ignition SKODA 105S 1980 Workshop Manual

Worrring
lights:
5 -
left-hond direction indicotors, green
6 -
oil pressure,
red
7 -
right-hond direction indicotors, green
8 -
broke system, red
9 -
chorging, red
10 -
fuel reserve, omber
11 -
high beom, blue
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 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
when thene ore less thon 5litres of fuel in the
fuel tonk.
The tochometer indicotes the speed (revol-
utions) of the engine. The
speed should
never
rise to the red zone. When chonging the geors,
on increose of speed within the ronge
of the
yellow zone is permissible.
The porking
lights come on when the switch
is thrown to the first
right-hond position.
The
Fig. 1.3/6 Switches -
port I
1 -
Porking light switch ond feeder of heodlomp
dipswitch
2 -
Horn switch, direction indicotor switch,
ond dipswitch
3 -
Switch of ouxiliory (extro)
heodlomps
4 -
Door switch 12
-
unoccupied, green -
fog lomp worning light
included in speciol
extros
13 -
unoccupied, green -
low-beom worning light
included in speciol
extros
14 -
unoccupied, red
switch switches on the heodlomps, toil lights,
ond the licence plote
light.
The heodlights, i. e. driving (high
beom) ond
dipped (low
beom), ore switched on by throw-
ing the switch to the second
right-hond pos-
ition. The switch switches on oll porking
lights
ond the heodlights
in occordonce with the pos-
ition of the switch stem-type lever: centre
position -
dipped lights,
towords the instrument
ponel -
driving lights. When the
driving lights
ore on, the blue worning light glows.
The ouxiliory heodlomps
come on ofter pull.
ing the switch knob, but only while moin
heod-
lomps ore on.
heodlomp flasher storts floshing
when
the switch lever
toword the steering
ring.
horn is sounded by depressing
the lever
the steering wheel shoft.
Fig.1.317 Switches -
port ll ond oshtroy
1 -
Switchbox ond steering lock
2 -
Switch of windscreen wipers ond
wosher
3 -
Heoter switch
4 -
Switch for on odditionol device -
not
stondord fitted
5 -
Disobility worrning light
switch -
not on
SKoDA 105 s
6 -
Heoter control
7 -
Ashtroy
The
pulling
wheel
The
toword
i
I
L 12

--
!
ti
f
I
n
i
Boot lid
up to 1978 -
To open it, press
down
the release on the
right-hand side
underthe facia
oanel. Then
lift
the lid on the right-hand side and
secure it
in its raised position with
the aid of
the
articulated strut. After
lowering the
lid, lock it by
pulling the release as
far as it will go.
'
Sinie 1978
open lid by pulling
handle and
lower as described above.
To
lock press lid above
catches. I
(in
egr
WO
r,nol
pul
T
rem
fore
B
Pus
the
lugs
forn
cusl
Fig.' OT
,4
Fig.1.3111 Controls
1 -
Geor lever
2 -
Hond broke
lever
3 -
Choke n
between Front
Seots
't488
Fig.1.3112 Switching Positions
of
Switchbox
c/w Steering Lock
0 -
All functions of
f, engine stopping
| -
lgnition on -
ignition system ond
oll ports
ol electricol equipment ore
supplied
with
curre nt
ll -
Engine storting -
before repeoting the
stort-
ing procedu,re,
return the key to the "0"
pos-
ition ond only then stort the
engine ogoin
STOP -
Position for
withdrowing the
ignition
key ond engoging the
steering lock (ofter
hoving withdrown the
ignition key,
turn the
steering wheel till
the lotch of the lock
c licks home
) .
lf the key connot be turned
when unlocking
the steering, relieve the stress
of the steering
geor by tuining the
steering wheel slightly-
LUGGAGE AND ENGINE
COMPARTMENTS
The moin luggoge comportment (boot)
is in
the forebody, the interior (inbuilt)
luggoge
comportment behind the
reor seot bockrests. 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.
For ony work in the engine comportment see
the notice in porogroph 1,
Chopter 2'1.
