r m i n u t e ,
ond it must not be closed by o bock pressure
of 0.16MPo (1.6kg/cm2).
W h e n r e m o v i n gt h e t h e r m o s t o tb y r o t o t i n g
tlre rivet in the volve disk, breok owoy sedi-

152
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Fig. 11.6/1- Section Through Heoter

1- Cover, 2 - Lower port of cosing (iocket) two-port, 3- Heot exchonger, 4- Heoter fan,
5 to 8-Control f lop volves,9-Ponel with control
levers

the bowden tubing of the bowden cobles ond

let the oil seep down olong their entire length.
Check the heoter fon for foultless running.
With the switch in position I, the fon must run
ot higher speed- for its wiring refer to Chopter
11.7- Electric Control. Fill the cooling system
with coolont ond bleed the system.
Fit the grips (buttons) on the levers observing the symbolson the grips:
left-hond lever- white orrows upword ond
downword,
centre lever - orrow downword,
right-hond lever- red orrow upword, blud orrow
downword.
To open the flow through the lower inlet
socket, turn the lever in this socket so thot it
coincides with its centre line. The socket
should be closed with the flop only when
testing the heoter, etc.

Heoter Disossembly ond Reossembly

o) Heot exchonger, volve, flops, ond levers
with links.
1. Disconnect the control bowden cobles
from the levers, remove the gosket from the
heoter beoring surfoce,loosen the locks of the
broces,ond lift owoy the broces together with
the cover ond fon.
2. Unscrew the liquid flow control volve ond
detoch the hose from the second inlet of the
heot exchongerond the bleed hose ofter hoving
removedthe hose clips. Do not detoch the link
from the volve lever - it will sove you odiust'
ment on reossembly.
3. Detoch the link of the flops from the reor
side of the heoter cosing ond unlock the flops
in the cosing by removing lock rings, woshers,
ond levers.

154

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11 . 8 - 1 1 . 1 0

11.8 HEATER CONNECTING LINE

Removol ond Refitting

T h e l i n e i s o c o m b i n o t i o no f s t e e l p i p e s o n d
r u b b e rh o s e s A
. l l c o n n e c t i o n sm u s t b e t i g h t e n e d
with clips of the strip type (see Fig. 11.411)or
the wire type (bleed hose). Toke core not to
overtightenthe clips of the lotter type os there
i s o r i s k o f d o m o g i n gt h e r u b b e r .
The hose from the pipe of the thermostot
body on the engine is routed to the heoter
through the f loor tunnel, the return bronch
p o s s i n go g o i n t h r o u g ht h e t u n n e l t o t h e p i p e o f
the pump.Arrongethe hoses olong the sides of
the floor tunnel so thot they do not touch other
portsin the tunnel.
For detoiled informotion obout the routing of
the hoses refer to Chopter 12.7.

D i s c o n n e c tt h e h o s e s f r o n r t h e e n g i n e o n d ,
occording to circumstoncesond the purposeof
the removol, detoch the oil cooler from the
engine guord or remove the engine guord
togetherwith the cooler ond brocket.Empty the
o i l c o n t o i n e di n t h e h o s e s o n d t h e o i l c o o l e r
i n t o o s u i t o b l ev e s s e l .
When refitting the oil cooler into the cor,
proceed in occordoncewith the circumstonces
o f t h e r e m o v o l .S e c u r et h e b o l t s c o n e c t i n gt h e
o i l c o o l e rw i t h t h e e n g i n eg u o r d o n d t h e b r o c k e t
(the brocket being locoted between the cooler
o n d t h e g u o r d ) w i t h s p r i n gw o s h e r s .B o l t d o w n
the guord over ploin woshers ond use o spring
wosher for the bolted connectionof the brocket
with the bodywork.
Use seoling woshers when connecting hoses
to the engine ond the oil cooler, ond put
o s e o l i n gw o s h e ro l s o u n d e rt h e b o l t . C l o s e t h e
bolt of the engineport ot the flonge with the
pressureswitch. Fosten the hoses so thot they
ore not stressed in their bends. The hose from
the timing geor cover should be routed horizontolly ond the hose ot the engine inlet so thot
it includes o downword ongle of obout 15 deg r e e s w i t h t h e h o r i z o n t o lp l o n e . T o p u p o i l i n
the engine.

11.9 otl COOLER

The oil cooler is stondordequipmentof Skodo
120 LS models. lts constructionresemblesthot
of the rodiotor.lt is instolled in the engine
comportment (boy) ond ottoched to the right-hond engine guord. Speciol pressurehoses
connect it with the engine. lts connecting
diogrom is shown in Fig. 11.911.
As regords oil coolers for subtropicol ond
'16.2.
tropicol regions,refer to Chopters 16.1ond

11.10 COOLING SYSTEM DEFECTS,

T E S T I N G ,R E P A I R S ,A N D C L E A N I N G
Defects ond Testing
o ) l f t h e r e i s o m a r k e d l o s s o f c o o l o n t ,c h e c k
oll connectionsfor leokoge.The loss of coolont
con olso be cousedby o leokogeof the rodiotor
( o r h e o t e r ) . l f t h e l e o k o g ep o i n t i s n o t v i s i b l e ,
pressure-testthe system without removing it
from the cor.
Admit seoled-offoir ot o pressureof 0.12 MPo
(1.2 kglcmz) into the filler neck ond look for
ploces where the coolont is seepingor dripping
out. Inspect not only the rodiotor but olso the
lreoter.
An excessiveloss of the coolont con be olso
coused by engine overheoting. In thot cose,
look for the couse of engine overheoting.
b)
-

DX tfSJ

F i 9 . 1 1 . 9 / 1- O i l C o o l e r - t o - e n g i nCeo n n e c t i n g
Diogrom
1 - Outlet from engine-right-hond
cooler socket,
2 - O i l c o o l e r , 3 - I n l e t i n t o e n g i n e- l e f t - h o n d
cooler socket

P o i n t st o c h e c k i f t h e e n g i n e i s o v e r h e o t i n g
coolont level
operotion of thermostots ond rodiotor fon
condition of rodiotor (whether clogged outside with dirt, or whether cooted inside with
scole)

c ) P o i n t st o c h e c k i f t h e e n g i n ed o e s n o t w o r m
up properly:
- operotionof thermostots

156

L9l

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691

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r2.1-t2.3

Dissssemblyond Reossemblyof Pedols

T h i s i s u s u o l l yn o t n e c e s s o r yT. h e p e d o l sc o n
b e d i s o s s e m b l eo
d f t e r r e m o v i n gt h e o x i o l s c r e w
in the pedol pin ond slipping off the return
spring. Do not remove the switches if it is not
obsolutely necessory- see odiustment. On reo s s e m b l y ,l u b r i c o t et h e p e d o l b u s h w i t h l u b r i coting greoseof the some brond os used for the
s t e e r i n gl i n k o g e - s e e C h o p t e r 7 . 5 , p o r . 3 .
Pedol Free Trovel Adiustment
Adjust the free trovel of pedols ossembled
w i t h m o s t e rc y l i n d e r ss o t h o t t h e p e d o l p i s t o n
r o d h o s o c l e o r o n c eo f 0 . 5 t o 1 m m w h e n b e o r i n g
o g o i n s t t h e p i s t o n h e o d s o f t h e m o s t e rc y l i n ders. The free trovel of the pedol pod should be
from 3 to 5 mm. lt con be odiusted by rototing
the eccentric pin on the pedol brocket - see
Fi9.12.111.
F o r t h e o d j u s t m e n to f t h e b r o k e p e d o l w i t h
broke booster ond/or levelling of the broke
p e d o l w i t h t h e c l u t c h p e d o l ,s e e C h o p t e r 9 . 6 A dj u s t m e n t .
Adiustmentof Switches
T h e s w i t c h e sc o n b e m o v e d i n t h e e l l i p t i c o l
holes of the brocket ofter looseningthe fosteni n g c o p s c r e w sw i t h p l o i n w o s h e r s u n d e r t h e i r
h e o d s .A p o c k i n gp i e c e s h o u l db e s l i p p e du n d e r
the switch of the broke pedol trovel worning
l i g h t o n d t h e p o w l o f t h e s w i t c h p i n s h o u l db e
held down under the fostening copscrew.
Ad just the stop-light switch so thot it
switches on the stop lights ot o pedol trovel
of 10 to 15 mm meosuredon the centre of the
pedol pod.
Adiust the pedol trovel signolling switch so
t h o t t h e p u s h e d - i n s i d e p u s h - b u t t o np i n i s
re,ecsed ot o pedol trovel of 100 to 110 mm
mecsuredon the centre of the pedol pod. Press
the push button into the switch ofter hoving
c o m p l e t e dt h e o d i u s t m e n t .
12.2 ACCELERATORPEDAL AND CABLE
T h e o c c e l e r o t o rp e d o l f o r m s o u n i t w i t h i t s
s e l f - l u b r i c o t i n gb e o r i n g o n d t h e l e v e r . l t i s
bolted to the floor tunnel. A coble possing
through the tunnel is ottoched to the pedol
lever ond the reloy lever on the engine by
meons of clomps- The coble is protected by
o B o w d e nt u b i n g .
Pedol Removing ond Refitting
1 . L o o s e nt h e c l o m p h o l d i n g t h e c o b l e o n t h e
e n g i n e - m o u n t erde l o y l e v e r .

162

2. Removethe copscrews holding down the

b e c r r i n gw i t h t h e p e d o l , d e p r e s s l i g h t l y t h e
pedol,ond lift it out of the f loor tunnel together
with the beoring.
3. Disconnectthe pedol from the coble ofter
i o o s e n i n gt h e c l o m p .
Removol ond Refitting of Bowden Tubing
ond Cqble
The Bowden tubing is fostenedto the brocket
irr the floor tunnel by meons of circlips. After
t h e i r r e m o v o l ,p u l l t h e B o w d e n t u b i n g i n s i d e
the cor.
O n r e fi t t i n g t h e t u b i n g , l u b r i c o t e i t w i t h
o low-viscosito
y il (of the SAE20 closs).lt hos
been lubricotedwith greose in the foctory. Fit
the clonrpsso thot their longer ports (from the
screw to their end) ore on the side of the
Ie v e r s .
AccelerotorCoble Adiustment
Adjustthe cobleso thot it is not excessively
tensioned or too slock. Loosen the clomps on
t h e e n g i n es i d e o f t h e c o b l e , m o v e s l i g h t l y t h e
clomp toword the reloy lever, ond tighten the
screws of the clomp.

12.3 GEAR SHIFT LEVER AND LINKAGE

I
T h e g e o r s h i f t m e c h o n i s mc o n s i s t s o f t w o
units: the geor lever with its housingond occessories, ond the geor shifter rod ond the
shifter lirrk with joint (ot the georbox) for
domping the vibrotion of the power pock
tronsnrittedto the geor lever.
RemovingGeor Lever Housing ond Link
1. Lift owoy the mot from the floor tunnel in
the front ond reor comportment. lf seporote,
remove the individuol floor mots ofter hoving
prised out their clips with o screwdriver or
o similor tool. lf o one-piecefloor covering is
used, remove the door sill strips on one side,
tip the seot, ond bend over the floor covering.
2. Removethe geor lever housing copscrews
o n d p r i s eo u t t h e l i d ( n e x t t o t h e c l i p ) b e t w e e n
the seots. Proceedthrough the opertureto dlsconnect the bolted connection of the link with
t h e h o u s i n gs h i f t e r r o d .
3. Lift owoy the housing with the lever
through the operture.Swivel the lever so thot
the shifter rod does not protrude over the
housing beoring thus obstructiongthe removol.
4. Usuolly it is not necessoryto remove the
geor shift link from the cor. lf obsolutelynecessory, the link con be disconnected only ofter

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12.6-12.f

2. Proceeding fronr below, rernove the fuel

t o n k s h e e t g u o r d o n d t h e g u o r do f t h e c o o l i n g
woter pipes.
3 . D i s c o n n e c t h e p i p e o f t h e c l u t c l rh y d r o u l i c
l i n e f r o m t h e c l u t c h r e l e o s eh o s e b r o c k e t .
4. Screw out droin plugs to droin fuel from
the fuel tonk ond ot the sometime disconnect
the fuel hose from the fuel pump. After comp l e t i n g t h e d r o i n i n g ,r e i n s t o l l t h e d r o i n p l u g s
( s c r e w s ) w i t h t h e i r s e o l i n gr i n g s .
D i s c o n n e c tt h e t r o n s v e r s eh o s e c o n n e c t i n g
both sectionsof the fuel tonk ond stop the open
p i p e sw i t h r r u b b epr l u g s ( t o p r e v e n tt h e r e m o i n ing fuel spilling over your honds ond clothes
when lifting the tonk owoy).
5 . D i s c o n n e c tt h e g e o r s h i f t l i n k o n d t h e
speedometerdrive from the georbox- see Chopt e r 4 . 1 ,p o r . 9 .
6. Detoch cobles from the hond broke rocker
ond pull them out from under the cor - see
Chopter 9.8.
7. Droin the cooling system- see Chopter
-15.13.
D i s c o n n e c tt h e m o i n w o t e r l i n e i n t h e
r n i d d l eo f t h e c o r . D i s c o n n e c t t h e p i p e s f r o m
the engine (from the hose of the thermostot
o n d t h e p u m p c o n n e c t i n gh o s e )o n d r e m o v et h e
pipes- see Chopter 11.4.
8. Disconnectthe hose of the fuel tonk from
t h e f u e l f i l l i n g p i p e , o n d , i n t h e u p p e rp o r t , t h e
h o s eo f t h e f u e l f i l l i n g l i n e v e n t p i p e .
9. Sever the electric connection of the fuel
level gougefloot systemunder tlre right-hond
I eor seot.
10. Use o iock to support tl're georbox ond
loosen tlre connection of the georbox cross
beorer with the bodywork.
11. Loosen the copscrewsfostening the fuel
tonk to the bodywork ond lower the iock to tip
the power pock. Retoin the fuel tonk while nen r o v i n g t h e c o p s c r e w s ,m o v e t h e t o n k b o c k words ond down, tip it down ond forword, ond
r e m o v ei t i n t h i s d i r e c t i o n .

F i g . 1 2 . 6 1 1 -F u e l T o n k D r o i n P l u g s

1 2 . S h o u l dt h e p i p e s o f t h e b r o k e s y s t e mo b s t r u c t t l r e r e m o v o lo f t h e t o n k , d i s c o n n e tt h e m
from the finol drive ond from broke hose brockets.
Refitting Fuel Tqnk in Cor
Reverse the procedureof the tonk removol.
F i l l t h e c o o l i n g s y s t e mw i t h t h e r e c o m m e n d e d
c o o l o n t o n d b l e e d i t , o d j u s t t h e h o n d - b r o k eo n d
the occelerotorcobles. Bleed the clutch hydroulic line ond olso the reor wheel brokesif
t h e h y d r o u l i cb r o k e l i n e h o s b e e n d i s c o n n e c t e d .
T i g h t e n p r o p e r l yo l l j o i n t s o n d c o n n e c t i o n s ,
f o s t e n t h e c o b l e s ,l i n k s , o n d p i p e s o b s e n v i n g
their correct orrongement- see Chapter 12.7.
Fuel Line ond lts Accessories
F i l l i n g p i p e . T h i s i s q s h e e t- m e t o l t u b e o t toclred to the hose on the fuel tonk by meons
o f o c l i p , o n d t o t h e b o d y w o r kb y t w o h o l d e r s
w i t h o c o p s c r e wo n d b o t h o s p r i n g o n d o p l o i n
w o s h e r .l t p o s s e st h r o u g l ro b u s h i n gi n t h e s i d e
of the bodywork.
Venting line. The hose is ottoched to the fuel
tonk filler neck in the upper port of the tonk
ond to the filling pipe by meonsof clips. For
its possoge through the bodywork stiffener,
see Fig. 12.714.
F o r c l i p s o n d t h e i r t i g h t e n i n gs e e F i g . 1 1 . 4 / 1 .
T h e o i r - f e e dh o s e i s s l i p p e d o n t h e f i l l i n g
pipe outlet ot the fuel tonk neck; its loop is
i n s e r t e du n d e r t h e d o m p i n g l i n i n g o f t h e b o d y work, ond its other end is insertedinto the hole
o f t h e f i l l i n g p i p e s o c k e tb u s h i n g .
Filler neck cop - see Chopter 1.5.
Fuel gouge - see fuel reserve signolling
switch, Chopter 13.17.
12.7 ARRANGEMENTOF PIPELINES,LINKS,
AND CABLES UNDER THE CAR
The routing, fostening, etc., of pipelines,
l i n k s , o n d c o b l e s i s d e s c r i b e di n c h o p t e r sd e o l ing with these ports. They oll leove the floor
tunnel under tlre fuel tonk to be covered by
o g u o l d h e l d i n p o s i t i o n b y s e l f - l o c k i n gn u t s
w i t h p l o i n w o s h e r s .T h e f o l l o w i n g i l l u s t r o t i o n s
show their correct orrongementwhich hos to
be mointoined if incorrect function or domoge
is to be prevented. lt is imperotive to ensure
free movement ond swing of the geor shift
link.
Securethe correct position of oll ports under
the fuel tonk by clips which hove to be provided with sleevespreventing domoge to Bowden tubings, etc. The overoll orrongement is
shown in Fig. 12.712ond 12.713.

164

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nolly emerges into spoce under the floor toword

the georbox. lt is ottoched to the speedometer
by meons of o union nut ond to the georbox by
o sleeve ond o screw.
It is lubricoted with oil from the georbox
which creeps olong it due to copillory elevotion" Lubricote it with engine oil of o lower
viscosity dripped into its sheoth only if the
lubricotion by creeping is inodequote.

166

When refitting it in position, put it into the

cor from the front, connect its both ends, ond
then orronge it so thot it does not form ony
shorp bends ond is not too tout. The speedometer con be disconnectedofter removing the
i n s t r u m e n tp o n e l ,o n d r e m o v e db y p u l l i n g i t i n
forword direction.
For the speedometer drive shoft possoge
under the ffoor refer to Chopter 12.7.

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lgnitioncoil
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ponel terminol boord
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1 - H i g h - b e o mw o r n i n g l o m p , 2 - L u b r i cotion worning lomp,3 - Telethermometer,
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y e l l o wfemole connector5.5

14.Fuse box
Centrol connection of conductors- do not
seporotethem from the bunch!

greenfemole connector7.

