ECO mode SKODA 105S 1980 Workshop Manual

ii
i ENGINE
Model
- for Skodo 105 S ond 105
L
- for Skodo 12o L
- for Skodo 120 LS
Type
Number of cylinders
Cylinder orrongement
Cooling
Swept volume
- Skodo 105 S ond 105 L
- Skodo 12O L ond
120 LS
Bore
- Skodo 105 S ond 105 L
- Skodo 120 L
ond 120 LS
Stroke
Compression rotio
- Skodo 105 S, 105 L ond 120 L
- Skodo 120 LS
Engine power
output to CSN ond DIN
- Skodo 105 S ond 105 L
- Skodo 12O L
- Skodo 120 LS
Moximum torque
- Skodo 105 S ond 105 L
- Skodo 120 L
- Skodo 120 LS
Fuel -
recommended octone number
- Skodo 105 S,
- Skodo 120 Ls
Corburettor type
Fuel lift pump
type
CLUTCH
Type
Control
GEARBOX
Type Speeds
Geor rotios -
1st-speed geor
2nd-speed geor
3rd-speed geor
4th-speed geor
reverse geor Skodo 742.10 Engine No/l
Skodo
742.12 Engine No/2
Skodo 742.12x Engine
No/9
four-stroke, spork-ignltion,
corburettor engine with overheod volves
4 in line
pump-circuloted ontifreeze,
thermostotic temperoture control
1,046 c. c.
1,174 c.c.
68 mm
72 mm
72 mm
8.5:1
9.5:1
33.9 kW (46
h. p.)
ot 4,800 r.
P. m.
38.3 kW (52
h. p.)
ot 5,(X)0 r. p.
m.
42.7 kW (58
h. p.)
ot 5,2(X) r. p.
m.
74.5 Nm ot 3,000 r.p.m.
85.2 Nm ot 3,000 r.p.m.
90.2 Nm ot 3,250 r.p.m.
90 minimum 95 minimumduol, twostoge, downdrought
nrodel JIKOV 32 EDSR
diophrogm pump, model
JIKOV MF
dry, single-plote, with direct
disengogement
hydroulic
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
105 L ond
12O L
18

metre), ond the
relotion of 1
kpm :9.806
Nm is'
opplicoble. When opplied to tightening
torques
of bolts ond nuts, use the relotion
10 Nm :
: 1 kpm.
d) The unit of power (output) tW'
(wott)
reploces the former "h.p."
(horsepower) ond
the relotion
of t h. p.:
735.499 W is opplicoble.
For procticol purposes,
o multiple of kW (kilo-
wott :
1,000 wotts) is used, i. e., t h. p. :
:0.736 kW.
e) The
unit of pressure "Po"
(poscol) or, in
proctice, MPo (megoposcol :
1,000,000 poscols)
or kPo (kiloposcol :
1,000 poscols)
reploces the
former "bor"
ond "kglcmz",
ond the following
relation is opplicoble: 1 MPo: 10 bors :1O.2
kg/cm2 (kp/cm2).
For current meosuring
of tyre
pressure etc., use the relotion: 100 kPo :
1 bor:
:1kglcm2 (kp/cm,) :1
otm.
1.10 GENERAL INSTRUCTIONS
With the exception of o few
speciol pro-
cedures or ossembly techniques
mentioned in
the respective section of
this monuol,
every
removol ond refitting (disossembly
ond re-
ossembly) should be governed
by the following
generol principles:
o) Use suitoble tools ond especiolly tubulor
box sponners which couse the leost domoge
to nuts ond bolt heods.
b) During disossembly note corefully how
the ports
hove been ossembled. This knowledge
is involuoble for correct reossembly.
c) Cleon ports
in trichloroethylene or tech-
nicol petrol.
They do not contoin substonces
(esoeciolly leod) which horm
the skin os motor
petrol does. Current bronds of seoling com-
pounds con be removed with denoturoted
ol-
cohol or scroped off. For o speciol
seoling
compound see the note ot the end of this
chopter.
Avoid contominotion of self-lubricoting
metol
beorings with ony degreosing
ogent os this
would unfovourobly offect 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 lubri-
conts do not spreod eosily on dry surfoces,
the
ports ore not properly
lubricoted, ond friction
oreos ore opt to get
domoged. Coot the os-
sembled ports with the lubricont which is used
to lubricote them in operotion. When lubricoted
with oil, dip
the ports
in motor oil, the f luidity of which mokes
it
especiolly suitoble for
this
purpose. Use greoses
ond hydroulic f luid bronds
specified in the Toble
of Recommended Lubri-
conts.