Fig. 13lM Reor Bonnet Releose Lever
SEATS, ADJUSTMENT AND CONVERSION
To moke the seot slide, unlock it by lifting
the lever ond tilt the bockrest by
rototing the
rosette. Set
Cor
by thr
only r
is pro
The
ofter
lifting
bock,
by its
positir
Ash
tion o
open i
its cos
hold i
inworc
first it
oshtro'
1.4 C,
Jqck
iock is
held in
14

Lifting
the cor with o
Power iock -
When
r-rsing o 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
lugs ond secure the pin
with o cotter pin (both
thL pin
ond the cotter pin
ore included in the
cor occessories).
1.5 SPARE WHEEL
AND FUEL TANK
Spore wheel -
After having opened the
lug-
goge boot lid, pull the hondle of the spore
wheel corrier releose
rod.
The corrier is
re-
leosed ond swings
down (speciol equipment of
the cor includes
o sofety lotch behind the
bumper which hos to be pushecl
oside to
releose the corrier
) . After
hoving closed the corrier (by
lifting it),
push the releose lever under
the bumper to the
right os for os it will go.
Fuel tonk -
The filler neck with cop is in the
reor on the right-hond
side of the cor- lt con
be locked ond unlocked by meons of
the re'
spective key.
1.6 STARTING THE
ENGINE AND CHECKING
ITS CORRECT RUNNING
1. Moke sure thot the geor
lever is in its
neutrol position,
switch on the ignition (pos-
ition I on the switch box) ond wotch the
coming on of the oil pressure ond chorging
worning lights, i.
e. check the function of the
olternotor -
see the informotion in porogroph
4.
Prepore the engine
to its temperoture:
- Storting from cold in
the occelerotor pedol
- Storting from cold in
the occelerotor pedol
choke for
storting occording
winter -
do not touch
ond use the full choke
summer -
do not touch
ond use only holf of the
Fig. 1.5/1 Hondle ot
Rod (f ronr obove )Spcre
Wheel Lock
crnrl Safety Lotch -
Storting o wormed-up engine -
depress the
occelerotor pedol
slowly to tlre
toe-boord, do
not touch the choke
2. Depress the clutch pedol
(odvisoble
in
summer, necessory in
winter) ond stort
the
engine by turning the ignition key to position
ll.
Let go
of the key os soon os the engine fires
ond releose the occelerotor pedol
{if it hos
been
clepressed).
It the engine ,refuses
to fire, return the key
to the position "0"
ond rePeot the
storting
Pro-
cedure. lf the engine is wormed up, depress the
occelerotor pedol
to obout one third of its totol
trovel. lf the cold engine stolls even
ofter the
second ond third storting ottemPt, enrich the
storting mixture by quickly
depressing the
oc-
celerotor pedol
once or twice to holf of its
trovel during the next storting ottemPt.
Never let tlre storter motor run for more
thon
obout 5 seconds. Woit
some 5 seconds before
repeoting the storting.
Fuel is injected
by every quick
depression of
the occelerotor pedol
ond enriches the mixture
so thot it is difficult to ignite. lf the engine
is flooded, stort
it
with o fully depressed oc-
celerotor pedol.
3. Increose the engine speed corefully while
releosing the clutch pedol. lf the
engine shows
signs of stolling, depress
ogoin the clutch
pedol.
Relecse
L.ever
Fi.1.5t2 Fuel Tcrtrk Filler
Neck
16

primory
feed to the distributor coincides with
the connecting line of the
distributor centre
line ond the first cylinder
heod
bolt os
per
Fig.2.3l10. Secure the distributor in this pos-
ition by lightly tightenning the tie-bolt ond
remove the timing geor
cover from the cylinder
block. The used type of distributor is described
in Chopter 13.5.
Fig.2.3l10 -
Position of Distributor on Engine
-l - screw of primory power
feed
2 -
cylinder heod bolt
3 -
index line rnorking the position
of the
distributor ornr when cvlinder No. 1 f ires
24. Coot with oil the moting
surfoces of the
timing geor cover ond the cylinder
block, locote
the cover gosket
on the block,
oil the timing
choin ond the comshott worm geor.
Remove the
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
position corresponds opproximotely
to the volve
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 tight-
ening the flywheel powl.