15.Direction indicotor switches, dip switch,

and horn switch
eight-pole terminol boord
six-pole terminol boord

17. Switch box

f e m o l e c o n n e c t o r s5 . 5 w i t h s y m b o l s " 1 5 " ,
"30", ond '50" to be connected to symbols
"15u, "30', ond '50" on the switch
box
18.Instrumentponel
ten-pole terminol boord
six-pole terminol boord
e o r t h i n gc o b l e w i t h l u g
'19.
Heoter switch
four-poleterminol boord

21. Door switch, right-hond

green - femole connector 5.5

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22. Dome light, right-hond

green - femole connector 5.5
- femole connector 5.5
red
23. Stop switches
forked (yellow) femole connectors5.5 . upper ond lower
switch
red femole connector5.5
upper switch
white femole connector5.5
lower switch
24.Fuel gouge
block - femole connector 5.5
yellow - femole connector 5.5
blue - femole connector 5.5
to be connectedto the respectivepins
(blodes) of the some colourof the fuel gouge

corburettor
iet seporotor

27. lgnition coil, voltoge regulotor, olternotor,

tochometer
conductor with femole connector ond
b r o n c h i n gl u g
femole connector-regulotorterminol 15/54
l u g- i g n i t i o n c o i l t e r m i n o l 1 5
blue - femole connector 5.5,
symbol "R" .
regulotor terminol "R"
yellow - femole connector 5.5,
s y m b o l" M "
r e g u l o t o rt e r m i n o l " M "
blue
connector "R" . olternotor terminol "R"
y e l l o wc o n n e c t o r" M " . o l t e r n o t o rt e r m i n o l " M "
lug
terminol "+B"
conductor with
lug
i g n i t i o nc o i l t e r m i n o "l 1 "
(tochometeroperotion)

16.Porking light switch ond high beom feeder

four-pole terminol boord

20. Switch of disobility lights

s i x - p o l et e r m i n o l b o o r d

telethermometer
primory element

28.Toil lomp cluster, right.hond

y e l l o wfemole connector5.5
toil light
b l o c kfemole connector5.5
direction indicotors
red femole connector5.5
stop light
greenfemole connector5.5
reversinglomp
29. Licence plote light
conductorswith femole connectors5.5
30. Toil lomp cluster, left.hond
se point 28.
b) Connection of free conductors
1. Storoge bottery
bottery coble positive (*) terminol storter motor
botteryeorthing strip negotive(-) terminalbodywork
(eorthing conductor)
2.Engine
e n g i n ee o r t h i n gs t r i p ( f o s t e n i n gl u g ) engine cross beorer
(eorthing conductor)
3. Distributor
speciol coble from distributor to ignition
coil; end with interference suppressing
terminol to distributor
coble from distributor to ignition coil
t e r m i n o l" 1 "

25. Storter motor, reversing lomp switch

conductorswith lugs
stater motor moin
terminol boord
c y l i n d r i c o l( p i n )
connector
storter motor
control switch
greenfemole connectors5.5
heodlompswitch
26. Oil pressuregouge,thermometer,corburettor
iet seporotor
greenfemole connector5.5
pressuregouge

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r3.2-t3.3

Observe strictly the following instructions:

1. Mointoin the electrolyte level ot the level
of the perforotedinserts between the plotes or
so thot the inserts ore coveredwith the electrolyte to o moximum height of 4 mm. The bottom
l i m i t o f t h e e l e c t r o l y t el e v e l i s 3 m m b e l o w t h e
perforotedinserts. Use only distilled woter for
topping up the electrolyte.Add electrolyteonly
if it hos been obviously spilt from the bottery.
In such cose, its density must correspond to
t h e d e n s i t y o f t h e e l e c t r o l y t eE e m o i n i n gi n t h e
bottery.
2. Keep the bottery terminols cleon, remove
o x i d e s o c c o s i o n o l l y ,o n d c o o t t h e t e r m i n o l s
w i t h m i n e r o li e l l y .
3. Wipe off the electrolytespilt over the bottery surfoce since it is conductlve ond couses
dischorgingof the bottery.
4. Check the chorging of the bottery occording to the electrolyte density or check the
voltoge drop using o voltmeter with o looding
resistor ond comporing the obtoined reoding
with on evaluotion toble or scole.
5. When chorging the bottery outsidethe cor,
use chorging current volues occording to the
t o b l e .T h e v o l t o g es h o u l db e c o n t r o l l o b l ei n t h e
ronge from 12.6 to 16.8 volts. The fully dischorged bottery is fully chorged in obout 13 to
20 hours when
l
i
i

ii

o) the electrolyte ottoins o density of 1.28 in

o l l c e l l s o n d d o e s n o t c h o n g e i n o p e r i o do f
two hours;
b ) t h e c e l l v o l t o g e( m e o s u r e d
w i t h o p p l i e dc u r rent) ottoins o volue of 2.6 to 21 volts ond
does not chonge within two hours of continuedchorging;
c) oll cells ore lively gossing.
6. An olreody used bottery must not be left
without electrolyteor dischorgedos it is opt to
suffer from such o condition.
7. The bottery in on unused cor must be
removed ond chorged outside the cor within
three months ot th-e lotest. lf the cor is under
repoir for o prolonged period, toke oll necessory
steps to keep the bottery in good condition.

At o 20 per cent chorging, the bottery is

consideredprocticolly dischorged.
Toble of Chorging ond Dischorging Values
Roted voltoge

12 volts

Roted copocity C 20 ot o
20-hourdischorgingto 1.75
volts per cell
37 omperehours
Normoldischorgingcurrent
for 20-hourdischorging to
1.75 omperehours
1.75 volts per cell
Normol uniform chorging
Two-stogechorging:
stoge I up to 2.4volts per
cell; gossing beginning 4.4 omperes
s t o g el l u p t o f i n o l m o r k s
of fuffychorgedcondition 2.2 omperes
Diffenentinstructions,determinedspecificolly
by bottery monufocturers,opply to moking o
new ond empty bottery reody for operotion or
t o s o - c o l l e dq u i c k c h o r g i n g .
Sofety Precoutions ond Other Meosures
During chorging, the electrolyte temperoture
must not exceed +40oC. As soon os this tem'
peroture is reoched, interrupt the chorging or
lower the chorging current (this opplies esp e c i o l l yt o s o - c o l l e dq u i c k c h o r g i n g ) .
During chorging, on explosive mixture of hydrogen with oxygen is liberoted from the electrrolyte.Therefore,the oreo where the bottery is
chorged must be ventiloted, ond it is forbidden
to opproochwith o noked flome (or spork) the
cell filling holes (even ofter o consideroble
period of time ofter the chorging hos been
completed).
W h e n c h o r g i n g t h e b o t t e r y ,o p e n t h e f i l l i n g
holes of its cells to enhonce degossing.
The electrolyteis on ocid hormful to the skin
ond clothes os well os to ports of the cor fini s h e d i n e n o m e l .R i n s e w i t h w o t e r i m m e d i o t e l y
ony contominotedspots.
13.3 ALTERNATOR

Electrolyte

(density)
g/cms

iChorgingl
I
I

freezing
temperoture

1.28
1.24
1.22
1.15
1.12

1ooo/o
Toolo
s0%
2oolo
0

-60 0c
-50 0c
-35 0C
-17 "C
-120C

3.7 omperes

Bottery Chorging versus Electrolyte Density

Specificgrovityl

tu

t(A
4

3t

2t
,t

Pe

lp
5
4

The olternotor is o three-phosegenerotorwith

o built-in semiconductorrectifier for feeding
electricol devices ond the bottery with direct
current.

Alternotor lnstollotion ond Generol lnstructions

They opply to both olternotor models. The

following principles should be observed:

174

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Alternotor Disossembly- Repoirs

g) Excitotion of the olternotor by o current

supply outside the cor is not permitted.
sould suffer.
A g o i n t h e s e m i c o n d u c t o rw
h) A blown chorging worning lomp must be
r e p l o c e di m m e d i o t e l yw i t h o n e w o n e .O t h e r wise correct excitotion of the olternotor is
n o t e n s u r e d .U s e o n e w l o m p o f t h e s o m e
r o t i n g ( o r i n p u t ) , i . e . , 1 . 5t o 2 W .
i) Be sure thot there is o perfect electricol
c o n n e c t i o no n t h e c o n n e c t i n gt e r m i n o l so n d
thot the olternotorond regulotorore properly
eorthed.
i) The olternotor is oeroted, open. Therefore
toke core when woshing the cor thot woter
or cleoning ogents do not get into it through
t h e v e n t i n gh o l e s .
Removing the Alternqtor
1. Disconnecthe bottery.
2 . D i s c o n n e c t h e o l t e r n o t o rl e o d s .l t w i l l b e
h e l p f u lt o r e m e m b e tr h e c o l o u ro f o n e c o n d u c t o r
o n d i t s c o n n e c t i o nf o r r e i n s t o l l o t i o n .
3 . R e m o v eo l l p o r t s h o l d i n gt h e o l t e r n o t o ro n
t h e e n g i n e ,o n d l i f t o w o y t h e o l t e r n o t o r .
L

Reinstolling the Alternotor

1 . C l e o n o l l m o u n t i n gs u r f o c e s F
. or the olternotor mounting,see Chopter 2.3, por.42.
2. With the bottery disconnected,insert the
conductorsinto the respectiveconnectors "M,,
o n d " R " ( t h e c o n d u c t o r sb e o r t h e s o m e s y m b o l s ) , o n d f o s t e nt h e r e m o i n i n gl e o d w i t h o n u t .
3. Reconnectthe botterv.

1. Screwoff the belt pulley nut ond remove

t h e b e l t p u l l e yo n d f o n .
2. Lift the brushes with o hook proceeding
t h r o u g ht h e h o l e s i n t h e c o m m u t o t o re n d s h i e l d
ond hold them in the lifted position by wires
i n s e r t e di n t o t h e s h i e l d t h r o u g hd i o . 3 m m h o l e s
u n d e rt h e t e r m i n o l su M ' o n d " R u .
3 . M o r k t h e m u t u o l ( r e l o t i v e ) p o s i t i o no f t h e
c o m m u t o t o ro n d d r i v e e n d s h i e l d so n d s e p o r o t e
r f t e rh o v i n g r e m o v e di t s c l o m p i n g
t h e q l t e r n o t oo
b o l t s . T h e d r i v e e n d s h i e l d r e m o i n sc o n n e c t e d
with the stotor.
T h i s d i s o s s e m b l yw i l l g i v e o c c e s s t o t h e
b r u s h e so n d s o m e o f t h e d i o d e s .A l l o t h e r i o b s ,
with the exception of the renewol of the beoring, shouldbe done by expertsin speciolized
r e p c i r s h o p s - s e e t h e n o t e s u p p l e m e n t i n gt h e
f o l l o w i n gp o r o g r o p h s .
Alternotor Reossembly
1 . I n s e r tt h e c i r c l i p i n t o t h e b e c r i n g b o r e i n
t h e c o m m u t o t o re n d s h i e l d .
2. Fit the drive end shield with beoringon
the rotor shoft.
3. Assemblethe stotor with the rotor ond the
c o m m u t o t o re n d s h i e l d .
4 " T i g h t e nt h e o l t e r n o i o rw i t h c l o m p i n g b o l t s
ond check the rotor for free rototion while
t i g h t e n i n gt h e b o l t s .
5 . S l i p t h e s p o c e ro n t o t l r e s h o f t , t o p t h e
k e y i n p o s i t i o n ,f i t t h e f o n o n d b e l t p u l l e y ,o n d
t i g h t e n t h e e n t i r e o s s e m b l yu s i n g t h e n u t w i t h
s p r i n gw o s h e r .
6 . P u l l o u t w i r e s f r o m t h e c o m m u t o t o re n d
shieldwhich hove been used to hold brushes
in their lifted position.
Replocementof Beorings
T h e u s e d b e o r i n g so r e f u l l y c l o s e do n d s e o l e d ,
ond they hove been filled in the foctorywith
l u b r i c o n t o l o s t t h r o u g ht h e i r e n t i r es e r v i c el i f e .
1 . P u l l t h e b e o r i n go f f t h e r o t o r u s i n g o s u i t o b l e p u l l e r .W h e n r e fi t t i n g t h e b e o r i n g ,p r e s s i t
o n t o b e o ro n t h e s h o f t c o l l o r 2 . B e f o r er e m o v i n gt h e d r i v e e n d s h i e l d b e o r i n g , f i r s t d r i l l o f f t h e h e o d so f t h e f l o n g e r i v e t s
ond then drive the beoring out from the outer
side of the drive end shieldusing o suitoble
m o n d r e l( d r i f t ) .
O n r e o s s e m b l y c, l o s e t h e b e o r i n g w i t h t h e
f l o n g eo n d r i v e t t h e f l o n g e t o t h e s h i e l d .
Replocementof Diodes

F i g . 1 3 3 l a- A l t e r n o t o r- S e c t i o n o lV i e w

T h e u s e o f t h e r e m o v o b l ed i o d e b l o c k w i t h
the individuol corriersof the so-colledpositive,
n e g o t i v e ,o n d o u x i l i o r yd i o d e s ,f o c i l i t o t e s c o n siderobly the replccement of ony defective

176

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j u n c t i o nw i t h t h e o l t e r n o t o ,or c c o r d i n gt o C h o p ier 13.3 ond mointoining o constont voltoge of

tlre power supply set within the entire ronge of
service speeds.
Tlre voltoge regulotoris instolledorr the body
c r o s s b e o r e r ,t o t h e r i g h t o f t h e e n g i n e o n d
b e s i d et h e i g n i t i o nc o i l .
T o f o c i l i t o t e h o n d l i n go f i t s l e o d s 'e s p e c i o l l y
the occess to their connections,it is recomrrrended to remove the regulotor fostening
screws. For disconnecting procedures, see
"Alternotor lnstollotion ond GenChopter 13.3
erol lnstructions".

i n g . l f t h e w s r n i n g l o m p d o e s n o t g o o . u tw h e n
d r i v i n g , i . e . , i f i t g l o w s o t i n c r e o s e de n g i n e
speed brightly or dimly, or if it does not stort
glowing ofter stopping the engine ond o new
iurning of the ignition key in the switch box,
the voitoge regulotoris proboblyfoulty.Another
symptom of o regulotorfoilure is o poor chorgirrg of tlre bottery or its overchorging..lf there
i s n o t h i n g w r o n g w i t h t h e r e g u l o t o r c, h e c k t h e
reguloted voltoge over the regulotor which
slrould reod 13.2volts ot the minimum ond 14.8
v o l t s o t t h e m o x i m u n r .T h i s c h e c k i n t h e c o r
i s o n l y t e n t o t i v eo n d o n l y o c h e c k o n t h e t e s t
b e n c h ' c o nb e c o n s i d e r e do s d e f i n i t e o n d b i n d '
in g .
Electricol Adiustment
The voltoge regulotot-should be tested ond
o d j u s t e do n l y o n o t e s t b e n c h i n o c o n n e c t i o n
slrown in Fig. 13.412.

At o lood of some 2 onrperes,the checked

voltoge should correspondto volues specified
i n t h e c o l u m n " C h e c k i n g " .l f t h e c h e c k e dv o l t oge is within the specified ronge,do not odiust
the regulotor.Othenwiseodiust it to the volues
" A d i u s t m e n t " .l f w o t e r
DK1565 s p e c i f i e di n t h e c o l u m n
evoporotesobnormollyfrom the bottery, odiust
the voltoge regulotor to the bosic volues of
F i g . 1 3 . 4 1 1 I-n t e r n o lW i r i n g D i o g r o mo f
" A d i u s t m e n t "u t i l i z i n gt h e l o w e r s e c t i o no f t h e
Outer
ond
Alternotol with Voltoge Regulotor
t o l e r o n c ez o n e .
Connections
Altenrotor:
B, R, M - olternotoroutlets
f - olternotorphose windings
m - o l t e r n o t o rf i e l d w i n d i n g
D1,2,3,4, 5, 6 - moindiodes
D 7 , 8 , 9 - o l t e r n o t o ro u x i l i o r yd i o d e s
D 1 0- o l t e r n o t o rc h o k i n g d i o d e
Voltoge regulotor:
R, M, 15/54- regulotoroutlets
reg - regulotor tension winding
Rk - boloncing resistor
Ro - protective resistor
Rr - odiustobleresistor
Kr - regulotorcontocts
Outer connections:
K - worninglomp (1.5W)
S - switch (switch box)
B - bottery
Checking Voltoge Regulotoron Cor
The regulotor operotion con be offected by
loosenedconnections ond on imperfect eorth-

DK1566
Fig.13.al2- Wiring Diogrom of Voltoge
RegulotorTested ond Adiustedon o Test Bench
G - olternotor
REG- voltoge regulotor
A - ommeter
V - voltmeter
S - switch
R - lood resistor
B - bottery

178

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6 . S c r e w o f f t h e r e t o i n i n gs p r i n g s .
7. Lilt owoy the vocuum chomber (do 19t
o p e n i t , o c h o n g eo f t h e c u r v e i s o n . i m p r o b o b l e
d'efect;do not chonge the screw-indepth of the
p
' ull-rod).
8. Lift owoy the contoct breoker bose plote
w i t h p o c k i n gp i e c e f r o m t h e h o u s i n g .
g. Litt owoy the shoft with the centrifugol
governor.
1 0 . l f n e c e s s o r yd, i s o s s e m b l ef u r t h e rt h e s u b '
ossembly of the shoft with the centrifugol
g o v e r n o r( o d v o n c em e c h o n i s m )o n d c o m .

