wheel 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

Broke
fluid:
- clossificotion
- brond filled-in in the foctrY -
FUEL TANK
Locotion Fuel cleoning (filtrotion)
CHASSIS LUBRICATION
TyPe
ELECTRICAL EQUIPMENT
Eorthing
Roted voltoge
Service voltoge
lgnition
Storoge botterY .
Alternator PAL Magneteton
Voltoge regulotor
Distributor
lgnition coil
Storter motor
Sporking plugs -
see ChoPter 137
BODYWORK
Type Seoting copocity
Luggoge comportments, coPocitY
H e oter
FILLING CAPACITIES
Engine -
Skodo 105 S, 105 L
ond 120 L
Skodo 120 LS
Georbox ond
finol drive cose
Steering box
Broke system
ond clutch
Cooling system
Fuel tonk SAE J
1703C
SYNTOL HD
190
suspended under
floor boord of cor reor holf
stroiner in fuel tonk,
fuel filter, ond stroiner
in corburettor
self-lubricoting beori
ngs,
by greose nipples;
wheel
greose
negctive pole
12 volts
14 volts repocking
with greose
beorings pocked
with
bottery (coil)
type
type AKUMA 6N 37 -
12 volts, 37 ompere-hours
14V 35 amps 1976-79
1O5/12O
L
14V 42 amps 1979 on
1O5/12O
L
14V 42 amps 1976-79
120 LS
14V 55 amps 1979 on
120
LS
type PAL Mogneton, 14 volts
type PAL Mogneton
with centrifugol timing
device ond vocuum unit
type PAL Mogneton, 12
volts
type PAL Mogneton, 12
volts
0.66 kilowotts (0.9
h. p.)
oll-metol, closed, four'door,
chossisless body
5 occuponts
0.40 mi (0.28
rn: moin luggoge comPortment for
q lood of obout
0 kg, 0.12 mr interior luggoge
comportment for
o lood of obout 10 kg)
hot-woter heoter
with fon, fed with woter
from
the engine cooling sYstem
4 litres moximum -
2.5 litres minimum
of engine oil
4.6 litres moximum -
3 litres minimum
of engine oil
2.5 lities of geor
oil (2 litres when
chonging oil)
0.16 litres of gecrr oil (obout
0.25 litres when
topping up)
O.4A titres of broke f
luid (f
illing for tropicol
regions, etc. see ChoPter 16.2)
12.5 litres of
ontif'reeze
38 litres 1.8 Tt(
BC
1. Ap
von ized
out o sL
2.tti
Threo
ENGINE
Connecti
Nut of c
Nut of c
Nut of vr
Nut of fr
Nut of c
Nut of si Nut of c'
Cylinder Bolt of c
Flywheel
Bolt of cr
Oil sump
Oil sump
Droin plu
Bolt of ft
Bolt of oi
Socket ol
Oil pressr
Sporking
CLUTCH Connectir Generol
20 Bolt
foste

il
tli
GEARBOX. FINAL
DRIVE
Connection DimensionsTightening
torque Nmt)
Nuts of cosing clomping bolts .
Nut of primory shoft
Plnlon nut .
Nut of pinion
beoring coP
Nut of releose sleeve
bol
Nut of front cover bolt
Nut of speedometer shoft clip bolt
Nut of speedometer drive beoring
bolt
Nut of reverse-geor pin
bolt
Bolt of reverse-geor pin
Bolt of shifter forks
Bolt of cop of lock-boll springs
Silentblock bolt
Bolt of differentiol cose
Bolt of crown geor
Droin ond inspection hole plugs
Switch or bolt of reversing lomps .
REAR AXLE
Connection M8
M 22x1.5
M 24x1.5
M8
M6 M8
M 22x1.5
M 14x1
Dimensions 40-50
14-17
6-8 19-25
7-9
7-9 17 -20
7 -9
14-17
7 -9
30-40 22-25
35-45
20-30
70-80
M6
M6
M8
M8
M6
M6
M10
M8
M 10x1 30-35
7 -9
Tightening torque Nmr)
Rood wheels nuts .
Nut of oxle-shoft boll
Nut of oxle shoft
.ioin;
boit M 12x1.5
M8 M 18x1.5
M8
M10
Dimension 60-70
20-25
17O *)
a
40-50
Bolt of broke
bocking plote
Bolt of wheel cylinder
FRONT AXIE
Connection 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 (connection
with steering
knuckle pivot)
Nut of lower wishbone pin (connection
with steering
knuckle socket)
Nut of wheel
hub beoring .
Nut of steering knuckle pivot
.
Nut of lower
wishbone brocket bolt .
Nut of bolt fostening shock obsorber to its onchor brocket
Nut fostening shock
obsorber to
bodywork
Wheel nuts
Bolt fostening
front oxle to bodywork .
Bolt of
onti-roll bor brocket see
Chopter 6.5, points
24 ond 25
see Chopter 6.5, point
21
M
,M M
M
M
M 12x1.5
12x1.5
12x1.5
12x1.5
12x1.5
12x1.5 6s-70
45-60
70-90
45-60
70-90
70*)
70 *l
40-50 50-55 12-14
60-70
40-45
12-16
M
12x1.5
M10
M 12x1.5
M10
M 12x1.5
M10
M7
*) Further tightening os
required for olignlng holes
for the cotter pin.
22