25. Turn
the distributor orm in the direction
of the
screw (1) in occordonce with Fig. 2.3110,
hold it down with the
finger in this position,
ond ref it the timing geor
cover on the cylinder
block. By sliding the worm geor
of the distribu-
tor 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
there is no coincidence of the orm ond timing
mork, od just
the position
of the orm by
slightly
rototing the distributor.
lf the
misolignment of the distributor
ornr
ond the timinq
mork of the
cvlinder
No'1 is so 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 cronk-
shoft ond the outer shoft end (stem)
of the
belt
pulley with oil, f
it the belt pulley,
the nespective
wosher, ond tighten the bolt. Bolt the
PumP
suction stroiner tothe cronkshoft centre beoring
ond use o spring
wosher under the bolt heod.
27. Bolt down the timing geor
cover using
spring woshers ond
cheese-heod bolts
(exclus-
ively) cnd f inolly fosten the timing geor
cover
in such o position
thot the contoct breoker
points open before the crronkshoft with
the con-
necting rod ond piston
hos ottoined the top
deod centre (TDC)
position (see
the lgnition
Timing Toble in Chopter 15.3).
For checking the ignition odvonce, on electric
power supply is required with 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 re-
quired ignition odvonce by turning the cronk-
shoft with o screw'driver inserted into
the geor
ring ond propped ogoinst the cylinder block
f longe. Rotote the shof t onticlockwise o bit
more thon necessory ond
bock it off so os to
odiust the bocklosh of the timing geors
ond the
distributor drive geors.
oK 6ls
Fi9.2.3111- Lomp for Checking the Opening
of Contoct Breoker Points
-1 - torch complete with dry cell ond bulb
2 -
leod with olligotor clomp
3 -
botterv cell
4 -
torch coo
5 -
contoct spring
6 -
insuloting plote
7 -
electricol-contoct connection of the leod
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.
shri n ks
of the
woter
move i
ively.
To Fit
Toppetr
25. r
remove
positior
sure thr
cylinder
cylinder nuts. F<
first bo
woteir p
oir clec
finol ti1
2.16.
Ploin
heod bo
which t
woshers
no wosl
heod bo
cy I i nder
the outs
hove to
of the rc
Tighte
broce or,
30. Sc
thermom
into the
cosing o
ofter ho
Use spri
thermost
cooted g
with the
with the
The th
should br
34

ilil
ll
I
Z,l
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
occelerotor linkoge to the intoke monifold, Use
spring woshers to lock the bolts in position.
38. Locote the corburettor gosket, sheet
guord, onother gosket,
the insuloting wosher,
ond o third gosket (oltogether
three 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
corburettor lever with greose
contoining molyb-
denum disulphide
ond mount on them the oc-
celerotor link (tie-rod).
Hold the link in pliers
ond slip securing clips over the heods.
Hook o spring on the shonk of the reloy
link-
oge 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. Secure the 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
wosher without tightening. Without tightening
the self-locking
nut, bolt the strut into the
brocket on the cylinder heod. Swing the olter-
notor toword the engine, fit
the V-belt ond,
while tensioning it, connect the olternotor with
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 slip-
ped o seoling ring ond o wosher on eoch bolt,
the some os in the cose of the push-rod
cover.
In oddition, fit the fuel pipe
holder on the reor
bolt ond hold it down by slightly tightening the
nut.
45. Fit the oir cleoner in position
ond fosten
it to the corburettor with 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 corburettor ond the oil filler neck.
When preporing
the 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 re-
commended types of sporking plugs
see Chopter
13.7.
The outlet on the distributor cop morked with
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 recesses for sporking plugs.
Plug Screws ond Lubricotion
System
Accessories
49. Plug the oil sump with the conicol screw
plug with its
seoling ring. In the cose of on
engine without the oil cooler, plug
the oilwoy
on the timing geor
cover with o screw plug
with o seoling
ring, ond the oilwoy ot the reor
end of the cylinder block with o pressure
switch. lf the socket for screwing down the
pressure switch is missing, instoll o new socket
together with its respective seoling ring.
lf on oil cooler is provided,
hoses ond o press-
ure switch should be
connected to the oilwoys
occording to Chopter 11.9.
Put the oil dipstick
with the f itted rubber ring
in its ploce.
For the type of the dipstick see
Chopter 2.17.