(Il
qt3

2tD
F

zsa
llti

!l!
rc

ReossemblY
l?;h.',0,

1. Reossemblethe centrifugol governor (the

weightsmust be freeto rototeon the pins).
shoft with the res'
2 . l n s t o l lt h e r e o s s e m b l e d
pective woshers into the distributor housing.
3. Fit the contoct breokerbose plote with the
copscrew fostening the distributor brocket to
f i x e d c o n t o c t h o l d e ro n d p o c k i n gp i e c e i n t o t h e
t h e s u p p o r to n t h e e n g i n e ( d o n o t l o o s e nt h e
housing.
4 . F i t t h e p u l l - r o do n t h e p i n o n d l o c k i t i n
b r o c k e tc l o m p i n g b o l t ) .
position,screw down the vocuumchiomberwith
Refit the distributor on the engine by reversing this procedure.The coupling on tlre
t h e c o p o c i t o r .C h e c k t h e i g n i t i o n o d v o n c e p o shoft is osymmetricolond it hos to engoge into
sition for the first cYlinder.
5. Screw down the retoining springs with
the heod of the drive shoft in the engine. To
seot properlyo new distributoror o distributor,
s h i m s ( t h e s p r i n gw i t h t h e d o g o p p o s i t et o t h e
the brocket of which hos been loosened,refer
t e r m i n o l" 1 " i ; t h e b o s e p l o t e m u s t r o t o t e f r e e l y
por.25
27.
to
to Chopter 2.3,
i n t h e d i s t r i b u t o rh o u s i n g . " 1 " .
6 . R e o s e m b l et h e t e r m i n o l
7. Fit the breoker orm on the pivot ond lock
Distributor Disossemblyond Reossembly
it in position. Adiust the contoct breoker point
gop
(lift) ond check the contoct Pressure'
T h i s s h o u l db e d o n e i n s p e c i o l i z e d w o r k s h o p s , " i f . ' S t i p w o s h e r so n t h e s h o f t i n t h e o r i g i n o l
e s p e c i o l l yw i t h r e g o r d t o t h e c h e c k i n g o f t h e
s e q u e n c e s, l i p o n t h e c o u p l i n g o n d l o c k i t i n
m e c h o n i c o lc o n d i t i o n o r o r e p o i r o f t h e d i s position^
tributor. lt is recommendedto use o suitoble
9 . F i t t h e l u b r i c o t i n gf e l t i n t o t h e h o l e o f t h e
holder for doing the moiority of the required
c o m o n d i n s t o l l t h e b r e o k e ro r m .
i o b s i n o v e r t i c o l p o s i t i o n .W h e n r e o s s e m b l i n g
1 0 . F i t t h e d i s t r i b u t o rc o p i n p o s i t i o n .
t h e d i s t r i b u t o r ,l u b r i c o t et h e s l i d i n g p o i n t s o c 1 1 . C h e c k t h e d i s t r i b u t o ro p e r o t i o n .
cording to Chopter 15.3 but bewore of overlubricotion.
Checking
Removeolso the copscrew on the bottom of
t h e d i s t r i b u t o rh o u s i n go n d d r i p s o m e l o w - p o u r
A d e fi n i t e i n d i c o t i o no f t h e c o n d i t i o n o f t h e
p o i n t o i l i n t o t h e h o l e t o i n c r e o s et h e o i l r e s e r v e
d
i
s
t r i b u t o r( d u r i n go n o p e r o t i o n ocl h e c k o s w e l l
o f t h e s h o f t s e l - l u b r i c o t i n gb e o r i n g- s e e C h o p "
S
p
e
c
i
o
l
o repoir) con be obtoined by testing
os
ofter
ter 15.2
Oils".
t h e d i s t r i b u t o ro n o t e s t s t o n d w i t h o c i r c u l o r
t f the
s p o r kg o p .A f t e r o p r e l i m i n o r yo d i u s t m e n o
Disossembly
contoc-tbreokerpoint gop, the stond is used for
c h e c ki n g :
1 . R e m o v et h e d i s t r i b u t o rc o p o n d t h e b r e o k e r
orm.
1. The contoctpoint contoctongle.
2. Removethe coupling from the shoft (note
2. The spork
- + 4 5 ongulor distribution (with o tolt h e r e l o t i v e p o s i t i o n o f t h e e c c e n t r i cd o g s o n d
o n g l e m i n u t e sw i t h i n t h e e n t i r e
e r o n c eo f
t h e b r e o k e ro r m ) .
o p e r o t i o n o rl o n g e ) .
3 . R e m o v et h e c i r c l i p f r o m t h e p i v o t o n d l i t t
3 . T h e r o n g J o n d c o u r s eo f t h e c e n t r i f u g o l
owoy the breokerorm.
ond vocuumcontrol.
4 . R e m o v et h e s u b o s s e m b l yo f t h e t e r m i n o l
4. The operotion ot moximum speed (length
"1" (current
s u p p l yt o d i s t r i b u t o r ) .
of spork on spork goP - 4 mm) for o brief period
5 . S c r e wo f f t h e c o p o c i t o r .
( o b o u t2 m i n u t e s ) .
Fig. 13.5i3- VocuumControl Courseopplicoble to both regulotor models

180

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orotely ( screen the other one). With left

directionol heodlomps,the borderline deviotes
towords the other side.
lf the heodlompsore neorerto the woll thon
the soid 5 metres, decreosethe meosureindicoting the deviotion of the light ond dorkness
bordeiline from the height of the heodlomps
obovethe ground in the direct proportionto the
decreose of tfre distonce, for exomple when
plocing the cor 2.5 metres from the woll, decreosethe deviotion bY holf. "B"
"A" ond
correspondto
Light proiections
the spocing of heodlomPson the cor ond they
hovethe followingdimensions:
Heodlomps,dio. 160 mm
, io. 130 mm
Duol heodlompsd
Auxiliory heodlomps,dio. 130 mm

1,030mm
1 , 1 1 4m m
790 mm

W h e n o d j u s t i n gt h e h e o d l o m p st,h e c o r m u s t
be empty ond the tyres must be correctly infloted. Hologen heodlompsshould not be left
switched on for too long o period os they build
up heot if not cooled by heod-onoir blost when
driving.
For lhe odiustmentof heodlomPsore intended
screws in their fromes.The screws ore occess'
ible ofter the removol of the side ports of the
grille. Remove the copscrews of the corners
o n d p u s ht h e g r i l l e o s i d e .
Heodlomp Assembly
o) The fundomentolfostening Port of circulor
heodlompsis the so-colledsupport plote (rectongulor plote) ottoched to the bodywork by
copscrews with lock woshers. The heodlomp
housing is bolted to this suPPortplote by bolts
with nuts ond lock woshers. One of the bolts

holds down olso the lug of the eorthing cobleThe inner frome, forming the odiusting element
of the heodlompinsert, is ottoched to the hous'
ing by two speciol odiusting screws ond two
tension springs. The heodlomp insert is ot'
toched to the bezel by three copscrews.
There is one left-hond ond one right-hond
supportplote. Both should be mountedwith the
"TOP" upwords.With the
oriow ond the word
exceptionof the ouxiliory heodlomps,the heod'
lomp inserts ore different for the left-hondond
the right-hondtroffic. The leods enter the housing through o rubber grommet.
When r-eplocingthe insert, remove the bezel
copscrews.After hoving fitted o new insert, it
is necessoryto reodiustthe heodlomps.
Front Direction Indicotors
T h e r i g h t - h o n do n d l e f t - h o n dd i r e c t i o n i n d i en i t s ( t h e l o m p
c o t o r s o r e u n d i s o s s e m b l o b lu
fostening sockets (locks) ore mounted in the
direction towords the cor longitudinol centre
l i n e ) .T h e y o r e f o s t e n e dt o t h e i r b r o c k e t si n t h e
bumperwith o nut ond o ploin ond o lock
wosher.

Toil Lomp Cluster

T h e l o m p c l u s t e ri s o n u n d i s o s s e m b l o b luen i t
fostened to the bodywork by nuts with ploin
woshers ond the respective bolts. Scrope off
the enomel ot the top bolt used for holding
d o w n t h e e o r t h i n gc o b l e .
F o r t h e s e q u e n c eo f t h e i n d i v i d u o ll o m p s o n d
their bulbs see Fig. 13.111ond the respective
p o r o g r o p ho n b u l b s .

I
s
I

I
I

(
(

t
l

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t
T
c

R
L
D

- Adiusting ond Fastening Screws of Right-hondHeodlomps- their locotion on

Fig. 13.812
is their mirror reflection
left-hondhe-odlomps
1 - Sidewoys odiusting screw
2 - H e i g h t o d i u s t i n gs c r e w
3 - F o s t e n i n gs c r e w s

182

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13 . 9 - 13 . 1 0

13.9 HORN
I t i s s i t u o t e db e h i n d t h e l e f t ' h o n dp o r t o f t h e
front bumper. To remove it, disconnect the
leods ond remove the fostening screw.
Operoting voltoge
M o x i m u mc u r r e n td e m o n d

12 volts
4 omperes

heor the ormoturebeing ottrocted (o cleor ond

l o u d c l i c k ) . N o w c o n t i n u et o s w i t c h t h e b o t t e r y
on ond off while rototing corefully ond sloryly
"1" onticlockwGetill the horn sounds'
the screw
iune it by rototing the odiusting.:cr9ryslightly
clockwiseor bock.-Afterhoving odiusted(tuned)
ih" honn,secureoll odiusting ports with o dob
of point.

Horn Adiustment
B e f o r eo d i u s t i n g ( t u n i n g ) t h e h o r n , c l o m p i t
firmly by th'e brocket ond tighten thoroughly
"4"
oll screws
ioiningthe horn cover with the
h o u s i n go n d t h e d i o P h r o g m .
"hoorse"- Using o screwdriver
1. The horn is
"1" clockwise to odiust
rotote slowly the screw
t h e c u r r e n td e m o n dt i l l t h e t o n e i s c l e o r .

-@

2. The horn sounds weokly - Using o screw"1" slowly onticlockwise

driver,rotote the screw
to decreosethe current demond till the tone is
loud ond cleor.

3. The horn does not sound ot oll-Proceeding

through the operture in the front cover, loosen
the nut "2" using o socket sPonner.Then insert
o screwdriverond rotote the odiusting screw
c l o c k w i s et i l l i t b e o r s l i g h t l y o n t h e c o r e .T h e n
bock off the screw by 1lz or moximolly 3/a of
o turn to odiust the distonce of the ormoture
from the core. Hold the screw in this position
with the screwdriverond tighten firmly the nut
by rototing it clockwise.After hoving connected
t h e b o t t e r y ( o f t h e s p e c i f i e dv o l t o g e ) ,y o u w i l l

c
@

F i g . 1 3 . 9 / 1- S e c t i o n o lV i e w o f H o r n o n d o V i e w
of Reor Adiusting Screw
13.10 STARTER MOTOR
This is o series motor for intermittent opero t i o n w i t h o n e l e c t r o m o g n e t i c o l l ye n g o g e d
pinion.

Specificotions
TyPe
Roted output
Storting torque
Speed for roted output
"30" of roted output
Voltoge ocross terminol
No-lood storting current
Direction of rototion
N u m b e ro f p i n i o n t e e t h / m o d u l u s.
Contoct spring pressure
Mointenonce
The mointenonce consists of periodicol in'
spections ond repoirs or replocementof foulty
ports:
o)
b)
c)
d)
e)

brushes
b r u s hs p r i n g s
commutotor
s t o r t e rp i n i o n o n d i d l e r
s e l f - l u b r i c o t i nbge o r i n g s

PAL-Mogneton 12 V/0.8 h. p. - 443'115'142'070

0.66 kw (0.e h. P.)
1 2 . 2 5N m ( 1 . 2 5 k g m )
'1,000r. p. m. moximum
9 . 5V m o x i m u m
65 A moximum
o n t i c l o c k w i s e( l e f t ' h o n d )
912.5
e.3 N (0.ss0 ks) +100/6
The brushes must be sufficiently long ond
they must slide freely in their-cells,their pressure springs must hove o sufficient thrust, the
commutotormust not show ony domoge,ond it
must be free of dust ond dirt. Cleon the commutotor with olcohol, petrol or trichloroethylene,
ond let it dry before closing it ond switching
on the storter motor. A burnt or mechonicolly
domoged commutotor must be repoired or re'
ploceJ immediotely.A commutotorin good con'
d i t i o n h o s o b r o w n i s hr e d h u e .

184

981
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deel) a)Drq aql lo sraqsDM eql qllM .raq1a6ol
'Z
plelqs pue rolDlntuuo" aq] Iorrto
l
l
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oq
Ple!qs
a q l u ! s e L l s n r qe q l l l ! l ' s l l o q 6 u l d t u o ; c a q l p u D
J a A O Cp l e l q s p u e J o l D l n t u u r o c a q l e ^ o u r a d ' [
,t;qtuassoss!O Jolol l rauols
'roloru JeilDls aq1 6u1111;eJueqrurernpaco.rd s1q1
e s J e A e U ' l o r v r ol ! 1 1 l p u o 6 u l s n o q x o q . r o a 6e q ] o l
Jolotrl JelJDls aq1 6ugua1sol slrra:csdDc enoueu
'Jolou Jauols aql uoJ+ fue11oq eql uoJl pDal
orll puD qo]lMs eql ol pDel eql ]ceuuocslc
' ( ; o ur u r
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'pJDoqJooll
lueul:oduoc e6o66n1aql u! srenoc
qloq enorreJ PUD'lDLu eql u!l 'uo!qsnc lDas
r o e r e q l d 1 1 ' x o q : o a 6 a q 1 1 o e p l s p u D q - q 6 ! ra q l

rolonl reUDtrSjo Metn lDuollcos- L/01'eL'6!J

W
LgL ilt}

0t't

Strike the slip-over ring off the circlip

(towords the motor windlng). Open the circlip
ond pull it off the shoft together with the releosed ports.
8. lf necessory, re-turn the commutotor ond
scrope or mill out the insulotion between the
lominotions."Mikonit" should be 0.4 to 0.8 mm
below the octive surfoce.
Note: The switch connot be further token
opat. lf defective, lt hcs to be reploced with
o new one. When cleoning ports of the storter
motor, do not dip the ormoture or the pinion
with the idler into petrol or onother degreosing
ogent.Thesome oppllesto the end shieldswith
beorings. By dipping them in o degreosing
ogent, the beorings become procticolly worthless"
Storter Motor Reossembly
1. Lubricote the hellx of the ormoture shoft
with greose - see Chopter 15.2 'Lubriconts of
foreing mokeu ond fit the pinion with the idler
o n d t h e s l i p - o v e r i n g i n p o s l t i o n .F i t t h e c i r c l i p
into the groove in the shoft, ond drive the slipon ring over it. The pinion with the idler must
move freely olong the shoft.
2. Slip the respectivewosherson the shoft in
their originol sequence (corrier ring, distonce
ring, fibre ring, distoncering) ond insert the
ormoturewith the engoging lever into the drive
end shield.
3. Suspend the switch ormoture into the
pre-engoginglever ond bolt down the switch
lightly. Fit the lever pin into the drive end
shield ond lock it in position with the retoiner.
4. Tighten the copscrewsof the switch ond
f i t t h e s t o t o ro n t h e d r i v e e n d s h i e l d .
5. Instoll the respective woshers into the
c o m m u t o t o re n d s h i e l d i n t h e i r o r i g i n o l s e quence (the dished wosher with its centre
f o c i n g t h e s h i e l d , t h e n t h e p l o i n w o s h e r ,t h e
toothed wosher, ond the drive wosher).
6. Fit the commutotorend shield with lifted
brusheson the shoft (in the position occording
to the recess for the excitotion outlet ond the
notch) ond screw in the clomping bolts.
7. Instoll the brush interconnectingstrip ond
bolt it down together with the field winding
outlets to the positive brush holders,lower the
brushes.
8. Fit the Insulotingstrip in position ond bolt
down the cover.
9. Test the storter mottr.
Diognosing Storter Motor Defects in Cor
o) lf the storter motor refuses to operote, look
first for on interruptedconnection between
the bottery ond the storter motor,the engine
eorthing ond the storter motor,or the engine
eorthing ond the bottery. lf these connections ore in order (current flows to the ter'

DK1575
Fig. 13.10/3- Storter Motor Testlng Connection
minols u30" ond "50" with switched on
ignition), stort looking for o foilure of the
storter motor switch. Even in this instonce,
the cousecon be o fully dischorgedor foulty
bottery.
b) lf the storter motor continues running even
ofter the ignition key hos beenswitchedin
"START",
the switch box from the position
it hos to be stopped without ony deloy by
disconnectingthe bottery (using its eorthed
pole).
c) lf the storter motor hos no power to cronk
the engine, stort with switched-on heodlights. A morked dimming indicotesc poorly
chorged bottery.
Tentotive Checking of Storter Motor
Outside Cor
"30'of the storter
Connect the terminol
properly
chorged bottery ond incor'
motor to o
poroteon ommeterwith o wide meosuringronge
into the circuit - see Fig. 13.10/3.Stort the
"50"). The
engine (feed current to the terminol
volue of the current ot idling speed must not
exceed65 omperes(not consideringthe peok ot
the first momentousdeflection).
The storter motor must run noiselessly,
smoothly, ond the pinion must move smoothly
into ond out of the rest position (engoge ond
d i e s e n g o g e )T. h e e n g o g e dp i n i o n m u s t n o t r o tote direct on the foce of the slip-on ring. The
run-out of the storter motor must not lost longer
thon 8 seconds ofter the disconnectionof the
switch from the current supply.
Inspect the brush pressure springs. The
brushes must beor on the commutotor by ot
leost two thirds of their surfoceond they must
move freely in their cells.
The ormotureshould hove o noticeoble oxiol
cleoronce (ploy) not exceeding 0.7 mm. At
o s l i g h t r o t o t i o no f t h e p i n i o n i n t h e d i r e c t i o n
of the storter motor rototion,the idlor must slip
freely.

186

(
1

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olpear
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pq 'uogurde6e6ueol pJeeqeq ueo roloru reuels H
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13.10-t3.11

13.11 WINDSCREENWIPER

Technicol Description
The rotory windscreen wiper consists of the
wiper motor with o geor cosing, o lever system
driving the wiper orms, ond two wiper orms
with wiper blodes.
The two-pole wiper motor with permonent
mognets is o two-speed unit with self'lubri'
coting beorings.The geor cosing compriseson

epicyclic geor ond on outomotic self-porking

device. The shoft runs in self'lubricotingbeor'
ings, the geors being lubricoted with greose
pocked into the geor cosing. The lever system
(leveroge) includes self-lubricotingioints ond
beorings.

Windscreenwiper tyPe - for left-hondsteering .

- for right-hond steering
Roted voltoge
Roted current
Wiping cyclesper minute

f1

Differenceof cycles between speeds

Direction of rototion when viewing the output
shoft

onticlockwise- for left-hond steering

clockwise- for right-hond steering

Removol ond Refitting

llr

According to the noture of the required repoir, removeeither only the motor with the geor
cosing after hoving disconnected the pullrod
from the cronk,the cronk from the geor cosing,
ond the geor cosing from the brocket,or remove
the completeunit ofter removingthe wiper orm
beorings- see wiper orm drive.
When refitting the windscreen wiper unit,
the wiper
observe the ossembly position of "Motor
ond
cronk - see the following porogroph
Geor Cosing". For position of the wiper orms
'Wiper Arms". ln( b l o d e s ) ,s e e t h e p o r o g r o p h
stoll the brocket into the body bulkheod ond
fosten it in position with the nut, using o rubber ond o flot wosher.

fi.,
il

PAL 443.122- 081.071

PAL 443.122- 076.071
-12
volts
4 omperesot high speed,
2.5 omperes ot low speed
6 0 o t h i g h s p e e d( m i n i m u m )
2 0 ( m i n i m u m )t o 5 0 ( m o x i m u m )o t l o w s p e e d
1 5 c y c l e sp e r m i n u t e ( m i n i m u m )

Cleoning ond Repoirs

When disossemblingthe windscreen wiper
motor, do the following jobs:
1. Reploceworn brushes ond use petrol to
cleon motor ports ofter blowing the dust out of
the brushes;moke sure thot the brushesmove
freelyin their cells.
2. lf the commutotor is dirty, cleon it with
petrol, if it is domoged,re-turnond polish it.
geor3 . D u r i n g c l e o n i n g ,t h e s e l f - l u b r i c o t i n b
ings must not come into contoct with the
, t c . ) .T h e y
c l e o n i n g( d e g r e o s i n g )o g e n t ( p e t r o l e
s h o u l db e l u b r i c o t e do n l y w i t h o l o w - p o u r - p o i n t
o i l d r i p p e di n t o t h e c u t - o u t so f t h e c u p r e t o i n i n g

t h e b o l l b e o r i n go n d t h e f e l t . U s e o n l y o s m u c h
oil os the felt con hold.
4. For the epicyclic geor in the geor cosing
use greoses specified in Chopter 15.3- either
of foreign moke or of Czechoslovokmoke- recommendedspecificollyfor windscreenwipers.
MOTOR AND GEAR CASING
Ports of the motor with the geor cosing (or
geored motor) is the wiper brocket, the pro.
tective housing, ond the driving cronk. When
i n s t o l l i n gt h e w i p e r , p u t t h e h o u s i n g o n t h e
motor with the geor cosing ond clomp it from
below. Bolt down the brocket using ploin
woshers under the bolts. Fosten the motor
e o r t h i n gc o b l e u n d e r o n e o f t h e b o l t s .
F o s t e nt h e c r o n k i n p o s i t i o nu s i n g o n u t o n d
o s p r i n g w o s h e r w h i l e o b s e r v i n gi t s o s s e m b l y
position:
o) with wipers for left-hondsteering-toword
the right-hond side of the motor ond deflected
13odownword from the oxis porollel with the
centre line of the motor;
b) with wipers for right-hond steering
toword the left-hondside of the motor ond def lected17"downword from the oxis porollelwith
the centre line of the motor.
Dismontlingthe Geor Cosing
1. Remove three screws ond lift owoy the
cover.