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
ond leove the joints
unsecured. Moreover, there
is o risk
of the broken ports
domoging other
functionol ports.
f) Cleon new ontifriction beorings (boll,
rol-
ler, ond topered roller beorings) of preserving
greose using kerosene.
Preserving greose is not
suitoble for lubricotion ond it mixes bodly with
I ubriconts.
g) Some of the joints
hove to be tightened
with o moximum occurocy to the specified
tor-
ques listed in the previous
chopter.
h ) 'Ihe
permissible rototion unbolonce is spe-
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 un-
bolonce con be determined
when fostening
o weight corresponding to the permissible
un-
bolonce 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
unbolonce is within the recommended limits.
The weight of the testing weight sholl be
de-
termined by dividing the volue of the permis-
sible unbolonce by the distonce of the weight
from the rototion
centre of the port.
i) Even slightly domoged seols ond pockings
must be reploced with new ones
Note: In the foctory,
the speciol seoling
compound
of the "Velvonton
C" brond is used for seoling
the engine reor
cover on the cylinder block, the
moting surfoces of the georbox housing holves,
ond the guide
of the clutch releose beoring.
This seoling compound is mode
on the bose
of o polyurethone
plostic ond it
corresponds to
"Hykemor", "Reineplost", "Curil
K" ond similor
compounds. lt con be removed from the ports
by scroping ond woshing with ocetone, butyl-
ocetone or chlorinoted solvents, for exomple
chloroform (trichloromethone)
ond corbon tetro-
ch loride.
24

2.2-2.3
threods. Fill the etrgine with oil ond the cooling
systenr with on ontifreeze, ond
bleed them.
2.3 REASSEMBLING THE ENGINE
The reossembly procedure depends
on the
extent to which the engine hos been
dis-
rnontled. For better understonditrg, o
reossembly
of o conrpletely disnrontled
engine is described
in the following
porogrophs.
lnspection of
Cylinder Block
1. Clomp the thoroughly cleoned
cylinder
block into the MP 9-101 stond with the engine
corrier type MP 1-101 ond check it for complete-
ness -
see Chopter 2.6. Fit the
block with its
lugs on the engine corrier pins
ond use the side
bolt for ltolding it down.
DK 1188
Fig.2311- Cylinder Block Fostened on the
Assenrbly Stond by lVleons of the MP 1-10-l
Corrier
2. Rernove the pressure
relief volve, moke
sure thot the boll contoct {oces ore cleon,
ond
refit the cleoned volve. Forr
f itting o new volve
see Chopter 2.6.
3. Remove the cronkshoft beoring
covers ond
tlre i;ylinder block reor cover.
To Refit the Cronkshoft
4. Force the beoring shell lrolves with the
fingers into the cronkshoft beoring bores so 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":urnols -
see Chopter 2.7.
5. Slip the oiled guide
ring on the cronkshcft
"vith oil grooves
pointing
toword the cronkshoft
'.veb ond {it the cronkshoft with the pressed-on
boll beoring (see
Chopter 2.7)
into the shell. 6.
Inscrt the
beoring shell
holf ir-rto
the cover
of the beoring No.-l
os described in
porogroph
4,
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 grooves pointing
owoy from the block so
thot itJ
lip engoges ogoin into
the slot in the
cover. Coot the ring
with oil ond slip on the
thrust ring. Fit the MP -1'112
thrust collor on the
cronkshofi ond
tighten the
beoring slightly
using the belt
PrrlleY bolt.
7. Instoll the next
two beorirrg covers
corl'l'
plete with beoring shells
ond lightly
tighten l.he
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,
compress them
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 subsequent correct locking
of the nuts.
Fig.2.312 -
Meosuring Cronkshoft Ploy
1 -
Thrust collor, type
MP 1 112
2 -
Diol indicotor in o
speciolly mode yoke
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 cronk-
shoft 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 ex-
ceed 0.10 mm, the recommended minimum ploy
being 0.04 mm. 10.