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

For the
instol lotion of the engine on the test
bench, we indicote the dimensions
of the en'
gine flonge ond flywheel. During broking, the
engine qnd
the engine oil must
be properly
cooled to preclude
exceeding the oPtimum
service conditions, i. e. woter temperoture
ofobout
80 to 90oC, ond oil temperoture of 12O"C
moximum -
see Chopter 2.5,
porogroph 51.
Engine Lubricotion
The inner lubricoting oil distribution system
is shown in Fig.2.5/5.
6 DK .r5+9 2.6
cYL
The cyl
mochined
the cronl
ports, forr
ore mode
B locks fo
72 mm di
I i ners.
Oilwoys, I
o) Befo
o new cyl
ossembled
blow thror"
b) Coot
pound or p
the oilwoy
c) Likev
into the e
pound or p,
of the
cyli
one (of
lo
limits indi
Ports) to er
d) Tighte
ot cylinder
under it.
e) Foster
the cop of
Fosten the
with o bolt
Fig.2.611 ond
1 -
choin gre
plug, 3 -
iniel
relief volve,
with cop, 6 -
inlet from o
ptug, I
9
8
7
5t
Fig.2.515 -
Engine Lubricotion Diognom
Skodo 120 LS
engine hos,
in oddition, on oil cooler incorporoted between the punrp
delivery
broncir on the timing geor
cover ond the moin oilwoy (see
Fi9.11.9)
srlctionstroiner,2-pump,3-pressurereliefvolve,4-moinoilwoy,5-oil filter,6-by-poss
hole, 7- oil pressure
switch, 8-pulsotingchomber, 9- rocker orms, 10-connecting rod
splosh hole, 11 -
choin splosh screw
4
2
4 t-
oil I
?
?
I
;
t

2.7.-2.8
Guide Rings Regrinding of the foce of the front
cronkshoft
web results in
on increosed (oxiol) ploy
of the
shoft. Reploce therefore the originol guide
ring with
on oversize one. Oversize guide
rings ore fitted exclusively
to
the regrround loterol
foce of the cronkshoft web.
Stondord size rings
should be olwoys fitted
to
the thrust ring side (next
to the timing geor).
Thrust Ring
lf the thrust ring under the cronkshoft timing
geor (sprocket)
obutting ogoinst the guide
ring is worn to on
extent
which mokes domoge of
the guide
ring likely, reploce it
with o new one
or regrind it.
The moximum permissible
regrinding is, how-
ever, to o thickness of only 3.75 mm.
Cronkshoft Moin Beoring Shells
Fit the cronkshoft moin beorings (shells)
occording to the respective nominol diometer
of the cronkshoft
iounnols. The shells
ore not
provided with o diometer symbol so thot they
hove to be checked for
the respective woll
thickness with o micrometer.
2.8 FLYWHEEL WITH GEAR RING
Boloncing -
Removol ond Refitting
A new flywheel ossembly is o
stoticolly bo-
lonced unit, its moximum permissible residuol
out-of-bolonce weight being '10
gcm. The finol
lf one of the
shells
is worn or domoged, o ll
cronkshoft moin beoring shells must be reploced without foil !
For the respective correlotion of the cronk-
pins ond connecting rod
big-end beorings see
Chopter 2.11. dynomi<
ism shr
sembfed
Thus
sitioq of
shoft be
from o
1
When
rnork on
zero line
ond prol
mork op
cylinder
the rem<
gcm sin
mosses (
concentr
cronksho
holes rot
wheel ir
interf erel
For thi
on the r
sition, i.
cronksho
fore the
When
one or wl
follows:
1. Fit .
residuol o
olly offec
2. The
bolonce r
hos o hig
correctior
once. lt
occording
porogroph
Chopter 1
bending t
To Reploc
Reploce
worn or d,
ring, toke
the interfr
sion). The
prime impr
ossembly
storter mo
The gec
removed b
port pod
cr
MP 1-153. I
ing the ge
it off. The
monufoctut
When ur
front foce
ond drill
o
Fig.2.8l1- Morking
Correct Position of
on Cronkshoft (prior
to removing theFlywheel
f lywheel)
Motching
Cronkshoft Main Beorings with Journols
Nominol cronkshoft mmiournol
diometer Thickness
of beoring
shell woll
mm Toleronce limit
of woll thickness
mm
dio. 55 dio.54.75
dio. 54.50 dio.54.25
dio. 54 stondord
1st regrinding
2nd regrinding
3rd regrinding
4th regrinding 1.497
1.622
1.747
1.872
1.997
-
0.007
44