188

lr

68r
(6ugsocroe6 puo .roloru)rad;41
uaercspulM lo Maln lDuoltces- LILL'9L'6tJ

J(

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uollces ;o y qdo.r6o;odees MeJcs eql ol ssaccD
Jol - Je^oceql ul r*eJcsaql asn 6u;lsnlpo .ro3
(po-unr rolou) 6u;>pod-;1eg1snlpy o1
'6u11.rod-1;es
'r3^oc eql
l!]ar ueql puD
eq1 1snlpo'Marcs 6u;lsnlpo eql aloqD pll oqr
'Jaloc srll onoruo.r'ilolco;s11os
lou
1no sserd
s! l! ll 'sradlrrreql lo 6u;lrod-;1aslceqC 't
're^o3 eql uMoP
lloq puD slloq aq] uo
slotlsDm1co1d11s'punodtuoc6u;;oas qlrrrn6u1
->1cod
puo 'Jsloo '6ugsoceql lo secDlJns6u;1oru
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epld lueulnqD sl! puo 6u1.rdseqt uesul .g
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q1;m 6u;1oepqdo.r6o.rod
"qt aes - ecods s;t;l
jo sprlql orltl ro llDrl D o1 asoalD qllM srDe6
eq] punoJoecods aqr lllt puo 'sroa6 eq] llDlsu!
'6ugsocaql u! 6u11codeql olu! asoelDqnu .Z
'esoal6 qUrtt qlael .roa6puo (secol.rnsuo;1c1r1)
sDeJolcDluo3 llo lDoc 'A;quassoeJuO 'Uoqs
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'seel6ap gg; q6norq] rolDls oql
urnl 'eslMlcolcltuD salDloJ Jolour eql ,l 'puo
luoJl Jolor aql 6ulrrrra;^ueqM os!M)colc alolol
lsnur Jolotu aq1 '6uguunl rcdold Jol l! ),lcoqc
puo l.relpq oq] ol roJoru eql ]csuuoC .g
's6u;.roeq
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lo
'plalqs pue rolDlnuuoc
eq] ur*op 6u;ploq slnu
aql ue1q611puD slloq uo sreqsom 6ug.rdsdgls
'Je^ocJoeJeql
'Jaqlo qcoa elgsoddoe.roseu11
lll
xepu! otrAl eql loql os rolDls eql llolsul 'g

'Mercs 6u11sn!po
aqt uesoo-l'6ugsoc
loe6 eq1 ;o ecods eq] u! Jaqsomlsnrql all] l!
.j
uo olDcol puo rolor eql lno glnd A1go11.ro6
'euoJ,
eql ol 6u;1;ncr1c-1Jor{s
Jo 6u1z1asuoJl seqsnJq
eql luane:d ol sJolcnpuoc eql qcJD puo 'Jolol
-nuuoc
or.{}
o}
uo sor.lsnrqaqt Jemol '6u1loaq
oql olu!
rolor aql lll 'soqsnrqoq] 1t!1 -t
uDqs
'lols
D q1rvrublsop logcedsto sl qsnrq
pecold Apenb;gqo'pr!qt oql 'u6gsap prDpuDls
'seqsnJq eql
]o aJo seqsnJq e1;soddoorvrl eql
lo lueuenour aeJl aql lceqc puD seqsnJqeql
Jepun s6u;.rds Uesu! '(pesn eJD seqsnJq rtteu
ol sJolcnpuoceql roplos 'Z
1g) seqsnrq eql'lsr!,
pollDlsu!eq plnoqs reqsDM
(uru S'O) u!q] sql'sror{sDlvrpezlraqqnroM} er{l
ueaMleq s! JoqsDrv\
llet aql ;o eco;d aql - spls
Jaqlle uo sJeqsDMaerql alDcol puD JoloJ eql uo
lololnuuoc eql ol 6u1.r.remo;q]-l!oeql r!l .L

'
J

rolo4 eq1 6u;lqulessDeu

'seqsnrq
lDnP!^lpu!aql
(s.rolcnpuoc) spoal lo srnoloc
o1 6ugu1ol.reddo
eql lo elou D elDu\l 'umop 6ulsserd ;o s1u;od
aq] lo llo uaql lnc 'peJaplos lou eJo seqsntq
aql t! ls.rolcnpuoc pelDlnsu! eql uJorl selqDc
rlaqt Jeplosun 'uroM erD seqsnrq eql I 'Z
'UDqs 6ugsoc.roe6eq1 6u;dd;rb Iq 'paso;c
s; 6u1soc .roab eql ;g '.ro 6ugsoc :oe6 aql ul
{q uorl;sod u! l! ploq 'rolDts
UDqs eql 6u1dd1r6
oql qtlM .raq1e6olpe^oueJ 6u1equorl rolor aql
'rolols
'JoloJ aql AorvrD
llll ueql puo
lueneld of
aql PUD plelqs pue JolDlnultuoc eql a^ouor
's1;oq Duldtuolceql
'L
lo slnu eq] Mercsun
I

Jolonl eql 6u;ltuorus;o

'sloeqm
lauogd
eql e^ousr puD Uoqs eql ;;o .toe6 elqnop eql
eq1 dgls 'l.rosseceu;; 'ugo.r1loe6 eql lno qsnd
ol UDqs (en;rp) I.rotul.rdeql lsulo6o sserd 'Z

t 3.tr*r 3.12

the wipers. lf necessory,turn the wiper cms

on the pins. The wipers must wipe the lorgest
possible oreo of the windscreen without, how'
ever, touching the windscreen glozing mouldin g .

1. lf the wiper moves with the switch in the

OFF position ofter its connectionto the electric
power supply,tighten (screw down) the screw
till it begins to be litfed by the geor com ond
till the wiper begins to be switched off ond
broked. Screw down the screw from this po'
s i t i o n b y o n o t h e rh o l f t u r n .
2. Press the lid into the cover ond seol it
with point.

13.12 RADIATOR FAN

Technicol Description

WIPER ARM DRIVE

The fon is on ossemblyof the fon motor ond

impeller. The impeller is pressed on to the
motor shoft.
The motor hos permonent mognets ond
o rotor running in self-lubricotingbeorlngs.The
impelleris mode of plostic.

T h i s d r i v e c o n s i s t so f t h e w i p e r b e o r i n g s w i t h
cronks,the tie-rod of the cronks, ond the drivi n g t i e - r o d .T h e d r i v e i s i n s t o l l e di n t h e c o r o s
o unit.
Tie-rods
The tie-rods should be slipepd on the cronk
p i n s i n t h e f o l l o w i n gs e q u e n c eo: s p r i n g w o s h e r
with its centre comber focing outword (owoy
from the pin), o flot wosher, the tie-rod, o flot
wosher, ond o lock ring.
lf necessory,lubricotethe ioints with greose
- see the following section deoling with beorings. Fill the cover at the point of the tie-rod
motor cronk connection with greose (of ony
brond) ond slip it on the tie-rod.

Motor type
Roted voltoge
Roted current
Roted output
Direction
of rototion
Coble poles

PAL 443.132- O97.O45

12 volts
7.5 omperes
55 wotts
c l o c k w i s e ( r i g h t - h o n d )w h e n
viewing the front end of the
shoft
coble with lug (blue)negotive pole
coble with femole connector
(red) - positive pole

Beorings
On one side, the beoring is inserted into the
wiper brocket from inside the body, on the
other side, it is fitted into o speciol wosher inserted with its nose foremost into the respective hole in the body. Locote o seoling
wosher with corefully smoothed-outedges ond
o flot wosher from outside, ond secure the
entire unit with the respectivenut. The unit is
seoled off by o rubber pocking. Fill the unit
with greose(see Chopter 15.3for recommended
foreign bronds or CzechoslovokLrrondsSP 4 or
A 4) ond press it down into the neck of the
bush.
lf it is necessoryto remove or disossemble
the beoring, prise the lock ring out of the pin
grooveunderthe rubberpocking.On reossembly,
insert o spring wosher under the bush with its
combered centre toword the bush. Lubricote
with the specified greose.
Wiper Arms
The wiper orms fitted with o rubber blode
con be swung owoy from the windscreen.They
ore held down by nuts on the groovedtopers of
t h e b e o r i n gp i n s .
After hoving fitted the wiper orms, sproy
woter on the windscreen ond test the run of

Removol ond Refitting

The fon is occessible ofter removing the
rodiotor to which it is fostened by meons of
o rim held down by copscrews ond sprlng
woshers.The motor rests on resilient bushes in
the rim. When refitting the fon moke sure thot
there is o spocer tube in the bush, locote the
flot ond the spring woshers, ond tighten the
nut.
Cleoning ond Repoirs
Refer to porogrophs 1 to 3 deoling with
cleoning ond repoirs in Chopter 13.11.
Dismontling Motor ond lmpeller
The motor con be removed (ond dismontled)
only ofter removingthe impeller.Use the puller
MP 8-102to pull off the fon or support the fon
hub in three points on its circumferenceond
press out the motor by opplying Pressure on
the motor shoft. No topping or blows on the
shoft ore permitted.
1. Remove the nuts of the clomping bolts,
hold the shoft by its grooved end, ond lift
owoy the commutotorend shield ond stotor.

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2. Removethe clomping bolt from the brocket

ond lift owoy the motor.
3. Removethe other clomping bolt from the
motor, lift owoy the stotor ond the brush
springs, ond push out the brushes. The other
motor ports connot be dissosembled.

Reossemblyof Motor ond lmpeller

1. lnstollthe stotor with the slot focing the
b o s s e so n t h e f r o m e o n d w i t h i t s i n d e x l i n e
focing the line on the frome,ond fosten the
ports with screws ond woshers.
2. Instoll the brushes ond brush springs,
suitobly orch the brush cobles so thot they do
not obstruct the movementof the brushesond
so thot they connot couse o short-circuit.
3. Top the stotor lightly with o soft mollet
to settle it in the beorings, ond lubricote the
beorings.
4. Connect the motor to the power supply
ond test briefly its running ond direction of
rototion. lf it rototes in the opposite direction,
rotote the frome ossemblythrough 180'.
5. Removethe clomping bolt of the motor on
the terminolboord side, instoll the motor in
the brocket, ond lock it in position with the
bolt ond wosher.
6. Fit the spring on the motor shoft, support
t h e s h o f t t o o v o i d d o m o g i n gt h e b e o r i n g s o
, nd
press-onthe impeller. The cleoronce between
the impeller circumference ond the brocket
must be smoll, obout 1.5to 2 mm. Lock the imp e l l e r i n p o s i t i o nb y p r e s s i n g- o n t h e l o c k r i n g
- ogoin the motor shoft must be supported.
7. Close the motor beoring from obove by
fitting the cover.

b r o n c h r e i n f o r c e dw i t h o c o l l o r ; t h e p o s i t i v e
pole is connectedto the suction side, the
negotive pole to the dischorge side (when
viewing the cor from the front, suction is on
t h e r i g h t - h o n ds i d e , t h e d i s c h o r g eo n t h e l e f t "
h o n ds i d e ) .
The distributor volve is fostened by o cops c r e w , t h e d i s t r i b u t i o np i p e l i n e b e i n g s i m p l y
fitted on it.
The nozzles (heods with nozzles) ore secured in position by pressing them down from
obove into bushings inserted into the cor body
by their necks.To odjust the requireddirection
of the woter streom, turn the nozzles to the
respective ongle using o needle inserted into
the nozzle hole.
Fil!ing the Reservoir

13.14 WINDSCREEN WASHER

Technicol Description
T h e w i n d s c r e e nw o s h e r i s o u n i t c o m p r i s i n g
o reservoir,o pump with motor, o distributor
v o l v e , t w o n o z z l e so, n d t h e c o n n e c t i n gp i p e l i n e .
Windscreenwosher type
Roted voltoge
.
Roted input .
.
P u m pd i s c h o r g e ,
minimum
.

Fig. 13.1a11-Windscreen Wosher

1 R e s e r v o i r2
, - S p r o y i n gn o z z l e s ,3 - M o t o r
with pump

MEZ MM 2004
12 volts
50 wotts
15 c. c. ot o pressure
of 10 MPo
(1 kg/cme)

Open the reservoir by turning its cop onticlockwise.In summer,fill it with woter or o mixture of woter ond one of the odditives for windscreenwoshersovoiloble on the morket,ond in
winter exclusivelywith on ontifreezeof o brond
intended speciolly for windscreen woshers never use on ontifreeze intended for motor
vehiclecooling systems.
Be coreful if the body finish is touched up
with other thon boking enomel. Additives in
t h e w o t e r o n d o t h e r l i q u i d s ,u s u o l l yc o n t o i n i n g
spirit, ore opt to leove unremovoblespots on
the enomel. Use only woter when testing the
windscreenwosher.

Fitting, Removol, ond Adiustment

1 3 . 1 5 I N S T R U M E N TP A N E L
The reservoiris held in its ploce by o cover
bond secured by copscrewswith flot woshers.
The motor with pump is bolted down, using
flot woshers under the copscrews.The suction
bronch socket is smooth,thot of the dischorge

Technicol Description
The instrumentponel contoins oll meosuring
instruments ond indicotors recommended by

192

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13 . 16 - t 3 . 17

focio ofter removing two copscrews ol-l the

ponel bottom. lt moy be olso necessoryto pull
off the heoter control push buttons.
c) Switch of disobility worning lights
-l
F o r f o s t e n i n g s e e i n f o r m o t i o ns u b b ) . h e
switch operotes only when connected to the
d i r e c t i o ni n d i c o t o rt i c k e r .
d) Dipswitch, direction indicotor, horn, windscreen wiper, ond winscreen wosher switch
This switch is instolled on the steering
c o l u m n s h o f t o n d fostened to the reduction
s l e e v e o f t h e t u b e w i t h s h o f t b e o r i n g so n d t o
t h e t o p p o r t o f t h e steeringwheel shoft shroud.

ox 1568

- S w i t c h B o x w i t h S t e e r i n gL o c k Fig. 13.16/1
the orrows indicote the copscrews (M 3.5)
h o l d i n gd o w n t h e s w i t c h b o x i n t h e s t e e r i n g
lock housing

Removol:

d i s e n g o g i n gt h e s h o f t f r o m t h e b o d y w o r k- s e e
Chopter 7.8, porogrophs1 to 5 - without, howe v e r , d i s e n g o g i n gt h e s h o f t f r o m t h e s t e e r i n g
box.
The switch box con be removedofter loosening two copscrewson the steering lock housing (seeillustrotion).
Reverse this procedure when refitting the
switch box. Turn the key ond the key hole of
the switch box into the left-hond extreme position (STOP), instoll the switch box in the
s t e e r i n gl o c k , t i g h t e nt h e c o p s c r e w so n d s e c u r e
them with o dob of point.

Remove the steering wheel ond the bottom

port of the shroud - see Chopter 7.8. The switch
con be releosed from the shoft ofter loosening
the screw in the driver ond the removol of the
driver ( if the switch is equipped with such
driver), ond the loosening of the screw in the
yoke on the switch bottom right-hond side.
Loosen or remove the fostening screws of the
shroud ond lift owoy the top port of the shroudlf you intend to remove olso the steering
geor, do not loosen the screw on the switch
bottom right-hond side but the screw on the
left-hond side, ond lift owoy the switch
t o g e t h e r w i t h t h e r e d u c i t - t gs l e e v e o n t h e s t e e r ing wheel shoft tube.
Refitting ond Adiustment

13.17 SWITCHESOF LAMPS AND WARNING

SYSTEMS,DIRECTIONINDICATOR
TICKER,RECEPTACLE

Reverse the described procedure when refitting the switch. lf the cor is equipped with
outomotic direction indicotor concelling

For the wiring of these electricol devices

refer to Chopter 13.1 - Electricol Equipment
C o n n e c t i o n s o n d W i r i n g D i o g r o m- o n d f o r
their operotionto Chopter 1.3.
A l l t h e d e v i c e so r e e x p e n d o b l eo n d t h e y h o v e
t o b e r e p l o c e dw i t h n e w u n i t s i f d e f e c t i v e .
All the switches ore of the contoct type,
s p e c i o lt y p e s o n d e x c e p t i o n o lc o n n e c t i o n so r e
m e n t i o n e di n t h e f o l l o w i n g t e x t .
o) Switch of porking lights ond heodlights
(feeder of chonge-over switch of these
lights)
The switclr is fostened to the instrument
ponel by o nut with o wosherunderthe push
b u t t o n .W h e n i n s t o l l i n gt h e s w i t c h , t u r n i t s o
t h o t i t e n g o g e si n t h e l o c k i n g s l o t s . T h e p u s h
b u t t o n c o n b e r e m o v e db y p u l l i n g i t o f f o n d
r e f i t t e d b v p r e s s i n gi t d o w n .
b) Heoter switch
T h i s i s f o s t e n e d i n t h e s o m e m o n n e ro s t h e
s w i t c h s u b o ) . A c c e s st o t h e s w i t c h b o d y c o n
b e g o i n e d b y r e m o v i n gt h e c e n t r e p o n e l o f t h e

194

:"

F i g . 1 3 . 1 7 1 1A- d i u s t i n g E l e m e n t s o f D i r e c t i o r r
Device
l n d i c o t o rS e l f - c o n c e l l i n g
1 - Centering pin of the left-hond switch or
mork on the switch foce, 2 - Boss on the bush
foce,3 - Driver

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Switching reloy

13.18 FOG LAMPS AND OTHER OPTIONAL

EQUIPMENT

U s e o s w i t c h i n gr e l o y o f t h e s o m e d e s i g n o s
f o r t h e o u x i l i o r yh e o d l o m p s( o n c o r s w i t h t w i n
heodlomps) or onother reloy operoting in the
some woy. Any ploce con be chosen for its incorporotion into the circuit.