50. Using spring
woshers with the bolts,
screw down the flywheel
guorcl
ofter removing
36

2,15-2.'t8
3. The
leokoge test 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
the exhoust ond intoke ports
using, for
exomple,
o rubber
cone. No oir bubbles must oppeor
oround the volve heods.
This test con be simplif ied by omitting the
fitting of vclve springs while pressing
the
volves into their seots by hond using o suitoble
Jixture (fork)
for holding down the volves.
Volves The volves
ore forgings of speciol high-tem-
peroture steel with o conicol seoling surfoce
ond ho,rdened stem end. The
volve heods ore
of unequol diometers (lorger
with intoke volves
ond smoller with exhoust volves).
Current reconditioning
of the conicol seoling
surfoce is done by grinding-in
with the respect-
ive seot. lf o mojor repoir is required,
regrind
the seoling surfoce
of the volve heod
on
o grinding
mochine to on ongle of 91 o
+10',
ond then grind
it in with the seot.
When regrinding the conicol surfoce, it is
obsolutely essentiol to keep it in
correct olign-
ment with the volve stem.
Valve Springs
rcs/po1201S
Outer Inner
Free Length 45.85
43.645.20
Wire 3.75 2.5
Diameter 4.OO
Mean Spring 26.75
18.5 26.5
urameter
T
Spring Pres-
sure
I nstal led
length L""En-I
3Omm Length
Length
30mm 29mm
299-358 N108-127N
460N hondle)
ond the short oil pumP,
to the cost oil
sump the 330 mn-r long dipstick ond
the longer
oil pump -
see Chopter 2.18.
2.18 TIMING GEAR COVER .
OIL PUMP
ln oddition to timing geors,
the timing geor
cover houses olso the oil pump
(f
orm ing its
housing) ond the distributor drive.
A generol
description of removing the timing
geor cover from the engine con be found in
Chopter 2.4
ond for detoils, regording its f
itting
on the engine, refer to
Chopter 2.3,
porogrophs
22 to 25.
The engine with the sheet oil sump hos the
shorter oil pump
with the suction stroiner
holder 72 mm long. The
engine with the
cost oil
sump hos the pump
30 mm longer.
Assembling Oil
Pump
Coot the pump geors
ond the drive geo'r
shoft
with oil, ond instoll them into the timing geor
cover. Insert the gosket
ond close the pump
with the lid with suction pipe
ond stroiner. Use
spring woshers to prevent
the lid screws from
s lcrcken ing.
Fi1.2.1811- Timing
Geor Cover Assembly -
Sectionol View
(for better illustrotion, the pinned
connection
of the shoft ond geor
is somewhot turned, its
correct position
being described in the text)
2.17
OIL SUMP
A sheet oil sump is used on engines with
o 68 mm cylinder bore.
Use o rubber gosket
when instolling the oil sump
on the engine.
Engines with o cylinder bore of 72 mm hove
o cost ond ribbed
oil sump. For its instollotion
use its respective
cork gosket.
A sheet boffle
is bolted
over the bottom of the oil sump.
Use
bolts with spring woshers to bolt it
down.
Relotion between oil sump,
oil dipstick, ond
oil pump:
To the sheet
oil sump oppertoins the dispstick
of o totol length
of 305 mm (including
its For
egi
stroiner v brrocket r
65 mm), 1
(the leng
proximott
The go
provides
geors. lf
gosket is
thicker tl" To prer
obnormol
respectivr
limits spr
Seol F it
the
t ig hte
n in1
thot it pr
edge of tl
Assemblir 1. Thre
brocket, s
pointing r
odio.4c in the pr
bore (pin
the pinne
When c
sure thot
line with
is importr
ignition d
To prev
ing durin
o pilot
m<
Then con
using o sr
2. After
ensure tl'
0.1 mm) I
3. Fit t
into the f
under the
Betwee
driven
I driven
I Axiol
c
I betwee
I and lid
58

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

I
I
( 1. Excessir
- overfloc
o) leoky n
b) too higl
- incorrec
c) too lorg
d) too sm<
e) oir-ventl
2. lncorrecl
- engine
o) choked
chokedi ncorrec
defectiv
- errotic i
e) portiolly
f) folse oir
l ncorrec
too low
lncorrect i ncorrec
i ncorrec
c) choked
4- Poor occ
chokedleoky no
defectivr
Loss of p
stoge | |
choked ,
domoge<
i ncorrect
stoge | | mutuolly
ond ll in
Engine w
storti ng
choked <
low fuel
i ncorrect
( excessir
o) lf no nera
hold the
connecte
emergen(
Fi1.2.1917
-
Floot Adjusting by Bending
the Lip of the Floot Honger
10 mm in diometer between the gosket
ond the
floot). The lip must lightly
touch the spring-
looded boll in the needle volve. The lip must
not press -
in the boll
or move owoy from it.