F
speciol
end onr Drive
suchr o
be turnr
cover. I
ever, tf
the cyl
speciol note in
11. Ti
the tigh
in the
covers. hoving
does no
must ro
Then lo,
woshers
ond nut
To Refil
12. R
greose i
it with i
o flywhr
engine,
with rec
under tt
Chopter
bending
shoft og
powl ins
For flyw
Fig.2.3l3
Using thr
Screw
holes, for
con be ur
further o1
the hondr
30

The rocker-shqft
support hos o poper
seol
preventing leokoge of the oil fed from the cyl-
inder block to the rockers vio the support. lf
o reody-mode seol (gosket
) is not ovoiloble,
moke it yourself
using poper
0.1 mm thick.
A thicker seol
is unpermissible os it
would
couse c distortion of the rocker shoft. The hole
in the seol
must coincide with the oil hole
of
the rocker.
Apply the seol
ond ref it the
exhoust ond in-
toke monifolds. For detoils see
Chopter 2.3.
porogroph 30.
6. Reinstoll the thernrostotic temoeroture
control cosing with its gosket
ond do not forget
to put
spring woshers under the nuts.
Note: When reossembling
the cylinder heqd
of on engine removed
from the cor, it is odvis-
oble to proceed
with the
iobs os
per
porogroph
5 ond 6 with the cylinder heod refitted
on the
engine to focilitote
the tosk.
lf the cylinder heod gosket
hos been reploced
with o new one, invite the customer to bring in
the cor ofter
trqvelling 500
to 1,000 kilometres
for o retightening of the cylinder heod ond
odiusting of the volve cleoronce. 3. To ensure o leokproof
cond ition 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
necessqry, rebore the guide
hole ond press-fit
o bush.
Volve guide bushes ore not ovoiloble os
sporre ports. They
con be mode
individuolly oc-
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 specificotions of theCzechoslovokSton-
dord 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.
DK 1+J6 Fig.2.16l
To Recon
These
volves fo
groph 3),
new volvt
Use o
conicol sr
with its r
1. Che
necessory
volves. F
shonk of,
eter, ond
will result
ing in ocr
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
Fi1.2.1613
-
Reconditioning Cylinder Heod
for Fitting Volve Guide Bush
Seoling of
Cylinder Heod
As o seporote unit or forming
o unit with
the cylinder block,
the cylinder heod
must be
seoled ogoinst leokoge
of goses
ond woter, i.e.
it must be gos-
ond wotertight.
1. When replocing
some of the bolts pro-
truding into the woter
iocket, seol
them
with
point. The woter
iocket of the
cylinder
heod
must be leckproof
when tested with woter
under c pressure
of 0.5 Mpo (5
kg/cm2).
2. lf it is necessory
to restore the flotness
of t-he cylinder heod
moting surfoce,
,egiind
the
surfcce only to the leost possible
exte-nt so os
not to increose
the engine
compression rotio.Valve
guide
tolerances
Guide 7.94 -
HB +
O.O22
o.oo mm
lnlet Valve 7.94 -
F7
t 9 9?q .n-
+ 0.013
0.025
56 Fi1.2.1614
-
Volve Guide Bush x
1Tr9

Technical
Description
Car Model 1976/1979 Carburettor type
and model
1979 onwards*
105
120 120 S
and 105 L
L
LS
Types of carburettors and
their functional elements according to
the,polex cdnparison table
or
their bore (in
millimetres) JlKOV32 EDSR
-
443751 290 1
00 JlKOV32 EDSR -
443751 292400
JrKOV32 EDSR -
443751 31 9 800 JlKOV32 EDSR -
443751 292500
J|KOV32 EDSR -
443751290000 J|KOVg2 EnFF -
443751 292600
to
;1
Car model 105S, 1O5L
itZOr- '
l2OLs:
Carburettor type and model Se.B
above
Elements of stage I and ll or in
common
Fge
1 2
1
2
t
2
Atomizer cone diameter
Main petrol jet
Main air jet
Pilot jet
Pilot air jet
Auxiliary pilot jet
Econostat petrol jet
Econostat mixture jet
Econostat air jet
Choke petrol jet
Choke air jet
diameter
Diaphragm control air valve
Pump by-pass orifice
Injector
Needle valve diameter
Suction connection diameter 21
105 170
50
140
60
95/85'70
90
4.5/5.5*
130 40/45*
50 1.5
1.2 22
1 12/1 10*
170 50
140
60
110
70 1 00/90*
4.5/5.5'
160 40/45*
50 22
23
'.112/110*
130/125*
170 50
140
1Orygo*
4.5/5.s*
.80
40/45*
22
120
160 45
1.5
1.2
1,5
1.2 23
125
160 45 160
45
60
Jo
70
1'to
70
50
Jo
*erF
or"fs?