Fog lomps
The fog lomps ore optionol equipment.When
f itting them on the cor, refer to the wiring diog r o m w h i l e o b s e r v i n gn o t i o n o l r e g u l o t i o n s( i n ternotionol regulotions hove not yet been unified os for os individuol requirementsore concerned) ond the following informotion. In
Czechoslovokio,the Decree No.100/1975of the
Book of Stotutes, porogroph 51, is opplicoble.

Cobles
For worning lomps ond the reloyswitching
circuit use cobles with o section of 0.75 mm2,
for the remoining electricol equipment 1.5 mm2
section cobles.
R,ELAYSWITCHING OF HEADLAMPS
Optionol equipment moy include on incorporc r t e dr e l o y f o r s w i t c h i n g i n t h e h e o d l o m p s .I n
some countries (for exomple Sweden), this
reloy is required by regulotions. For the res p e c t i v ec o n n e c t i o n ss e e t h e f o l l o w i n g w i r i n g
diogrom.

;;---A.i'
t..[9-+'--'o
B

5-l l

r369

1L7

F i g . 1 3 . 1 81i - W i r i n g D i o g r o mo f F o g L o n t p s
1 - S w i t c h , 2 - F o g l o m p s ,3 - W o r n i n g l o m p ,
4 - Switching reloy (A - reloy closing circuit,
B - f o g l o m p sf e e d i n gc i r c u i t ) , 5 - F u s e N o . 1 o f
cor electricol equipment,6 - Fuse No. 4 of cor
electricol equipment, 7 - Fuse No. 7 of cor
electricol equipment, 8 - Fog toil light, I Switch of fog toil light, 10 - Wcrning lomp
I
I
I

l';

1L7a

DK 1582

- Wiring Diogrom of Heodlomps

Fig. 13.1812
U s i n g S w i t c h i n g R e l o y- o d d i t i o n o l i n c o r p o r o t i o n i n t o t h e b o s i c e l e c t r i c o le q u i p m e n t
(Fi9. 13.1/1)
147 - Reloy of moin heodlomps
1 4 7 o - R e l o y o f o u x i l i o r yh e o d l o m p s

Switches
I n s t o l lt h e m o n t h e o u x i l i o r yp o n e l ( s t o n d o r d
port of the cor) under the focio. Use the switch
w i t h t h e b u i l t - i nw o r n i n g l o m p f o r t h e t o i l l i g h t .
Worning lomps
Use the unconnectedgreen wo,rninglomp in
the instrumentponel for fog lomps;the worning
l o m p o p p e r t o i n i n gt o t h e t o i l l i g h t i s b u i l t - i n
in the switch.

Heated Rear Window (1979 on)

Circuit
Divide into two sections.
1. Heaterswitch with five positionsfrom left
to right.a) Heatedscreen b) off c) High speed
fan d) Slow speed fan e) Slow speed and
heated screen.
2. Power supply.

196

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1t . 1- 1 4 . 3

surfoces ore sproyed with o Protective com'

p o u n d .T h e f l o o r b o o r d s i n c l u d i n gt h e f l o o r o f
the boot ore coveredwith textile corpets while
r u b b e rm o t s o r e u s e d i n S k o d o 1 0 5 S . T h e i n t e r i o r l u g g o g ec o m p o r t m e n ti s l i n e d w i t h i n s u lotingfelt sheet.
f n e b o d y f i n i s h c o n s i s t so f s e v e r o ll o y e r so f
speciol onti-corrosivecootings, o primer coot,
ond o synthetic boking enomel top coot in
c o l o u r sc o m p l y i n gw i t h o s p e c i o ls p e c i f i c o t i o n .
14.1 BUMPERS
To Remove Front BumPer
D i s c o n n e c tt h e l e o d s o f t h e h o r n o n d f r o n t
direction indicotors. Remove bolts connecting
t h e s i d e s e c t i o n so f t h e b u m p e rw i t h t h e w i n g s
ond bolts of the bumper brockets,connecting
them to the wheel splosh guords.Now the
e n t i r e b u m p e ri s f r e e o n d i t c o n b e r e m o v e d .
Te Remove Reor BumPer
Proceedin the some woy with the exception
t h o t t h e r e o r e n o l e o d st o b e d i s c o n n e c t e d .
To Remove Overriders
Screw off the nut M 10 ond lift owoy the
overrider.
14.2 WTNGS
To Remove Front Wing
First remove the front bumper (see Chopt e r 1 4 . 1 ) ,t h e f r o n t d o o r ( s e eC h o p t e r1 4 . 5 ) ,o n d ,
i n t h e c o s e o f t h e l e f t - h o n dw i n g , t h e b o o t l i d

(see Chopter 14.3). lf the door sill is covered

with o trim moulding,loosen this moulding
portiolly.
Now remove the bolts fostening the wing to
t h e b o d y w o r ku n d e rt h e s i l l ( f r o m u n d e r n e o t h ) ,
on the side edge of the body post, in the chon'
nel next to the boot, ond in the forebody under
the heodlomp.
To Reinstqll Front Wing
lf the seol strip in the front Portof the wing
i s d o m o g e d ,r e p l o c e i t w i t h o n e w o n e , o n d
stick it on if it hos got unstuck. Pock olwoys
o new seoling strip between the wing edge ond
t h e b o d y f r o m e w o r k .T h e n i n s t o l l t h e w i n g i n
p o s i t i o no n d l o c o t e i t b y t i g h t e n i n gs l i g h t l y t h e
c o n n e c t i n g( f o s t e n i n g ) b o l t s . D o n o t t i g h t e n
the bolts firmly before hoving fitted properly
the wing.
14.3 BONNET AND BOOT LID
Removing Boot Lid
Remove the nut ond bolt of the strut ond
the screws fostening the hinges, ond lift owoy
t h e c o m p l e t el i d .
Removing Engine Bonnet
Slip the bonnet strut out of its guide, screw
o f f t h e n u t s o f t h e h i n g e f o s t e n i n gb o l t s , o n d
lift owoy the bonnet.
Reinstollotion ond Adiustment of Boot Lid
ond Engine Bonnet
Instollthe lid (or bonnet) over the luggoge
( o r e n g i n e ) c o m p o r t m e n to n d t i g h t e n l i g h t l y
the bolts ond/or the nuts of the hinge bolts.
Moke the lid (or bonnet) fit perfectly with the
edges of the bodywork by shifting the hinges
in their respective holes os necessory, ond
tighten fost the bolts ond/or nuts of the hingesAssemblethe strut of the boot lid.
Boot Lid Releose Rod ond Engine Bonnet
ReleoseCoble

- e m o v i n gF r o n t W i n g - o r r o w s
Fig. 14.211R
i n d i c o t ef o s t e n i n gp o i n t s

The releose rod of the boot lid (Fig. 1.3113)

is connected with the reloy link by meons of
o p i n o n d f o r m s o n o s s e m b l yu n i t w i t h t h e l i d
locks. The hondle of the releose rod con be
removed ofter pushing out the pin. The entire
ossemblycon be lifted owoy ofter removingthe
lid locks.
Reverse this procedure to reinstoll the os'
s e m b l y .T i g h t e n t h e b o l t s o f t h e l o c k s l i g h t l y
ond fit the lid properly in positlon. Now odiust

202

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9't t-'tt

l o c k a r e w o r k i n g a n d e n s u r i n gd o o r i s n o t
being stressed by excessivetension up or
down, in or out.
A d j u s tt h e d o o r c a t c ht o e n s u r ew h e n t h e d o o r
i s c l o s e d ,i t w i l l n o t r i d e u p o r d o w n '
E n s u r et h e d o o r d o e s n o t c a t c ht h e d o o r p i l l a r ,
w i n g , o t h e r d o o r e t c . ,w h e n b o t h a r e o p e n o r
closed.
Door top half
lf you-havecorrectlyadjustedthe bottom half
of thb dooryou mayfind that the window frame
t o p h a l f s t i l l n e e d sa n a d j u s t m e n t .
Here it will be necessaryto lower the moving
w i n d o w a n d c a r e f u l l yb e n d t h e f r a m e o f t h e
window to match the frame of the door'
F i g . M 5 1 1 - P r i s i n go f f D o o r P o n e l
W h e n i t i s r o i n i n g o r w h e n w o s h i n gt h e c o r ,
woter runs down the gloss ond penetrotes
i n t o t h e i n n e r s p o c e o f t h e d o o r .T h e f o i l i s
supposedto prevent the forming of underpressurein the cor interior ond to prevent
the woter from sookingthe interior trims ond
r u n n i n gd o w n i n t o t h e c o r . T h e r e f o r ei,t h o s
to be stuck on by rubber cement os shown
i n F i g s .1 4 . 5 1 2o n d 1 4 . 5 / 3( c r o s s h o t c h i n g ) .
First slip the lower port of the insulotion
( f o i l ) , t h e i n n e r e n d , i n s i d et h e d o o r ,o n d
t h e n o p p l y o s e o l i n g c o m p o u n do n t o t h e
t onel ond the insud o o r i n n e r m e t o l - s h e ep
l o t i o n o s i n d i c o t e di n t h e i l l u s t r o t i o n( b l o c k
dots) .
C l o s eb o t h d o o r s o n t h e s i d e t o b e a d j u s t e d
a n d v i s u a l l ya s s e s sw h i c h a r e a so f e a c h d o o r
r e q u i r e r e - p o s i t i o n i n gt o p r o d u c e a n e v e n
c o n t o u rj o i n i n g t h e f r o n t a n d r e a rw i n g b o d y
l i n e s i n r e l a t i o nt o t h e d o o r h e i g h t s .
With carefuladjustmentof hinges,satisfactory
body linescan be obtained.
H i n g e sc a n b e m o v e do n t h e d o o rp i l l a ri n t h e
following ways.
1 . U p a n d d o w n a f t e rs l a c k e n i n gb o l t s .R e s u l t :
height of door in relationto door ap_erture.
2 . I n a n d o u t a f t e r s l a c k e n i n gb o l t s . R e s u l t :
Position of the door leading edge in
relationto bodY aPerture'
3 . S h i m s P t . N o . 11 3 - 9 8 B 9 O O b e t w e e n
h i n g e sa n d p i l l a r
a ) S h i m su n d e rb o t h h r n g e sm o v e st h e d o o r
the gap between
rearwardsand increases
the door leading edge and the wing
( F r o n td o o r ) .
b ) S h i m su n d e rt h e b o t t o m h i n g eo n l y ,w i l l
lift the lower edge of the door.
c) Shims underthe top hinge only, will
have the reverseeffect.
I t i s s o m e t i m e sp r e f e r a b l teo r e m o v et h e d o o r
catch(On pillar)to removemisleadingstresses
b e i n g p l a c e do n t h e d o o r .T h i s p a r t b e i n g r e fitted and adjustedso that both stagesof the

Fig. 14.4/14
Common Areas the Door Touches

Front Door lnsulotion- ":t;

Fig. 14.512h o t c h i n g i n d i c o t e sw h e r e r u b b e rc e m e n th o s t o
b e o p p l i e d ,b l o c k d o t s i n d i c o t e s e o l i n g c o m '
poundopplicotion

204

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Door Cotch Retoiner

The position of the door cotch retoiner on
the door pillor ond/or the reor wing foce con
be odiusted within certoin limits ofter loosening its fostening screws. Adiust the retoiner
in the requiredposition,check the door for correct closing ond fitting with the other ports of
the bodywork, ond then retighten the screws.
The door cotch must slide on to the leodlng
surfoceof the retoiner so thot it rests ogoinst
it.
Sometimes, it moy be necessory to ploce
o pocking piece under the retoiner (to prevent
the fouling of the door cotch pin). ln such
o cose, mork the position of the cotch on the
bodywork, slocken the screws, ond instoll o
pocking piece under the retoiner slipping it
over the lower screws ond tipping it into position on the upper screws.
It is importont to observe the correct ongle
of the inclinotion of the retoiner leoding surfoce, which hos to correspondwith the incli.
notion of the beoring surfoceof the door cotch
(outer door lock). Therefore,fosten the bose
plote of the retoinerso thot its upright stiffener
is porollel with the edge of the mouldedrecess
for the retoiner on the door pillor ond the reor
wing.
The leoding surfoceof the retoineris provided
with o friction plote. In the cose of domoge
(excessiveweor, impoct of on incorrectly odiusted door, etc.), prise off the originol friction
plote ond fit o new one. lf the frictionplote is
l o c k i n go r i f i t i s e x c e s s i v e l yw o r n , t h e d o o r i s
opt to rottle.

rubber moulding using o suitoble tool. Now

press corefully ogoinst the gloss from inside
the cor ond slip the liP of the glozingrubber
moulding step by step over the edge of the
windscreenor window frome olong its entire
circumference,ond finolly lift owoy the gloss
together with the glozing rubber moulding.
To Refit Windscreen ond Reor Window
F i r s t c l e o n t h o r o u g h l yt h e e d g e s o f t h e g l o s s
ond of the window opening (frome). Slip the
g l o z i n g r u b b e r m o u l d i n go v e r t h e e d g e s o f t h e
gloss.
lnsert o twine with o smooth surfoceor, pre'
ferobly,o rubber insulotedcoble of 2.5 to 3 mm
in diometer into the inner groove of the glozing
r u b b e rm o u l d i n g .

F i g . M . 6 l 1 - F i t t i n g G l o z i n gR u b b e rM o u l d i n g
on o GlossPone

- Door Cotch Retoiner

Fi1.14.514
14.6 WINDSCREEN,REAR WINDOW,
S I D EW I N D O W S
To Remove Windscreen ond Reor Window
- Insertingo Twine into the Groove
Fig.14.612
o f t h e G l o z i n g R u b b e rM o u l d i n g

Rernovethe connection of the spocing Insert

o n d l i f t o w o y t h e s p o c i n gi n s e r t o f t h e g l o z i n g

206

LOe
(lsod erluec 1o lrod .reddnu! Mercs prlql)
lsod elluac
e q l l o s l n u p u D s M a : c s 6 u r 1 s n l p o 7 6 u ! u e l s-otJ
p o . r1 1 n de l p u o q r o u t r l- Z
( p o : 1 1 n d )l u r l l o r l u o c q c l D l r e u u l - I ,
s M e r c s 6 u r l s n l p y T 6 u l u e l s opJu D
e 6 o 1 u 1 1l o r l u o C r o o C l] u o l l - g / g ' t L ' 6 l l

a c ! ^ a c l u ! - > l c D dL 9 L - 8 d 1 ^]l o p r v e L l l
r l l l n l r+ r a s u l 6 u l c o d g 6 u 1 1 . r a s u- ; g i t l t L ' 6 l J

dun4 ;91-g 66;

t i L r 1 s 1( f"s1! u r D nl t O , o u o 1 l o c 1 1 d d- yV l g ' V L ' b l J
s l n u u M o p - p 1 o qs 1 1 6 u r
-nourgrJeuo AoMo pell!l eq uD3 JaPurMMoPUTM
eqf 'aurDJl Joop eqt q6no.rql leuuDqc 6u11.rod
-dns s11 qllrvr ssol6 eql MDrpqll4,q 'lsod orluao
e q l o n o t u e J p u D l n o 6 u r r v r su a q l p u D ' l s o d s . r l u a c
aql to yod .reddn eql u! errDr' roop eql
tuo.rl (paldnrralu!) d1.r1sraq1oeM
eql tno sserd
lsod arluac eql ul 11orepgn6
sll,o ]no t! sse:d puo elqlssod sD rol so sso16
a q l l a M o l M o N ' s s o 1 6a q l o u l u o d d n s l e u u o q c
er{l uor} rapulrvr eqt e6o6ueslp puo lvtop
-ulrlrreql rslvro'l 'lsod e:luec aq] ,o ({11,roc toop
eql ul sr lnu aql) lnu eql puD s]loq alll a^oul
- a J o l p a e c o r 4 ' ( s - r o o p l u o J l a q ] r u o . t 1l ; u o a ; q o
- A o r . r t asr g l r o . r a p r n Br e l r o q s a q l ) ; r o r a p t n 6 a q l
A o r * o 1 1 1 9p u o ' d r . r l s r a q l D e M a q ] l n o s s a : d ' 1 1 o . r
- o p r n 6 J e t r J o q sa q l 6 u ! u e l s D ] M a J c s e q l e n o u r e u
'o6
1 1 1 ml ! s D r D l s D M o p u l M o r l l d n p u t M u e q ]
p u o D u l t u r u r J lr o o p e q l a n o u e J ' l l o j o l s J l J

6 u r u e d g A p o g a q 1 1 o e D p 3a q 1 r a n o
d r 1 6 u r p l n o n r e q q n U a q l 6 u r d d 1 l-gg g V L ' 6 t J

s r v \ o p u l n 1r o o 6 1 s n l p y p u o ' l 1 o 1 s u g o 1 ' e l o t u e u o l
' e c a 1 d6 u l l c e u u o c a r l l
q l l M d D D 6 u g u 1 o !a q l r a ^ o c p u o e c ! ^ a p u t - 1 c o d
L g ! - g d t ^ e q l l o p r o a t l l q 1 ; M 6 u 1 p 1 n o ur e q q n , r
6urzo16 aql olu! lresur 6ulcods eql ]rasul
'dund
L 0 L - 8d t 4 l e q + j o
o s n e q ] q l l M s s D l 6 a q l p u D 6 u 1 p 1 n o ur e q q n r a q l
u e o M l e q q s ! u J D ^ l l o 6 u 1 c . r o 1A q l q B l l l a q l o a r u t
MopurM JDel pLrD uoejcspurM aql a)olA
' a n o o . r 6e q ] u o J + o l q o o a L l l
A 1 l o n p o . r 66 u r M D r p L l l ! r ' rr t q 6 u l u e d o a q l 1 o a 6 p a
a L l ] r e ^ o d e l s A q d a l s 6 u l p 1 n o u rr e q q n r a L 1 1
1o dtg
a q 1 d 1 1 sp u o J o c a q ] o l u t l e e ' a P t s l n o t u o l ; i p o q
a q l l o 6 u g u e d o e n g l c e d s a . er L l l o l u o 6 u 1 p ; n o u
r e q q n r 6 u 1 z o 1 6a q l q l l r * s s o 1 6e q l s s e r d r u o 1 1

rsr y0

Reversethe dismontling procedure to rein'

stoll tl-rewindow ond its winder. The loterol
ploy con be odiustedby odiusting (swinging
the
out) the centre post ofter hoving loosened
'14.6/6
ond/
respectivebolts ond nuts - see Fig.
or 14.617.
Use this occosion to lubricote inner door
mechonisms- see Chopter 15.12.