The doshed lines show
the floot in its lower
position.
Petrol and Air
Jets
Cleon them by swilling
in petrol
ond blowing
though with compressed oir. When removing
them, note
their locotion to focilitote reinstol-
lotion in their proper ploces.
Volume Iniected by Accelerotion Pump
ond Pump Hondling
Fill the corburettor with fuel
ond operote the
corburettor lever 10 times through its full stroke
to iniet fuel. Operote the lever ot intervols
of
3 to 4 seconds
ond cotch the fuel into o grodu-
oted vessel. The
iniected omount should be 7
to 9. c. c. lf necessory,
deflect the injector so
thot the
iet of
fuel posses
directly through the
chomber ond does not flow down its
wolls.
When refitting the occelerotion pump
cover,
prelood the diophrogm by opening the throttle
disk of stoge I to its full
stroke before retight-
ening the cover copscrews.
To Adiust Throttle Discs
Turn over the corburettor
with the throttle
discs on top ond loosen the reguloting screws
in the flonge till
the throttle discs ore fully
closed. Ploce the indicotor MP 1-128
on the
flonge necr one of tlre throttle
discs ond force Fig.
2.19/8 -
Adjusting Throttle Discs Using
MP 1-120'lndicotor
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
disc) ond the indicotor reods 0.10 to 0.12 mm.
Proceed in
the some woy to odiust the other
throttle disc.
Setting ldle Run Adiusting Screws
After o dismontling, etc., set the screws in
their bosic positions
so thot the engine con
be
storted up ond be kept running.
o) Rotote the oir correction screw (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 180o
to closed
position.
Do not
tighten the screws forcefully in their
closed positions.
They must beor ogoinst their
seots iust lightly so
os not to foul them.
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 moni-
fested by oudible clicks. The seporotor closes
the pilot
iet when
the current is switched off
(switched off ignition).
Corburettor Defects ond Their
Removol
Notice: Turn your
ottention to the corburettor
ofter hoving oscertoined thot the
engine, fuel
supply, ond ignition operote correctly.
# b)
c)
d)
s) h)
3. o)
b)
o)
b)
c)
5.
o)
b)
;i
6.
o)
b)
c)
//"\
'//
\
/\\
-.--- rrr)
V,I rV
64

'i
iiiI 14. Fuse box
Centrol connection of conductors -
do not
seporote them from the bunch!
15. Direction indicotor switches, dip switch,
and horn switch
eight-pole terminol
boord
six-pole terminol boord
16. Porking light switch ond high beom feeder four-pole terminol boord
17. Switch box femole connectors 5.5 with symbols "15",
"30", ond '50"
to be
connected to symbols
"15u, "30', ond '50"
on the switch box
18. Instrument ponel
ten-pole terminol boord
six-pole terminol boord
eorthing coble with lug
'19. Heoter switch
four-pole terminol boord
20. Switch of disobility lights
six-pole terminol boord
21. Door switch, right-hond
green -
femole connector 5.5
22. Dome light,
right-hond
green -
femole connector 5.5
red -
femole connector 5.5
23. Stop switches
forked (yellow) -
femole connectors 5.5 .
red -
femole connector 5.5
white -
femole connector 5.5upper ond lower
switch
upper switch lower switch
24.Fuel gouge block -
femole connector 5.5
yellow -
femole connector 5.5
blue -
femole connector 5.5
to be connected to the respective pins
(blodes) of the some colour of the fuel gouge
25. Storter motor, reversing
lomp switch
conductors with lugs stater motor moin
terminol boord
storter motor
control switch
green -
femole connectors 5.5 heodlomp switch
26. Oil pressure
gouge,
thermometer, corburettor
iet seporotor
green -
femole connector 5.5 yellow
-
femole connector 5.5
green - telethermometer
primory element
femole connector 7.