,.w'1'
80
Acceleration pump
discharge
Float weight 2O t 1 gram 7 to 9 c.c.
per
1O strokes (1976-79)
6 to 8.$19f9 onwards)
Fuel level. Float Removed.'28mm t'1mm frEm bp
face
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.
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 con-
nected to the moin systems
of both stoges in
the zone
of the emulsion orifice
by the re-
spective elements terminoted by the odiustoble
idling screw ond fost-idling (ouxiltory
oir)
screw.
- Stoge
I incorporotes
the petrol
iet seporotor
for the prevention
of self-ignition. The
idling ori-
fice is interconnected with the mixing
chomber
by two by-poss bolts enobling
c smboth tron-
sition to the moin system,
ond o hole is pro-
vided in the mixing chomber to obviote
onyinterference
with the smooth flow ot o hlgtler
underpressure (vocuum).
.
ln stoge ll, the by-poss hole enhonces
o smooth ond continuous intgrconnection
of
both corburettor stoges.
Econostot or rich-mixture syste4
(Fig. 2.19/3)
This system enriches the
mixture in stoge I
ot higher engine lood (output).
lt operotes
outomoticolly occording to the
volue of under',
pressure in the otomizer ond
in dependence onf
the flow of oir sucked-in by
the engine.
Accelerqtion pumP
(Fig. 2.19i5)
This is o mechonicol, diophrogm-type
PumP
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 open-
ing 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

d)
e) f) choke
plunger
sticking in its
bottom
position storting worm engine
too high fuel level in floot chomber
incorrectly odiusted
idle run unstick
the plunger
or reploce it with
o new one
odjust the
floot
odiust idle
run correctlY
2.2O FUEL PUMP
Technicol DescriPtion
The model JIKOV MF 3407 fuel pump
is of
the diophrogm ond
lever type, controlled by 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 dio-
phrogm. Fuel flows through o stroiner, o mud
trop, ond the suction volve to the delivery
volve. A priming lever is provided
for hond
priming of the fuel. The moving mechonism
is
lubricoted with oil
sploshed from the cylinder
block. Stroke of the driving disk 4
mm
Suction heod 1.5
mm
Deliveryheod. 2mm
Pump dischorge ot 2,000 strokes
per minute ond free outflowwithout
counter-pressure 30
ltrs/hr.
Mointenonce, Repoirs, Disossembly
ond Reossembly
For routine
mointenonce (cleoning
of the
mud-trop screen) see Chopter 15.3. After hoving
operoted the hond-priming lever lift it
till it
engoges sofely in its locked position.
ln the cose of o defect, inspect the diophrogm
ond check the volves for leokoge. After hoving
removed the pump
from the engine, remove the
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'
pressed oir. Reploce domoged ports
with new
ones. lf necessory, remove the diophrogm from the
octuoting lever in
the lower port
of the fuel
pump (its
monufocturer recommends the dio-
phrogm to be reploced ofter obout 50,000 kilo-
rnetres with o new
one). Do not stretch the
spring of the diophrogm ond do not olter its
compression force chorocteristic in ony woy.
Do not forget to put
fibre pocking rings
underthe
volves
when reossembling the
fuel
PumP.
Put o spocer ring under the suction volve (close
to the mud trop). Fig.2.2Ol1 shows
the pos-
itions 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. Oper-
ote the hond lever
to compress the 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
under the clomping bolts.
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 pressure
of 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. Foulty fuel
supply
o) clogged mud trop
b) domoged diophrogm
2. Fuel pump
does not hold fuel
o) dirty or defective volves cleon it
reploce it
with o new one
wosh them in petrol,
reploce defective
volves with new ones
66

Proceed
in the some woy with the
3rd- ond
4th-speed geors.
lf the morked position
of the neutrol is not
midwoy between the side morks (check
visu-
olly), remove the pinion,
mork the positions
of
the striking forks on
their rods (preferobly
on
either side), slocken the forks ond 'rnove
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
ond the odioining teeth, ond swing the striking
fork of the first ond second speed
to moke sure
thot it connot foul
the teeth.
14. Reinstoll the pinion
with its respective
woshers ond lock it in position.