12345-

- Reor Door Control Linkoge

Fig.14.617
ond Fostening/AdiustingScrews
Innerlotch control link (short)
Reloy lever
lnnerlotch controllink (long)
I n n e r h o n d l ep u l l r o d
Fostening/odiustingscrews ond nuts of the
centre post
(third screw in upper port of centre post)

- l !

5 4 1 7- S

3 . W h e n b o l t i n gt o g e t h e rt h e r e g u l a t o rd r i v i n g
p l a t ew i t h t h e w i n d o w g l a s sc h a n n e lm a k e s u r e
t h a t t h e h o l e s i n t h e s e t w o p a r t sc o i n c i d ea l o n g
t h e w h o l e l e n g t h o f t h e c h a n n e l .l f i t i s n o t s o ,
move the channel into a satisfactoryposition.
4. lf the regulatoris not lubricated,lubricatethe
r e g u l a t o rc a b l e i n t h e t u b i n g w i t h g r e a s e a n d
a p p l y o i l t o t h e r e g u l a t o rc r a n k s p i n d l e .

Repair of Window Regulator Defects

l f t h e w i n d o w s a r e d i f f i c u l tt o w i n d u p a n d
down (the maximum torque applied on the
s p i n d l e o f t h e w i n d o w r e g u l a t o rw i t h t h e g l a s s
i n s t a l l e di n t h e d o o r s e x c e e d s2 . 5 N m ) ( 1 . 7 7 t t
l b s ) ,i t i s r e c o m m e n d e dt h a t t h e f o l l o w i n gs t e p s
aretaken as regardsboth the front and reardoors:
1 . D i s c o n n e c t h e r e g u l a t o rd r i v i n gp l a t ef r o m
t h e w i n d o w g l a s sc h a n n e l .P u s ht h e g l a s su p w a r d
and try the relieved regulator by turning the
regulatorcrank. lf the regulatordoes not work
s m o o t h l y( j a m m i n g ,r a t t l i n g )o r i f a t o r q u eh i g h e r
t h a n O . 7 N m / ( O . 4 9 5f t l b s ) i n f r o n t a n d 1 . 1
Nm/(0.78 ft lbs) in the rear is required for its
operation,replacethe whole regulatorwith a new
one working satisfactorily.
2 . A d j u s tt h e c e n t r ep i l l a rp o s i t i o ni n t h e d o o r
u s i n g t h e j i g a s p e r d r a w i n gN o . A 1 - 15 4 1 7 - S .
Loosen the top screw of the centre pillar and
retighten it while pressing the centre pillar
a g a i n s t h e w i n d o w g l a s sw o u n d u p t o i t s u p p e r most position. Loosen the bottom screw of the
c e n t r ep i l l a r a n d r e t i g h t e ni t w h i l e p r e s s i n gt h e
c e n t r ep i l l a ra g a i n s tt h e w i n d o w g l a s s .

208

To Removeond Reinstoll Reor Door Fixed

Window
Agoin remove first the door trimming. The
gloss is only inserted into the door frome ond
supportedby o bolted-down holder with o rubber pocking piece. The gloss con be moved in
the door covity ond withdrown through the
door frome.

14.7 TRIMMING UPHOLSTERY

AND WEATHERSTRIPS
Ponel-typeTrimming
This type of trimming is used for the doors see Chopter 14.5,Fig.14.511-ond for the front
ond reor window posts. Ponel-type trimming
f o s t e n e db y c l i p s ( f l e x i b l es p o c i n gp i n s ) c o v e r s
olso the porcel troy below the reor window, the
outer guideroils of the front seots, the front
wheel orches, ond the focia. On centre posts,
the trimming is fostened by screws.

flu

602
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6',il-l'tl

softened by odding 2 to 2.501sof sodo, then

with o solution of chromium trioxide (1 gr. to
1 litre of soft woter) heoted up to 80oC (thls is
the so-colled possivoting rinse). Now let the
spot dry.

the ploces from which you hove removed the

sticking dirt ogoin, ond wipe the entire bodywork diy, including chromium'plotedports,with
chomois leother. Wosh ond wlpe dry the vor'
nished surfoces with uniform strokes in one
direction, i. e. not by circulor movements.
After hoving wiped oll vornishedports of the
b o d y w o r kd r y , p o l i s ht h e m w i t h o s o f t ( f l o n n e l )
d u s t e r .D o n o t u s e p o l i s h o f o n y k i n d .
lf the bodywork is so dirty thot it connot be
woshed cleon with woter, use cor shompoo.
lf it is necessoryto refreshenthe gloss of the
finish, use o cor polish occordingto instructions
of its monufocturer.
To wosh the underbody, use o hose ond
running woter, worm or cold; never use petrol,
kerosene,diesel oil, etc.
Remove greose spots with o cloth, dry or
To removetor, dip
sooked in petrol if necessory.
the cloth in keroseneor o speciol tor removing
preporotion,ond rub the spots.Then immediotely
wosh owoy oll troces of kerosene or the tor
r e m o v i n gs o l u t i o n ,o n d r e p o l i s ht h e s p o t s w i t h
o cor polish.

Degreosing
Degreose the spot to be touched up by rubbing it down with trichloroethyleneor technicol
petrol.
1. Touching-up with low-boking points the most perfect procedure

TOUCHING.UPVARNISH
Preporotion:
Removol of Polishes etc.
I

x
li
I

I.t

When touching up o repoiredbodywork (domoged surfoce finish), it is importont to olso

cleon the surroundingvornish to prevent the
t o u c h i n g - u pp o i n t f r o m f l o k i n g o f f l o t e r o n i n
ploces of overlopping.
R e m o v ec o r p o l i s h e sw i t h o s h o m p o oS
. ilicone
o i l , c o n t o i n e di n s o m e b r o n d s o f p o l i s h e so n d
preventing the odhesion of the touching-up
point, con be woshed owoy only with o speciol
preporotion. !n Czechoslovokio, this is for
e x o m p l eV E N E D I N .R u b w i t h t h i s p r e p o r o t i o n
olso vornished oreos which will be roughened
by grinding where the bore ploces poss into
ground ond cemented oreos.
Removol of Rust
R e m o v e r u s t m e c h o n i c o l l yb y g r i n d i n g o r
rubbing with emery poper ond woshing with
c derusting ogent (for exomple SK 2, which is
bosicolly o 300/s phosphoricocid).
Procedure:f irst cleon the rusty spot with
e m e r yp o p e r N o . 8 0 o n d 1 0 0 o r u s i n g o g r i n d e r .
Then rub the spot with o 150/6 solution of
phosphoricocid (SK 2 deruSter) heoted up to
4 0 o C .W h e n u s i n g o c o l d s o l u t i o n ,i t s c o n c e n trotion must be obout 300/e (undiluted SK 2
deruster).Work in rubbergloves.
After hoving removedthe rust, wosh the spot
twice. First with tepid or cold woter, soft or

o) Cleon the touched-up spot, derust ond

degreoseit (see the previousporogrophson
preporotion)
b) Sproy over with priming point
c) Let the priming point dry ot 80oC to 110oC
for o period of 50 or 15 minutes (50 minutes
o t 8 5 o C ,1 5 m i n u t e so t 1 1 0 o C )
d) Coot over with synthetic cement or polyester cement
e) Let the cement dry ot 85oC or 110oC for
o period of 50 or 15 minutes respectively;
when using polyester cement, the drying
period con be shortened- this cement dries
of normol temperoture
f ) Grind under woter with emery poper No.280
to320till the spot is perfectly flot ond even,
ond let it dry
g ) S p r o y w i t h t o p - c o o tv o r n i s h
h) Let it dry ot 80oC to 110oC for o period of
15 or 50 minutes respectively;ofter boking,
the vornishhos o high gloss ond it is not
necessoryto polish it
i) Use o polish to remove ony visible troces of
tronsition between the originol ond the new
vornish.
2. Touching-up with nitro-combinotion vornish
o) Cleon, grind, derust, ond degreosethe spot
to be touched up
b) Apply priming point with o brush or o
sproy-gun
c) Level up, if necessory, with on oil-bose
cement (once or twice)
d) Let it dry lor 24 hours ond then grind with
emery poper No.220
e) Sproy the entire touched-up oreo with
sproyingcement ond let it dry for 24 hours
f) Grind with emery poper No. 280 ond 320
under woter till the oreo is perfectly smooth
ond flot, ond let it dry
g) Sproy the touched-upspot with o vornish
prepored by mixing low-boking ,vornish
(Toolol ond touching-upvornish (300/e);use
exclusively o nitro-thinner for diluting the
vornish

210

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l4.ll-14.12

has two anchoring points. The seat belts have

anchoringbolts on the size 7/16-20 UNF-2A'
In front, the anchoringthreads are easily
accessible being provided on the door posts
(removeonly one of the pair of pins coveringthe
thread),on sills below the posts,and on the sides
o f t h e ' f l o o rt u n n e l b e h i n d t h e f r o n t s e a t s '
Anchoringpoints for rearseat belts are shown
in the illustation.For the seat belt of the person
s i t t i n g i n t h e m i d d l e ,t h e t h r e a d sa r e u n d e r t h e
seatcushionsand ratherremovedfrom eachother
(A3). For the seat belts of personsoccupyingthe
butsideplacesthe threadsare also under the
cushions,nearerto the centre (A2), in the body
s i d e s c l o s e t o t h e c u s i o n s( 8 2 ) , a n d i n w i n d o w
pillars(C2).These latterthreadscan be found by
touch in the point of intersectionof the plane
p a s s i n ga b o u t 1 6 5 m m a b o v e t h e r e a r w i n d o w
parceltray and in parallelwith the door frame at a
distanceof about85 mm. To gain accessto them,
it is necessaryto cut through the trimming.
We must stressthat for the fitting of points A2
and A3, the bolts should not protrudebeyondthe

F i g . M . 1 1 l 2- L o w e r A n c h o r i n gP o i n t s
14-12 FACIA
l - h e f o c i o c c t l b e r e n t o v e do t t e r u n s c t - e w l l l g
ifting
l o l t s o n d o f t e r l '13'15'
the nuts of its peripherob
see
Chopter
ponel
instrument
owoy the
It is olso necessory to remove the steering
wheel with the shroud of the steering wheel
shoft (see Chopters7.7 ond 7.8), ond the heoter
c o n t r o l p o n e l ( s e e C h o P t e r1 1 . 0 ) .
The bolts holding down the focio ore occessi b l e o f t e r r e m o v i n ! t h e i n s t r u m e n tp o n e l o n d
the heoter control ponel, ond ofter swinging.out
the glove box. To swing out the glove box,
o p e n i t s l i d o n d l o o s e nt l r e s c r e w so f i t s s t o p s '

F i g . 1 4 . 1 2 1-1F o c i o M o u n t i n gP o i n t s

- Upper Anchoring Point

Fig. 14.1111
captive not more than 1lz mm or there is every
l i k e l i h o o do f d a m a g i n gt h e f u e l t a n k .
The depth of the nut from the mountingface is
15 mm.
Child seat fixing
instructions
Followthe seat belt manufacturers
as to the spacing of the belt straps.
The straps can be mounted to the rear parcel
s h e l fi f t h e m o u n t i n gh o l e sa r ed r i l l e d3 0 m m f r o m
. h e s o u n dd e a d e n i n g
t h e f r o n t e n g i n eb u l k h e a dT
t ill needto be
t r i m i n t h e e n g i n ec o m p a r t m e nw
lowered to fit the spreadingplate and nut.
Be careful when drilling the shelf, not to
scratchthe rear screen.

14.13 WATER LEAKS

To determine the source of a water leak
proceed in a progressivemanner.
1 . D e t e r m i n ea r e a w a t e r f i n a l l y r e s t s '
2. lf possiblefollow water trace to source'
3. lf hot, remove carpets and clutter'
4. Dry car inside and out'
5. Us'ea sprinkler ratherthan a hose jet'
6. Start on the underside of the vehicle and
work up. Do not do any adjustments or
sealing until after the first test.
7. When"you have finished adjustments and
s e a l i n gR E T E S T .

212

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2. WINDSCREENS
W i n d s c r e e ns e a l i n gi s i n f a c t s e a l i n gt w o j o i n t s
t aysand
a n d t h e y s h o u l d b e t r e a t e di n d r f f e r e nw
as separatejoints.

14.13,2 WATER LEAKS INTO THE

P A S S E N G E RC O M P A R T M E N T
1 . I N G R E S SO F W A T E R F R O M T H E F R E S H
AIR BOX

1 . G l a s st o G a s k e t
2. Gasketto body.

'^'i-T
/c^sKEr
{af
Fit expanding cable here
(b)

Fis. 14/13.5
a) Box drain tubes (One eitherside of car) Pt No.
11 3 - 7 9 0 9 7 0 i f p e r i s h e d r e p l a c e , s e a l i n g
r u b b e rt o m e t a l w i t h c l e a r m a s t i c .
b) Heater bleed tube/speedometer cable
grommets. lt is suggested that the original
g r o m m e t sa r e r e p l a c e dw i t h d o m e d g r o m m e t
PtNo.113-793801.

EXISTING
GROMMET

Fig. 14.13/8
1 . T h e j o i n t b e t w e e nt h e s c r e e na n d t h e r u b b e r
i s s o m e t i m e sf a c t o r ys e a l e dw i t h a s e a l a n vt a r n i s h
w h i c h h a r d e n sa n d w h e n d i s t u r b e ds h a t t e r s a; n d
t h i s i n t u r na l l o w sp a s s a g e fso r w a t e r f r o mo u t s i d e
. p p l i c a t i o no f g l a s sm a s t i cs e a l e r
t o t h e i n t e r i o rA
will drive out the water and seal the joint' lf,
however,this is not achievedit will be necessary
t o r e m o v et h e r u b b e ra n d c l e a nt h e s e a lf a c e sa n d
t h e g l a s s i n o r d e rt o e n s u r et h a t t h e j o i n t c a n b e
made.
T h e e x p a n d e ro f t h e 1 0 5 / 12 0 r a n g es h o u l d b e
fitted to the rubber after fitting the glass and
r u b b e rt o t h e b o d y u s i n g s p e c i a lt o o l M P 8 - 1 6 1 .
Carefullyfit the rubberto the glass,stretching it
e v e n l ya r o u n dt h e w h o l e g l a s sa n d n o t s t r e t c h e d
over the last side/cornerto be fitted.

U S EO F P T N O 1 1 3 - 7 9 3 8 0 1

Fig. 14.13/6

" : I
II
I
i

T h e d o r n e s h o u l d s t a n d u p i n t h e a i r b o xa n d
s h o u l db e p a r t i a l l yf i l l e d f r o m i n s i d ew i t h D u m
Dum.
T h e g r o m m e t s h o u l d b e s e a l e dt o t h e b o d y
u s i n gc l e a rm a s t i c .
l a s eu s i n gD u m
d i J a c k s o c k e t .S e a lt h e t e r m i n a b
D u m .T h e b a s e s o c k e t ss h o u l db e s e a l e dw i t h
c l e a rm a s t i c .
d) Water entering through Centre of heater. The
cover plate over heater, motor fan if it is not
f u l l y b u t t e d a g a i n s tt h e s h u t t l e( i e . a g a p ) s e a l
with
e) Bodyjoints insideairboxto innerwing. Ensure
s e a l a n tc o v e r sa l l j o i n t s u p t o t h e u n d e rs i d e o f
t h e s c u t t l ep a n e l .

F i g .1 4 . 1 3 / 7

After f itting the screen/rubber assembly,

e n s u r e t h a t t h e g l a s s i s c e n t r a l i s e di n t h e
aperture.
T h e e x p a n d e rc a n n o w b e f i t t e d u s i n g M P 8 1 6 1 e x p a n d e rf i t t i n g t o o l .
2 . T h e s e c o n dj o i n t i s b e t w e e nt h e r u b b e ra n d
the body.We must stressthat there are two areas
o f t h i s j o i n t , o n e ( a ) i s a w a t e r d r a i nc h a n n e la n d
the second (b) servestwo duties of holding the
glass in the apertureand stopping the ingressof
water into the passengercompartments.
T h e w a t e rd r a i nc h a n n e lm u s t n o t b e f i l l e dw i t h
a n y s e a l a n ta n d t h e d r a i nh o l e sa t t h e b a s eo f t h e
apertureshould be free of obstruction.
T h e w a t e rs e a l i n gp r o p e r t i e so f t h e j o i n t c a n b e
re-inforcedby the applicationof mastic sealant
into the joint (b) shown in the diagram.
Test for water leaks
Spray water onto and around screen being
t e s t e d ,l i n g e r i n ga l o n g t i m e i n a l l p o s i t i o n s ,t o
ascertain the point of entry. Determine it is
c o m i n g f r o m t h e g l a s s r u b b e rs e a l o r t h e r u b b e r
body seal then correct the leakage.

214

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216

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l'gL

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qclnlc

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puo sluocuqnl pepueuruoceu z'gl

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sll puo eu16u3 g'St

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aql qllM JDc eql lo :aAnq aql ol Je^o papuDq
l o o g J e q c n o ne c ! ^ r e s e q l u ! l l l o n p ; n 1 p u lP e ! ]
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t'91

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Czechoslovokoils
PP 90 (SAE 90) geor oil; PP 80 (SAE 80)
geor oil

tificotion number, or in words. For exomple

Mobiloil 30 is on oil in the SAE 30 viscosity
closs, Mobiloil Speciol belongs to the SAE
10W/30 closs. We quote the viscosity closs
s y m b o lo f o i l s i d e n t i f i e di n t h i s w o y i n b r o c k e t s
f o l l o w i n gt h e o i l b r o n d ( t r o d e n o m e ) .
Oils designotedby o doubled viscosity closs
symbol ore the so-colledmultigrode oils. Their
c o m p l i o n c ew i t h v i s c o s i t yc l o s s i f i c o t i o ni s e x pressedby the symbol before the froction line
progressivelyto the clossificotionexpressedby
the symbolbehind the froction line. Thus,for
instonce,the SAE 10W/30oil hos the properties
of the sAE 10w, sAE 20w120, ond sAE 30
closs.