corburettor
iet seporotor
27. lgnition coil, voltoge regulotor, olternotor,
tochometer
conductor with femole connector ond
bronching lug
femole connector-regulotor terminol 15/54
lug -
ignition coil terminol 15
blue -
femole connector 5.5,
symbol "R"
. regulotor terminol "R"
yellow -
femole connector 5.5,
symbol "M"
regulotor terminol "M"
blue -
connector "R"
. olternotor terminol "R"
yellow -
connector "M".
olternotor terminol "M"
lug terminol "+B"
conductor with
lug ignition coilterminol "1"
(tochometer operotion
)
28. Toil lomp cluster, right.hond
yellow -
femole connector 5.5 toil light
block -
femole connector 5.5 direction indicotors
red -
femole connector 5.5 stop light
green -
femole connector 5.5 reversing lomp
29. Licence plote light
conductors with femole connectors 5.5
30. Toil lomp cluster, left.hond
se point
28.
b) Connection
of free conductors
1. Storoge bottery
bottery coble positive
(*)
terminol -
storter motor
bottery eorthing strip negotive (-)
terminal -
bodywork (eorthing conductor)
2. Engine engine eorthing strip (fostening
lug) -
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
terminol "1"
cylindricol
(pin)
connector
pressure gouge172

junction
with the olternoto,r occording to
Chop-
ier 13.3 ond mointoining
o constont voltoge of
tlre power
supply set within the
entire ronge
of
service speeds.
Tlre voltoge regulotor
is instolled orr the body
cross beorer, to
the right of the engine ond
beside the ignition coil.
To focilitote hondling
of its leods' especiolly
the occess to their
connections, it
is recom-
rrrended to remove the regulotor fostening
screws. For disconnecting procedures,
see
Chopter 13.3 "Alternotor
lnstollotion ond Gen-
erol lnstructions".
DK 1565
Fig.13.411- Internol
Wiring Diogrom of
Alternotol with
Voltoge Regulotor ond
Outer
Connections
Altenrotor: B, R, M -
olternotor outlets
f -
olternotor phose
windings
m -
olternotor field winding
D1,2,3, 4, 5, 6 -
moin diodes
D7, 8,9 -
olternotor ouxiliory diodes
D10 -
olternotor choking diode
Voltoge regulotor:
R, M, 15/54 -
regulotor outlets
reg -
regulotor tension winding
Rk -
boloncing resistor
Ro -
protective resistor
Rr -
odiustoble resistor
Kr -
regulotor contocts
Outer connections: K -
worning lomp (1.5
W)
S -
switch (switch
box)
B -
bottery
Checking Voltoge Regulotor
on Cor
The regulotor operotion con be offected by
loosened connections ond on imperfect eorth- ing.
lf the wsrning lomp does not go
o.ut when
driving, i. e., if it glows
ot increosed engine
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 regulotor
is probobly
foulty. Another
symptom of o regulotor
foilure is
o poor
chorg-
irrg of tlre bottery or its
overchorging.. lf there
is nothing wrong with the regulotor, check the
reguloted voltoge over the regulotor which
slrould reod 13.2 volts ot the
minimum ond 14.8
volts ot the moximunr. This check
in the
cor
is only tentotive ond only
o check on
the test
bench'con be considered os definite ond
bind'
i ng.
Electricol Adiustment
The voltoge regulotot- should be tested
ond
odjusted only on o test bench
in o connection
slrown in Fig. 13.412.
At o lood of some
2
onrperes, the checked
voltoge should correspond to
volues specified
in the column "Checking".
lf the checked volt-
oge is within the specified ronge, do
not odiust
the regulotor. Othenwise odiust it to the volues
specified in the column "Adiustment".
lf woter
evoporotes obnormolly from the bottery, odiust
the voltoge regulotor to the bosic volues of
"Adiustment" utilizing the lower section of
the
toleronce zone.
Fig.13.al2 -
Wiring Diogrom of
Regulotor Tested
ond Adiusted on
o
G -
olternotor
REG -
voltoge regulotor
A -
ommeter
V -
voltmeter
S -
switch
R -
lood resistor
B -
bottery DK
1566
Voltoge Test Bench
178