Shift the strik-
ing fork rods to moke sure thot, for exomple,
o movement opposite to the required one of the
striking forks did not toke ploce,
i. e. thot the
neutrol is midwoy betvr'een the engogement
positions of the synchronizing clutches. Correct
ony error ond remove
ogoin the pinion.
Fitting Drive Geors ond Clutch Shqft
15. lnstoll the ossembled drive shoft into the
housing ond slip the splined bush on it.
Top home the seol ring with its seoling lip
pointing outwords into the guide
of the clutch
thrrowout sleeve, ond smeor it with oil. Then
threod the clutch shoft through the ring to
instoll it into the splined bush ond put
it into
the housing together with the guide provided
with o cooting of seoling compound on its cyl-
indricol bedding surfoce. Secure both the shoft
ond the sleeve with circlips.
lnstoll the sleeve guide
with its droin hole
level with the porting plone
of the housing ond
focing the pinion.
For the speciol seoling compound see the
note in Chopter 10.1.
16. Put the pinion
with geors
into the housing
ond oil oll synchronizing rings. Fit the MP 5-104
iig for
setting the crown wheel bocklosh into
the bore of the differentiol beoning ond the
fitted cover, fit the ossembled differentiol in it,
ond close the housing with the other housing
holf ofter hoving cooted the seoling surfoces
with o seoling compound.
Fit o rubber ring in the recess of the boss
beside the stud
bolt ond put
o spring wosher
under the nut. Tighten the remoining nuts
without ony woshers (the
stress of the bolts
ofter the tightening of the nuts provides
for'
their suff icient securing). Tighten the nuts
moderotely for the time being.
For the speciol seoling
compound refer to the
note in Chooter 10.'1. 17.
Proceeding through
the bore of the differ-
entiol beoring in the upper holf of the housing,
fit another
iig, the MP
5-104,
on to the differen-
tiol with flonges clomped so os to fit
into the
topered roller beoring cover, locote the cover
pocking, ond fosten
the cover by meons
of three
nuts. lf the clomping or drowing close of the
flonges of this jig
proves inodequote, it is
necessory to drow close the flonges olso of
the
first, previously
inserted
iig.
18. Drive the guide
of the clutch throwout
sleeve into the housing using the MP 3-103 drift,
top home the drive shoft, ond insert
two od-
iusting woshers under the collor of the
pinion
shoft boll beoring on both holves of the housing
ofter hoving determined their thickness by
meosuring. Using o wire needle
inserted into
the holes of
the tobs of the woshers orronge the woshers so
thot they do not overlop the porting plone
of
the housing,
then instoll the cover ond spring
woshers, ond tighten the nuts (seeChopter
1.8).
19. Fosten the housing by tightening the nuts
(see Chopter 1.8) ond lock in position
the guide
of the clutch throwout sleeve with the respect-
ive clip using the spring wosher under the
clip
nuts.
4.3 ASSEMBLING
FINAL DRIVE
Ref itting Differentiol 20. Turn the housing into the horizontol pos-
ition. Rotote the ends of the knurled hondles
of the inserted iigs MP 5-104
to move the re-
instolled differentiol (see previous porogrophs
16 ond 17) until the crown wheel withdrows
Fig. 4.311- Adiusting
1 -
MP 5-104 iig,
3 -
MP 5-106
iig,Bevel
Geor Bocklosh
2 -
MP 5-101
iig,
4 -
Screwdriver from
the
Determir
swivellin
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
wheel sic
fied volut
the hond
fully its c
( preferob
wheel). I
opened f1
respectivr
of the
iigr
Now tl"
iusted on
flonges o'
topered r
This situc
trot i o n.
Fig. a3fi
for tc
1
22. Rem
side (turn
withdrow
dimension hos to be
roller beori
Measuring 23. Unscr
the toperer
locote it o
q,
ry
80

r3.2-t 3.3
tuJ
t(A 4r
3t 2t
,tl
(
Per
lp
5
4
3
2, I
Ah re€
l
i
i
ii Observe
strictly the following instructions:
1. Mointoin the electrolyte level ot the level
of the perforoted
inserts between the plotes
or
so thot the inserts ore
covered with the electro-
lyte to o moximum height
of 4
mm. The
bottom
limit of the electrolyte level is 3 mm below the
perforoted inserts. Use only distilled woter for
topping up the electrolyte. Add electrolyte only
if it hos been obviously spilt from
the bottery.