Foreign oils
Agip: F. 1 Rotro 140; 85/90; 75Wl8O
BP: Geor Oil 140 EP; 90 EP; 80 EP
Costrol: Hypoy B 140; B 90; B 80
Mobil: MobilubeGX 140; GX 90; GX 80
Shell: Spirox E. P. 140; E. P. 90; E. P. 80 W
Other geor oils of foreign moke con be used
if equivolent o the listedoils.
SPECIALOILS

Czechoslovokoils
Motor oil M6 AD (SAE 30), M4AD (SAE 20W/
20), Mogul Super SAE 20W50, Mogul Speciol
SAE 2OW/30
Modit Oil SAE30 (M6 AD), Modit Oil SAE
2 O W l 2 O( M 4 A D ) , M o d i t O i l S p e c i o lS A E 1 0 W /
30, Modit Super SAE 10W/40

Distributor beorings (service inspection)

Czechoslovokmoke - ON 1 low'pour-pointoil
Foreign moke - for exomple, Shell Clovus 17
o n d s i m i l o ro i l s

Foreignoils
Agip: Agip F. 1 Motor Oil HD SAE 10W/20,
2OWl30, 4Ol5O;Agip F. 1 Super Motoroil
10w/40,20wl50
BP: Energol HD SAE 40, 30, 2OW (2OW|?O),
10W; Super Visco-Stotic 10Wi30, 10W/40,
20wt20
'10
Costrof: Costrol 40,30, 20Wl2O, W; Costrolite
(SAE 10W/30), XL (SAE 20W/50); GTX
(SAE 10w/50)
Mobil: Mobiloil 40, 30, 2OWl2O,10W; Speciol
(SAE 10W/30); Speciol 20W/50;Super (SAE

Woter pump

Shefl; X-10040, 30, 2OWl20,10W; Super (SAE

Clutch releosebeoring
Czechoslovokmoke - SP 4 or NH 2 soop
greose*)
Steering tinkoge boll ioints, cronkshoft beoring
Greoses listed in the porogrophon greosesof
foreign moke

10w/so)
10w/so)

O t h e r o i l s o f f o r e i g nm o k ec o n b e u s e d i f e q u i v o l e n t t o t h e l i s t e d b r o n d s ,f o r e x o m p l e ,A v i o ,
E s s o ,H e n o ( O p t i m o l L D ) , I N A ( D e l t o T L X ) ,
N o f t o g o s( G o l o x G T X , O m n i o ) e t c .
GEAR OILS - type E. P. (high-pressure)
L u b r i c o t i n gn o i n t

I Viscosity j
Ambient
c
l
o
s
s
t
e
mperoture
I
!

sAE 140*) -r50to +15 oC

Georbox/finol
drive

teering box

SAE 90

*35 to -15 oC

SAE 80

* 5 to -30oC

SAE 90

throughout
the yeor

*) Not used in Czechoslovokio

GREASES- use throughoutthe yeor

Czechoslovokmoke - SP 4 sooP greose,NH 2
or A4 motor greose
Front wheel beorings, geor lever brocket
Czechoslovokmoke - SP 4 or NH 2 soop greose
King pins
Czechoslovokmoke - A 00 motor greose
Inner door mechonisms,locking mechonisms
Czechoslovokmoke - SP 2-3 soop greose*)

Greosesof foreign moke:

Agip: F.1 Greose30; BP: EnergreoseL2; Costrol:
Costroleose l. M.; INA: Automost Speciol;
M o b i l : M o b i l g r e o s eM P ; S h e l l : R e t i m o x A ,
o n d o t h e r g r e o s e se q u i v o l e n tt o t h e l i s t e d
ones.
BRAKE FLUID
To SAE J 1703C Specificotion
ln Czechoslovokio- SYNTOL HD 190 broke fluid
Abrood - SYNTOL HD 190,PentosinSuperFluid,
M o b i l H y d r o u l i cB r o k e F l u i d , A T E B l o u , B P
B r o k e F l u i d ,S T O PS P 1 9
r) Greosesof foreign moke should be preferred.

220

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, i l i
I

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iellnDts eql llo /v\ercs
ll IcDd
s6ultDog dun4 rolDn1 lo uollDcllqnl

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ll
'l! MoueJpuo pDeq lloq eq] rapun 6u1.r6u1;oes
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,l
eql
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'uo!lDz!l!qDlssl! reuo
la^el llo eql Iceqcer
p u o e u 1 6 u aa q 1d o l s u a q l ' e 6 o 1 o a ;l o l 6 u ; 1 u n o u
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' l l o q e q t u e l q 6 l t p u o a u 1 6 u aa q l u o J D l l o c
lol
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q11melogdlsnrqt eq]
6u1.rds
prDMol spls s!ql qllM luausle eql u.rn1'(e1ou
u61aro1to slueuele Jotlll euos lo osDc aql s!
qc!qlvr)e1o1deql u! lDas uouoq lDuotltppDuD
q l l M p s p ! ^ o . r ds 1l u e u a l a r e l l l l a q l l l : e t o N
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eql unu 'llo qserl qurlt eu!6ua aql ll!l
l ! o a q l p u o 6 n p du g o l pd r u n sl l o e q l p e l l D l s u l e r
sarleruol!l Jo Jeqrrnu
6u;noq JaUV '(pa11anor1
eql uo Dulpuedep) ouo /l^ou D qllM lueuele
Joll!l aql ecolda: rolpuD lmoq sl! uDelc PUD
roll!l llo eql oslD a^ouleu 'lno /v\oll llo eql lel
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e6uoq9 119
6nta
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'le^al
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te1lo Alalogpauu! le^el t!o eql lceqc lou oC
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11 6u11o1o.r
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'lq6leq ulnulxDtx puD unullu!tu
l!o oqt dn do1
seu!l eql ueomleq 1sn! eq Plnoqs
s116u1>1.rotu
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eql olu! ISolcvle
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' 6 ' a ' ( o 1 > 1 o ^ o l s o q c a zu C
!) SfZSSUJIINV

p r e s s u r eo i r . W h e n d r i v i n g o f t e n o n d u s t y r o o d s ,
i h e c l e o n i n g i n t e r v o l ss h o u l d b e s h o r t e n e db y
holf.
F o r o i r c l e o n e r m o i n t e n o n c ei n t r o p i c o l r e '
gions refer to ChoPter 16.2.
Air Cleoner- winter oPerotion
Removethe rubber cop from the cover extension orm ond use it to stop the mouth of the
o r m . F i t o g u i d e e x t e n s i o ni n t o t h e c l e o r e dh o l e
in the ornr ond insert the corrugotedpoper hose
(includedin the cor equipment) into the exiension ond the holderon the intoke ond exhoust monifold.
G i v e t h e h o s e t h e r e q u i r e ds h o p e b y b e n d i n g
i t s l o w l y o n d c o r e f u l l y .A b o v e o l l , p l o c e i t i n t o
t h e h o l c i e rs o t h o t t h e r e i s o s u f fi c i e n t d i s t o n c e
(wide enoughto insert o finger) between it
t onifold.
c r n dt h e e x h o t - t sm

F i g . 1 5 . 3 / 3- O i l F i l t e r
I -

.'t

oil filter bowl witlr filter element

centre-boll
o i l p r e s s u r es w i t c l r

Tightening of cYlinder heod bolts

T h e c y l i n d e rh e o d b o l t s s h o u l d b e t i g h t e n e d
i n t h e r u n n i n g - i np e r i o d b e f o r et h e g o s k e t g e t s
settled ond then ofter every replocementof the
gosket, i.e., ofter obout 1,000 kilometres' For
itre tightening procedure, s9e Chopter -2'16'
Check'ilg of vilve cleoronce ofter every tighten'
ing of tlie cylinder heod is o routine procedure
which must not be omitted.
Volve Cleoronce
s n d o d i u s t i n gv o l u e s ,
F o r c h e c k i n gp r o c e d u r e o
refer to ChoPter2.13.
Alternotor V'belt Tensioning

F i q . 1 5 3 1 4- L u b r i c o t o ro f W o t e r P u m p B e o r i n g s

oll the greose into the beorings. Tighten the

cop thoioughly so thot it connot be worked
loose by vibrotion.
Air Cleoner - cleoning ond replocing of filter
element
Unclosp the cover fostening clips and lift
owoy the lid. Depress the cross broce in the
it, ond
1ock6t,rotote it slightly to disengoge
c
l
e
on the
W
i
p
e
e
l
e
m
e
n
t
.
withdrow the filter
inside of the iocket, cleon the filter element or
reploce it with o new one, ond reclose the oir
c l e o n e r p r o c e e d i n g i n r e v e r s eo r d e r .
Shoke ond top the filtet element to rid it of
clirt porticles, oncl blow it off ond through with

Loosenthe nuts of the bolts in the olternotor

f l o n g e( f o s t e n i n gi t t o t h e e n g i n e o n d t h e s t r u t )
ond'of itre bottJ holding down the strut on the
olternotor,ond swing oside (tip) the olternotor'
Adiust the belt so thot it gives woy 10-to
15 mm midwoy between the belt pulleys when
d e p r e s s e dl i g h t l y ( o t i f o - w e i g h t o f o b o u t
2 k g w e r e o p p l i e a l w i t h t h e f i n g e ro t t h i s p o i n t '
LoCkthe olternotor in this position by tighteni n g p r o p e r l Yo l l t h e n u t s .
B e l t d i m e n s i o n s9: x 9 . 5 x 1 , 0 O 0m m .
To Cleon the Distributor
The contoct breoker points, the cover, ond
the rotor orm of the distributor must never be
greosy or dirty. Scrope off ony burns on the
distributor cover.
lf you hove cleoned the distributor with
oetrol, do not refit the cover till ofter the petrol
h o s c o m P l e t e l Ye v o P o r o t e d .

222

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6u1u1lsq] ol e1;soddo
roe6 6u;tu1laql uo >1.rou
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los s! Ae11nd
eu;6ua eqt urni '!
eql loql os (11oqs1uo.rc)
:sp!o tnorlllM ernpaco.rd6u;lsnlpy (o
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sl ozl puo 1 ozl vclo)$

rolnqtrlsrC- llt'gL '6tJ

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1 901 PUD S 901 VAO)S

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clsDg ;o lueulsnlpy
ecuDApVuog11u61
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aq1 BuluesoolJelrD Japloq ]cDluoc aq1 6u1nor-u
Aq do6 oql lsnlpD puo 's1u1odralDarq lcDtuoc
aql ueeMleq do6 lcerloo eql ro' g'g1-.to1doq3
ol Jelou 'ruDc llot{s lo}nqlr}slp eq} }o }l!l lln}
eql o] eu16uaeql urnl pLrD'turD .ro1oleq1 'Iro
- s s e c a ul ! ' p u D i a ^ o s J o l n q l l l s l pe q l e ^ o u o u
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so 'ruDcaq] aplsu! llsl aql Puo tuDc aq1 6uo1o
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JoloJ eql PUD Je^oc Jolnqlllslp eq] a^oueu

u o l l o l e d g J a l u l l " ^ .l o ] e s o H P U D
'6ll
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rouqlrlslo oql elDclrqn'l ol

F i g . 1 5 . 3 / 9- A i r - c o r r e c t i o nS c r e w- i d l i n g s p e e d
correction screw

F i g . 1 5 . 3 / 8- D i s t r i b u t o rA d i u s t i n g E l e m e n t s
1 - c o n t o c t h o l d e r ,2 - r o t o r o r m , 3 - c o m ,
4 - distributor brocket,5 - distributor brocket
c l o m p i n gb o l t

To Adiust ldle Run

A l w o y s t u r n t h e e n g i n e c l o c k w i s et o e l i m i n o t e
o n y p l o y i n t h e d i s t r i b u t o rd r i v e g e o r o n d t o
o v o i d l o o s e n i n go f t h e b o l t . T o r e l i e v et h e c o m p r e s s i o nr e s i s t o n c e i,t i s r e c o m m e n d e d
to bock
o f f t h e s p o r k i n gp l u g s .
b) Stroboscopicmethod:
W h e n u s i n g t h i s m e t h o d ,t h e v o l u e s o f t h e
bosic ignition timing ond the odvonce cont r o l l e d b y t h e c e n t r i f u g o tl i m i n g c o n t r o l ( f o r i t s
diogrom refer to Chopter 13.5) should be odded
u p w h i l e m u l t i p l y i n gb y t w o t h e o d d e du p v o l u e s
o c c o r d i n gt o t h e d i o g r o m .A n y e f f e c t o f t h e
v o c u u mc o n t r o l m u s t b e e l i m i n o t e db y d i s c o r r n e c t i n g t h e r e s p e c t i v eh o s e ( c o n n e c t i n gt h e
d i s t r i b u t o rv o c u u m u n i t w i t h t h e c o r b u r e t t o r ) .
T h e m e o s u r i n gp r o c e d u r ei s i n d i c o t e d b y t h e
d i o g n o s t i ce q u i p m e n ti t s e l f .
To Adiust ldling Speed
Use the oir-correction screw (speed correction screw). The speed decreoseswhen rot o t i n g t h e s c r e w c l o c k w i s eo n d i n c r e o s e sw h e n
rototing it onticlockwise.
A d i u s t t h e i d l i n g s p e e d i n o c c o r d o n c ew i t h
t h e t o c h o m e t e ro n d w i t h i n t h e l i m i t s s p e c i f i e d
in the following porogroph "To Adiust ldle
R u n " . T h e e n g i n e m u s t b e w o r m e d - u pb e f o r e
s t o r t i n g t h e o d j u s t i n gp r o c e d u r e( s e e o l s o t h e
f o l l o w i n g p o r o g r o p h s )o n d i t s i g n i t i o n m u s t b e
in perfect condition (distributor contoct-breoker
p o i n t s , s p o r k i n gp l u g e l e c t r o d e s o
, nd ignition
odvonce).

Acljustthe contoct-breokerpoint gop,the gop

o f t h e s p o r k i n g p l u g e l e c t r o d e s ,o n d t h e i g n i t i o n o d v o n c eT. h e n c h e c k t h e v o l v e c l e o r o n c e
( i f t h e r e i s n o c l e o r o n c e ,o d i u s t t h e v o l v e s ) ,
c l e o n t h e o i r i n t o k e f i l t e r e l e m e n t ,o n d m o k e
r edol link hos the re'
s u r et h o t t h e o c c e l e r o t o p
12.2see
Chopter
quired free trovel
Use o needle to remove the plug covering
t h e f o s t - i d l i n gs c r e w o n d l e t t h e e n g i n e r u n o t
obout 2,000r. p. m. to ottoin on oil temperoture
of 70oC. Insert the probe of the thermonreter
into the hole for the oil diPstick'
Now connect the speed indicotor (tochom e t e r ) o n d t h e o n o l y z e ro f c o r b o n . m o n o x i d e
( c o n t o i n e di n e x h o u s tf u m e s ) . U s e t h e o i r ' c o r iection screw (Fig. 15.3/9) to set the speed
-r-?n
at 800 l;; t. p. ni. cnd the fost-idling screw
( F i q . 1 5 . 3 / 1 0 )t o o d i u s t t h e c o n t e n t o f c o r b o n
moioxide to 2*0.50/sor the oir-fuel proportionb y - w e i g h tm i x i n g r o t i o , c o m p o r o b l ew i t h t h e
+$.t.
specified corbon monoxidecontent,to 1+.2
A f t e r a b o u t o n e m i n u t e o f t h e c o n t i n u e di d l e
r u n n i n gr e c h e c kt h e o d i u s t m e n to n d c o r r e c t i t ,
i f n e c e l s o r yC
. l o s et h e h o l e w i t h t h e f o s t - i d l i n g
s c r e wb y d r i v i n g i n o n e w p l u g w i t h i t s b o t t o m
outword.
of odiusting
N o t e : F o r t h e b o s i c p o s i t i o "nM
ointenonce
s c r e w s r e f e r t o C h o p t e r 2 . 1 9ond Adjustment".
To Lubricote Accelerotor Mechonism

N o t e : F o r t h e b o s i c p o s i t i o no f t h e o d i u s t i n g
screw refer to Chopter 2.19- "Mointenonceond
Adiusting".

224

Pour severol drops of oil into the end of the

bowden coble tubing ond lubricote both ioints
(on top ond below)-of the corburettorpull-rod
itself with obout one drop of oil. Then depress

9ZZ
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osDeler eql ]o lle/v\ l!o eqt olu! uMoP Moll lilM
ilo eql qc!qM uoJl re^el esDslal qclnlc eql +o
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a q l l o r * o U ! l p u D 6 u 1 . r d se q 1 l o m o 6 u 1 r * s u a q l
'sloes rDor eql pulqeq
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ur pJDoqJoolt eql ,o Ja^oc sJluec eq] a^oujeu
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u! uearos
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aql ADMD1l!l puD lMoq aql to Luolloq aql ]D
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f r i c t i o n f o c i n g . l n o d e q u o t ep l o y r e s u l t si r r o t o o
short free trovel of the clutch pedol ond on
o l m o s ti m m e d i o t ec l u t c hd i s e n g o g e m e nAt .c c e s s
t o t h e r e l e o s ec y l i n d e r c o n b e g o i n e d o s d e scribed in the previous porogroph on clutch
lubricotion. Hold the rod protruding from the
r e l o s e c y l i n d e r o n d f o r c e f r o m i t c o r e f u l l yt h e
r e l e o s el e v e r , o g o i n s t w h i c h i t i s r e s t i n g i t h e
l e v e r c o n b e r e l i e v e d b y d i s e n g o g i n gt h e t e n s i o n ( p u l l - o f)f s p r i n g s .
ln service, the forcing-off must be ot leost
2 m m . A d i u s t i t t o 4 t o 5 m m b y o d i u s t i n gt h e
length of the rod. After hoving loosenedthe nut
on the rod of the releose cylinder, rotote the
releosefinger to obtoin the correct rod length.
Then retighten the nut, thus locking the releose
f i n g e r i n i t s p o s i t i o no n t h e r o d .
lf the ploy is correctly odjusted, the f ree
trovel of the clutch pedol pod should ronge
from 40 to 50 mm. lt should not be ollowed to
'!0
drop below
to 15 mm. lf the described odj u s t i n g p r o c e d u r ef o i l s t o b r i n g t h e r e q u i r e d
r e s u l t ,i t i s n e c e s s o r yt o o d j u s tt h e c l u t c h m e c h o n i s m i n o c c o r d o n c ew i t h i n f o r m o t i o n c o n
t o i n e di n C h o p t e r3 . 2 .

15.5 GEARBOX AND FINAL DRIVE UNIT

Checking Oil Level ond Topping'up Oil
Renrovethe centre cover ol the f loor boord in
the luggogecomportmentbehind the reor seots.
Pull off the filler neckcop ond usethe dipstick
t o c h e c kt h e o i l l e v e l .W i t h t h e d i P s t i c ki n s e r t e d
i n t o t h e n e c k u p t o i t s s e o l i n gr i n g , t h e o i l l e v e l
should be obout 8 mm obove the upper line'
For this check, the cor should be ploced on
level ground. After hoving topped up the oil,
w o i t o b o u t 2 m i n u t e s( w h i l e o i l f l o w s f r o m t h e
g e o r b o xp r o p e ri n t o t h e f i n o l d r i v e o n d i t s l e v e l
i s s t o b i l i z e d ) ,o n d t h e n r e c h e c ki t s l e v e l -

Bleeding the Glutch Hydroulic System

The movement of the clutch pedol is tronsm i t t e d h y d r o u l i c o l l yt o t h e c l u t c h r e l e o s ec y l i n der. The couses ond symptoms of penetrotion
o f o i r i n t o t h e h y d r o u l i cs y s t e m ( s i m i l o r t o t h e
broke hydroulic system) ore describedin detoil
i n t h e s e c t i o n d e o l i n g w i t h b r o k e s .T h e p r o c e d u r eo f b l e e d i n g t h e c l u t c h i s t h e s o m e o s
w h e r r b l e e d i n gt h e b r o k e s - s e e C h o p t e r 1 5 . 8 .

- T r o n s m i s s i oU
n n i t F i l l e rN e c k
Fig.15.5/1

ffi

;rt'i,*
tiiffi
ii.! i;

br'ill

- TronsmissionUnit Droin Plugs

Fig. 15.512
o n d I n s p e c t i o nP l u g
1 g e o r b o xd r o i n p l u g ,2 - f i n o l d r i v e d r o i n p l u g ,
3 - inspectionplug,4 - switch of reversinglcmps
(except SKoDA 105 S)

- d i u s t i n gE l e m e n t so f C l u t c h
F i g . 1 5 . 4 1 1A
Control Mechonism
I - r e l e o s ec y l i n d e r r o d , 2 - r e l e o s ec y l i n d e r ,
3 - releose lever, 4 - bleed screw

226

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31XV INOUJ I'91
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I 5 . 7 *15 . 8

s e l l - l u b r i c o t i n gt y p e b u t t h e g r e o s e i s i n t e n d e d
t o r i d t h e b e o r i n g so f o n y m o i s t u r ew h i c h m o y
get to them post the seols in certoin circumstonces.Apply the greose gun till the lubricont
seeps post the upper rubber cuP.
Front Wheel Toe-in
F o r m e o s u r i n go n d o d i u s t i n g t h e t o e - i n , s e e
Chopter 6.1.
Fliminqtionof King Pin PloY
Removethe coter pin of the king pin nut ond
rotote the nut to the next cotter pin hole position. lf the ploy is not elinrinoted ond no
friction sets in with the nut in this position,
continue rototing it until this condition is
ochieved - see Chopter 6.5, porogroph21. Lock
t h e n u t i n t h e f i r r o lp o s i t i o n w i t h t h e c o t t e r p i n

- Broke FluidTonk
Fig. 15.8/1
o screw cop. lt servesolso the r:lutclrlryrlrotrlic
control systenr.
Keep the brqke fluid level withirr tlre ronge
of the moximum filling, i. e., not lower thon
"MAX"
10 mm below the
mork or so high thot
j
u
s
t
it
covers the pcrtition woll of the tonk
which con be seen on looking inside the tonk.
O b s e r v e o b s o l u t e c l e o n l i n e s sw h e n f i l l i n g i n
the broke fluid through the screen in the tonk
filler neck. Refer to Chopter 15.2 for recon'r.
mended broke fluid bronds.
For broke fluid hondlinq precoutions,see
Chopter 9.9.
Brqke Fluid Chonge
T h e b r o k e f l u i d o b s o r b so t m o s p h e r i ch u m i d i t y
ond the chcnge of its propertiesis opt to offect
broking ond even bring obout corrosion of some
ports of the broke system.
T h e t i m e p e r i o d ,i n w h i c h t h e s e c h o n g e s c o n
toke ploce, connot be defined with ony precision. Therefore forestoll troubles ond chonge
the broke fluid in the broke ond clutch system
every few yeors (preferobley two to three
y e o r s) .
Suck out the old fluid from the tonk, fill in
fresh fluid, ond remove the bleeding screws one
ofter onother to let the old fluid be forced out
by the fresh one from oll bronches of the broke
line to the clutch - see the broke ond clutch
bleeding procedure.

F i g . 1 5 . 7 1 2- K i n g P i n H o l d - d o w n
cnd Adjusting Ntit
Note:
irr the list of servicing (mointenonce) iobs,
I,he porogroph on "Checking Front ond Reor
Wlreel Brokes" includes
o ) i n s p e c t i o no f t h e b r o k e - s h o e l i n i n g o n d i t s
replocement,if necessory
b) in the cose of the front broke, the cleoning
ond inspection of the protective (dust) cups
of pistons octing on the broke pods (shoes),
in the cose of the reor broke, the inspection
of the wheel cylinder dust cups (boots), ond
in both coses the replocement of domoged
ports.
i5.8

Broke Bleeding
Air con get into the hydroulic system of the
brokes either due to lock of the broke fluid in
the tonk (low level) or when removing or dismontling some ports of the hydroulic line. lf
there is o smoll omount of oir in the hydroulic
"spongy" ond the
system,the pedol broke feels
broke efficiency decreoses. Ingress of o lorge

BRAKE SYSTEM

B r o k e F l u i d T o n l k- f i l l i n g
The brake fluid tonk is instolled in the boot
{ i n o i n l u g g c r g ec o m p o r t m e n t ) c n d c l o s e d w i t h

228

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p o r t s o g o i n s td i r e c t c o n t o c tw i t h s p e c i o lc h e m i col solvLntsor limit the durotion of this contoct

t o o m i n i m u mb e f o r eo c o m p l e t ew o s h i n g o f f o f
t h e s o l v e n t sw i t h w o t e r ( b y h o s i n g d o w n ,e t c . ) '
Keep the oil cooler, if fitted on the cor, in
c l e o n ' c o n d i t i o n .H o s e i t d o w n w h e n w o s h i n g
the cor, ond if dirt still sticks to the cooling
surfoces,use some of the detergents.

D i s m o n t l e t h e h o u s i n g ,r e m o v e o l d g r e o s e ,
c l e o n t h e i n d i v i d u o lp o r t s , o p p l y f r e s h g r e o s e ,
t h e h o u s i n g .S o o k t h e f e l t r i n g s
ond reossemble
o n t h e l i n k s ( p u l l - r o d s )i n e n g i n eo i l .
1 5 . 1 0 W H E E L S A N D T Y R E S ,S N O W C H A I N S
Tyre Inflotion, Boloncing ond lnterchonge
of Wheels

Bodywork Lubricotion
R o u t i n em o i n t e n o n c ei n c l u d e st h e l u b r i c o t i o n
o f d o o r h i n g e so n d l i m i t e r s ,h i n g e s o n d r e l e o s e
m e c h o n i s m io f t h e e n g i n eb o n n e t o n d b o o t l i d ,
t h e r e l e o s em e c h o n i s mo f t h e s p o r ew h e e l , o n d
the leverogeof windscreen wipers. Lubricotion
o f i n n e r d o l o rm e c h o n i s m si s i n c l u d e di n s p e c i o l
mqintenonce.
Lubricote oll occessiblemechcnismswith
h i g h - q u o l i t yg r e o s e sw h i c h d o n o t d r y , d o n o t
oxldize, ond protect the mechonisms ogoinst
c o r r o s i o nf o r o l o n g t i m e . O i l i s n o t s u i t o b l ed u e
to its short-timeefJect.Any greosecon be used
t o l u b r i c q t et h e d o o r l i m i t e r so n d t h e f r o n t s e o t
s l i d er o i l s .

T h e p r o c e d u r e so r e o u t l i n e d i n C h o p t e r s1 0 . 1
through 10.3. Snow choins ond their use ore
deolt with in Chopter 10.6.
Wheel Toe-in - see Chopter 16.1.
"Shock
Shock Absorbers- see Chopter 8.3
".
Absorbers
EQUTPMENT
15.11 ELECTRTCAL
Checking electrolyte level ond topping up -see Chopter 13.2.
Sporking plugs - electrode gop odiustment,
etc. - see Chopter 13.7.
Stqrter motor - exqminqtion ond renewol of
brushes,etc. - see Chopters13.11through 13.14.
lgnition timing, odiustment of contoct breoker
point gop, distributor lubricotion - see Chopter 15.3.

Lubricotionof SporeWheel Corrier BearingsR e m o v et h e s p o r ew h e e l ,c l e o n t h e h i n g e s ,o n d

o p p l y o i l o n i h e i t u p p e r s i d e s . I n o d d i t i o n ,r u b
i n g r e o s eo f o n y b r o n d .
Lubricotion of Windscreen Wiper LeverogeR e m o v et h e c o v e r o f t h e i o i n t ( o p l o s t i c c u p ) ,
f i l l i t w i t h g r e o s e ,l u b r i c o t et h e i o i n t , o n d r e i n stoll tlre cover.

15.12 BODYWORK- UNDERBODY

Woshing ond Mointenonce
T h e v i s i b l e p o r t s o f t h e b o d y q r e f i n i s l r e di n
o h o r d s y n t h e t i cb o k i n g v o r n i s h ,t h e r e m o i n i n g
p o r t s i n s y n t h e t i cv o r n i s h .
T h e u n d e r b o d yi s s p r o y - c o o t e w
d ith o plostic
c o m p o u n d- f o r d e t o i l e d i n f o r m o t i o n s, e e C h o p '14.9.
ter
Follow the usuol procedures when
w o s h i n g ,c l e o n i n go n d p o l i s h i n gt h e c o r , o n d
observethe specific instructionsfor the use of
w o s h i n g o n d c l e o n i n g p r e p o r o t i o n s i,s s u e d b y
their monufocturers.
A l l l i g h t s w i t h t h e e x c e p t i o no f h e o d l o m p s
hove cosings of plostic moteriols qnd they
s h o u l db e c l e o n e do n l y w i t h w o t e r o r s h o m p o o s .
W h e n h o s i n gd o w n t h e c o r rc o v e rt h e v o l t o g e
r e g u l o t o ro f t h e o l t e r n o t o ro n d t h e i g n i t i o n c o i l
t o p r o t e c t t h e m o g o i n s t s p l o s h i n gw i t h w o t e r ,
ond do not sproy woter direct on the door lock
o n d t h e l i d c o v e r i n gt h e f u e l t o n k f i l l e r n e c k .

The Lubricotion of Inner Door Mechonisms

i s p o s s i b l eo n l 'yd oo fot re r r e m o v i n gt h e d o o r p o n e l
m e c h o n i s m .U s e o n l y r e ond the inner
commendedgreosebrcnds.Lubricotethe bowden
c o b l e o f t h J w i n d o w w i n d - u p m e c h o n i s mw i t h

Woshing ond Core of Underbody Mechonisms

The underbody mechonisms ore protected
with o synthetic vornish which stonds well the
usuol woshing procedures.Protect oll rubber

Fig.15.1211-Lubricotion of Windscreen Wiper

LeverogeJoint - ioint cover

230

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pw
es) The greoter portion of the filling
the p
' f il o
out through the outlets ond this will
will
suffice in the event of droining before dismon'
tling the engine.
3.-Uncouple the hoses from the engine line
i n t h e e n g i n e b o y - S e e F i 1 . 1 5 . 1 3 1 AP. r o c e e d i n g
from und6r the vehicle, pull the hoses behind
the cross beorer of the georbox, ond let the
liquid flow from the hoses.
4. Remove the droin plug of the cylinder
b l o c k o n d , i f n e c e s s o r y ,f r e e t h e o u t ' f l o w u s i n g
o length of wire, etc.
N o t e : I n o l l , o b o u t 8 5 0 / 0( 1 0 . 5 l i t r e s ) o f t h e
coolont will f low out, ond the differenceshould
be reckoned with when refilling the systemA l l o n t i f r e e z e so r e t o o c e r t o i n e x t e n t h o r m f u l
t o t h e s k i n . l t i s t h e r e f o r e n e c e s s o r yt o p r o t e c t
oneself qgoinst contoct with the liquid, especiolly the eyes (do not touch them with

F i g . 1 5 . 1 3 / 4- H e o t e r L i n e o n E n g i n e
ond Droin Plug
1 - droin plug
2 * pump ond heoter connecting line
3 - thermostot ond heoter connecting lirre

fingers soilded witlr the liquid). Wosh ony

stolns off the skin os quickly os possible with
soop woter etc. Rinse the stoins off the vornished cor bodY with woter.
Fridex-Spolqno Antifreeze

F i g . 1 5 . 1 3 1-2C o o l i n g S y s t e mB l e e d C o c k

As clreody mentioned, the cooling system is

filled with this liquid,or with o solutionof its
concent'rote with soft woter, in the foctory.
For the preporotion of this solution olw.oys
use soft ond cleon woter. In the following toble,
its concentrotion in dependenceon its freezing
resistonce is indicoted. Alternotively, the concentrotion con be determined from the density.

Volume Ports

D e n si ti yt F r e e z in g
point "C
o t +20
II ot
+ 2 0 oC
'
W
o
t
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r
S
p
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l
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o
Fridex
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1.029
79
21
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2 ; t.oqs
1
-25
62 I 1.055
38
'1,5
-27
1.O57
1
-30
1.062
56
44
-35
53 |I 1.067
47
-40
1 i 1.074
I
-45
47 i 1.080
53
I
-1,5
-60
4

F i g . - 1 5 . 1 3-/ 3F u e l T o n k G u o r d S h e e t o n d P i P e
DroinPlugs

232

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1 6 . -1 1 6 . 2

16.1 EQUTPMENTFOR SUBTROPTCAL

REGIONS

f 50 oC, or where on extro high cooling eff i c i e n c y i s r e q u i r e dg e n e r o l l y :

Stondord equipment of cors for subtropicol

regionswhere the temperoturedoes not exceed
+40oC, or where increosedcooling efficiency is
requiredgenerolly:
1 . C o p p e r r o d i o t o r ( c o p p e r l o m i n o t i o n s )f o r
oll types.
2. Oil cooler for oll types, the some os thot
fitted in the stondord 12OLS model.
3. Cost finned oil sump for oll types including occessories (longer oil pump suction
s t r o i n e ro n d l o n g e r o i l d i p s t i c k ) , l i k e t h o t f i t ted in stondord 120L ond 120LS models.
4 . O i l t e m p e r o t u r es i g n o l l i n gt e l e t h e r m o m e t e r
( 1 2 5 + 3 ' C ) i n c o r t y p e S 1 2 0 t - S .T h e p r i m o r y
e l e m e n ti s m o u n t e di n o s p e c i o lc o n n e c t i o nf i t t e d t o t h e o i l c o o l e ro u t l e t .T h e w o r n i n g l o m p
o n t h e i n s t r u m e n tp o n e l i s r e d o n d w i t h o u t
o s y m b o l ( t h e i n s t r u m e n tp o n e l h o s o d i f f e r e n t
w i r i n g f o r t h e c o n n e c t i o no f t h e w o r n i n g l o m p
t o t h e t e r m i n o lb o o r d ) .
The coble of the primory element is connected to the terminol "10" of the terminol
boord "111" (morking occording to wiring diog r o m i n F i g . 1 3 . 1 / 1 ) .T h e c o b l e i s l e d o u t o t
the engine together with cobles to the engine
temperoturegouge ond the oil pressureswitch.

1. Copper rodiotor (copper lominotions) for

oll cor types.
2. Oil cooler for oll types like thot fitted in
stondord S 120 LS mod6l. The bolt connecting
the rodiotor hose of the outlet from the engine
timing geor cover to the rodiotor hos, however,
n o b y - p o s sh o l e s .
3. Cost finned oil sump for oll cor types refer to Chopter 16.1,porogroph3.
4. Oil temperoturesignolling telethermometer
(125+3oC) for types 120 L ond 120 LS. For
loyout see Chopter 16.1,porogroph4.
5. Thermostot with o nominol opening temperotureof +75oC for oll types.
6 - I n c r e o s e dv o l u m e o f c o o l o n t ( s t o r o g e )
tonk - 4 litres for oll types.
7. Fr-relpump with o longer priming lever.
I t i s i n s t o l l e do n t h e e n g i n e o n t w o i n s u l o t i n g
pcrds

16.2 EQUTPMENTFOR TROP|CAL REGTONS

Stondord equipment of cors for tropicol regions where the temperoturedoes not exceed

M o i n t e n o n c eo f o i r c l e c n e r :
T h e s t o n d o r do i r c l e o n e r f i l t e r e l e m e n t ( t h e
some for oll cor types) must be chonged in
dust-lodenenvironmentsofter every 2,000 kilometres.On dusty roods in deserts,this element
must be inspected doily ond reploced doily, it
necessory.
Keep the coolont level ot obout the middle
of the tonk or only slightly obove the middle.
T h e t o t o l v o l u m e i s 1 35 l i t r e s o p p r o x i m o t e l y

234

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MP 1-112 Thrust beoring supportingbush

MP 1-113 Volve supportingplote

MP 1-114 Volve spring instoller

MP 1-121 Wqter plrmp shoft drift

M P 1 - 1 2 2 W o t e r p u m p b e o r i n gd r i f t

MP 1 123 Woter pump beoring drift

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MP 1-128 Gouge for corburettor throttle disks

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MP 3-109 Lock pin guides

M P 3 - 1 1 1 P i n i o n c l o m P i n gb r o c k e t

1 7 . 4 R E A RA X L E

M P 5 - 1 0 1 B o c k l o s hg o u g e

MP 5-102 Pinion beoring retoining fixture

MP 5 104 Differentiql odiustirrg support (2. )

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MP 5-116 Seolingring drift

MP 5-151 Pinion odiusting gouge

MP 5-152 Wheel hub puller

17.5 FRONT AXLE

MP 6-150 Front oxle ossemblybroclket

MP 6-105 Steering orm drift

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MP 6-126/A Wheel beoring inner roce extroctor

MP 6127

Wheel beoring inner roce drift

M P 6 - 1 2 9 P r e s s i n g m o n d r e l o f w h e e l beoring outer roces

MP 6-130 Pressing mondrel of wheel beoring outor roces

M P t i - 1 3 1 S e o l i n gr i r r g d r i f t

MP 6--140 Disc-brokegouge

MP 6--134 Expondingpliers

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MP 8-101 Cement syringe

MP 8-102 Rodiotor fon hub puller

MP 8-152 Toe-in gouge

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MP 8-157 Comber gouge

MP 8-158 Reor oxle olignment check gouge

MP 8-159 Check gouge for underbody (front)

MP 8-160 Check gouge for underbody (reor)

MP 8-161 Window frome moulding fitting fixture

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sKoDA.(GB)LTD

PARTSDEPARTMENT
Bergen Way, North'Lynn Industrial Estpte,

K i n g sL y n n ,N o r { o l k .
T e l e p h o n eK: i n g sL y n n ' 6 1 Z

; , s e d a n d r e - p r i n t e db y . J e m t e c hP r i n t i n gL t d . ,
- ) l l i r r l ) o ! [ , r el -, l a i t s ,E r g l a n d .