In such cose, its density must correspond to
the density of the electrolyte Eemoining in the
bottery. 2. Keep the bottery terminols
cleon, remove
oxides occosionolly, ond
coot the terminols
with minerol
ielly.
3. Wipe off the electrolyte spilt
over the bot-
tery surfoce since it is conductlve ond couses
dischorging of the bottery.
4. Check the
chorging of the bottery occord-
ing 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
outside the cor,
use chorging current volues occording to the
toble. The voltoge should be
controlloble in the
ronge from 12.6 to 16.8
volts. The fully dis-
chorged bottery is fully chorged in obout 13 to
20 hours when
o) the electrolyte ottoins o density of 1.28 in
oll cells ond does not chonge in o period
of
two hours;
b) the cell voltoge (meosured
with opplied cur-
rent) ottoins o volue of 2.6
to 21
volts ond
does not chonge within two hours
of con-
tinued chorging;
c) oll cells ore lively gossing.
6. An olreody used bottery must not be left
without electrolyte or dischorged os 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.
Bottery Chorging versus Electrolyte
Density
Specificgrovityl i Electrolyte
(density) iChorgingl freezing
g/cms I I temperoture
1.28
1.24
1.22
1.15
1.12 1oo
o/o
Toolo s0% 2oolo
0 -60
0c
-50 0c
-35 0C
-17 "C
-120C At o
20 per
cent chorging, the bottery is
considered procticol
ly dischorged.
Toble of Chorging ond Dischorging Values
Roted voltoge 12 volts
Roted copocity C 20
ot o
20-hour dischorging to 1.75
volts per
cell 37 omperehours
Normol dischorging current
for 20-hour
dischorging to
1.75 volts per
cell 1.75 omperehours
Normol uniform chorging 3.7 omperes
Two-stoge chorging:
stoge I up to 2.4 volts per
cell; gossing
beginning 4.4 omperes
stoge ll up
to f inol
morks
of fuf fychorgedcondition 2.2 omperes
Diffenent instructions, determined specificolly
by bottery monufocturers, opply to moking o
new ond empty bottery reody for
operotion or
to so-colled quick
chorging.
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 es-
peciolly to so-colled quick
chorging).
During chorging, on explosive mixture of hy-
drogen with oxygen is liberoted from the elec-
trrolyte. Therefore, the oreo where the bottery is
chorged must be ventiloted, ond it is forbidden
to opprooch with o noked flome (or
spork) the
cell filling holes (even
ofter o consideroble
period of time ofter the chorging hos been
completed). When chorging the bottery, open the filling
holes of its cells to enhonce degossing.
The electrolyte is on ocid hormful to the skin
ond clothes os well os to ports
of the cor fin-
ished in
enomel. Rinse with woter immediotely
ony contominoted spots.
13.3 ALTERNATOR The olternotor is o three-phose generotorwith
o built-in semiconductor rectifier
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

I
I
t
b
c ll
e
c
tl
d n
tN'
>
\'
J I
(Il
qt3
Fig. 13.5i3 -
Vocuum Control Course -
opplicoble to both
regulotor models
copscrew fostening the distributor brocket to
the support on the engine (do
not loosen the
brocket clomping bolt).
Refit the distributor on the engine by
re-
versing this procedure. The
coupling on
tlre
shoft is osymmetricol ond it hos to engoge into
the heod of the drive shoft in the engine. To
seot properly
o new distributor
or o distributor,
the brocket of which hos
been loosened, refer
to Chopter 2.3, por.25
to 27.
Distributor Disossembly ond Reossembly
This should be done in speciolizedworkshops,
especiolly with regord
to the checking of the
mechonicol condition or o repoir
of the dis-
tributor. lt is recommended
to use o suitoble
holder for doing the moiority of the required
iobs in
o verticol position.
When reossembling
the distributor, lubricote
the sliding points
oc-
cording to Chopter 15.3
but bewore of over-
lubricotion.
Remove olso the copscrew
on the bottom of
the distributor housing ond drip some low-pour
point oil into the hole to increose the oil reserve
of the shoft
sel-lubricoting beoring -
see Chop-
ter 15.2 "Speciol
Oils".
Disossembly 1. Remove the distributor cop ond the breoker
orm.
2. Remove the coupling from the shoft (note
the relotive position
of the eccentric dogs ond
the breoker
orm).
3. Remove
the circlip from
the pivot
ond litt
owoy the breoker orm.
4. Remove
the subossembly
of the terminol
"1" (current supply to distributor).
5. Screw off the copocitor. 6. Screw
off
the retoining springs.
7. Lilt owoy the vocuum chomber (do
19t
open it, o chonge of the curve is on.improboble
d'efect; do not chonge the screw-in depth
of the
pull-rod).
' 8. Lift owoy the contoct breoker
bose plote
with pocking piece from
the housing.
g. Litt owoy the shoft with the
centrifugol
governor. -
10. lf necessory, disossemble further
the sub'
ossembly of the shoft with the centrif
ugol
governor (odvonce mechonism) ond
com.
l?;h.',0, ReossemblY
1. Reossemble the centrifugol governor
(the
weights must be free
to rotote on the pins).
2. lnstoll the reossembled shoft
with the res'
pective woshers into
the distributor housing.
3. Fit the contoct breoker bose plote
with the
f ixed contoct holder ond pocking
piece into the
housing. 4. Fit the pull-rod on
the pin
ond lock it in
position, screw down the vocuum chiomber with
the copocitor. Check the
ignition odvonce po-
sition for the first cYlinder.
5. Screw down
the retoining springs
with
shims (the
spring with
the dog opposite to
the
terminol "1"i;
the bose plote must
rotote freely
in the distributor housing.
6. Reosemble the terminol "1".
7. Fit the breoker orm
on
the pivot
ond lock
it in position. Adiust the contoct breoker point
gop (lift) ond check the
contoct
Pressure'
"
if. 'Stip
woshers on
the shoft in
the originol
sequence, slip on the coupling ond
lock
it in
position^ 9. Fit the lubricoting felt
into the hole of
the
com ond instoll the breoker orm.
10. Fit the distributor cop
in position.
11. Check the distributor operotion.
Checking A def inite indicotion of the condition of
the
distributor (during on operotionol check
os
well
os ofter o
repoir) con be obtoined by testing
the distributor on
o test stond with
o circulor
spork gop.
After o preliminory
odiustment of
the
contoc-t breoker point gop,
the stond is
used for
check i ng:
1. The contoct point
contoct ongle.
2. The spork ongulor distribution (with o
tol-
eronce of -+45
ongle minutes within
the entire
operotionol ronge).
3. The rongJ ond course of the
centrifugol
ond vocuum control. 4. The
operotion ot
moximum speed (length
of spork on spork goP -
4 mm) for o
brief period
(obout 2 minutes).
180
t
5
2tD zsa !l!
F llti
rc

t 3.t
r*r 3.1 2
1. lf the wiper moves with the switch in the
OFF position
ofter its
connection to 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'
sition by onother holf turn.
2. Press the lid into
the cover ond seol it
with point.
WIPER ARM DRIVE
This drive consists of thewiper beoringswith
cronks, the tie-rod of the
cronks, ond
the driv-
ing tie-rod. The
drive is instolled in the cor os
o unit.
Tie-rods The tie-rods should be slipepd on
the cronk
pins in the
following sequence:
o springwosher
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, lubricote the ioints with
greose
- see the following section deoling with beor-
ings. 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.
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 in-
serted with its nose foremost
into the re-
spective hole in the body. Locote o seoling
wosher with corefully smoothed-out edges ond
o flot
wosher from outside, ond secure the
entire unit with the respective
nut. The
unit is
seoled off by
o rubber pocking.
Fill the unit
with greose (see
Chopter 15.3 for recommended
foreign bronds or Czechoslovok Lrronds SP 4 or
A 4) ond press
it down into the neck of the
bush.
lf it is necessory to remove
or disossemble
the beoring, prise
the lock ring out of the pin
groove under the rubber pocking.
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 grooved
topers of
the beoring pins.
After hoving fitted
the wiper orms, sproy
woter on the windscreen
ond test the run
of 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
mould-
i ng.
13.12 RADIATOR FAN
Technicol Description
The fon is on ossembly of 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-lubricoting beorlngs. The
impeller is mode of plostic.
Motor type
Roted voltoge Roted current
Roted output
Direction
of rototion PAL 443.132
-
O97.O45
12 volts
7.5 omperes
55 wotts
clockwise (right-hond) when
viewing the front end of the
shoft
Coble poles
coble with lug (blue) -
negotive pole
coble with femole connector
(red) -
positive pole
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 removing the impeller. Use the puller
MP 8-102
to pull
off the fon or support the fon
hub in three points
on its circumference ond
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
commutotor end shield ond stotor.
190