Turn
the flonge
on the centering
orbor so thot
the longer, cylindricol port
foces the clutch,
push it ogoinst the friction plote
hub, ond olign
the ends of the levers to touch the flonge.
A deviotion from the ploneness
of 0.1 mm
is
permissible. Use feeler gouges for checking
this deviotion.
lf it is not possible
to odiust the out-trovel of
the clutch releose levers to o volue given
by the
length of the flonge cylindricol port
due to
excessive weor
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 pre-
cludes ony further odiustment
of the clutch.
4. After hoving reossembled
the engine with
o new or odiusted clutch,
check ond, if necess-
ory, odiust the cleoronce between the releose
levers ond the throw-out beoring -
see Chop-
ter 15.4.
3.3 CLUTCH DISMANTLING
Owing to its simplicity,
it is not necessory
to
describe in detoil the dismontling
of the clutch,
but some speciol feotures
deserve ottention.
1. lf the friction plote
ond clutch cover ore
intended to be re-used, mork their relotive
positions using centre punch
morks to preserve
the originol bolonce of the ossembly.
2. To dismontle
the clutch, it is
necessory to
compress the clutch cover to relieve the stress
of the releose lever bolts. For this purpose
use
the MP 2-101
ossembly plote
shown in Fig.3.4/1.
After screwing off the releose lever nuts ond
compressing the clutch cover,
the clutch is
reody for dismontling.
3.4 CLUTCH REASSEMBLY
1. Locote
the clutch pressure
plote
on the
MP 2-101
ossembly plote
ond fit springs
on the
cylindricol bosses. Before fitting
the springs, it
is odvisoble to check them for
complionce with
the volues specified
in the following Toble.
Toble of Clutch Springs
Lood
Length of spring in mm
lin -rrr"ltp1
Mounted length
31.55'10+36
(s2t3.6)
Length of compressed spring 29.5
I 580 (59) 2.
Instoll retoining plotes
on the clutch
springs ond fit the clutch cover with releose
lever springs in position.
Assemble the clutch
cover with the pressure plote,
observing the
morks indicoting their relotive positions.
When
ossembling new pot'ts,
their positions
ore of no
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
using pods
of different heights, the plote
con be
odopted for different
types of clutches), fit the
yoke of the
iig on
the plote
bolt ond compress
it by screwing down the nut till the bottom port
rests on the pod.
When compressing the 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
under the springs instolled in the cover ond fit
them with their longitudinol
slots on the sup-
ports. Slip odiusting woshers on the bolts of the
pressure plote ond screw down the nuts with
their cylindricol port
focing the woshers. Then
odjust the height of the releose levers with
these nuts so thot their ends touch the shoulder
of the yoke
bottom port.
The difference of the
lever height should not exceed 0.'l mm. This
odiustment olso sets the recommended
distonce
of the levers from the pressure
plote
beoring
surfoce.
Use clinch nuts for locking the odiusting nuts
in position,
put
supporting clips under the re-
leose f ever ends os shown in Fig.3.111 ond3.212,
ond slocken the nuts of the ossembly plote.
The
clips ore useful when fitting the clutch to the
f lywheel since it is not necessory to overcome
the tension of the clutch springs.
To Check Adiustment ond Bolance
The described od justment
of the releose levers
in the
iig is
the most occurote, the ossembly Fig.3
Dim
plote be
simulotin
For on<
porogropl
The cl
with the
friction ;
ports of '
clutch on
To bol
centering
pressure
the chips
lf thesr
boloncing ing holes
in o circk
4mmofr
between
fostening
3.5 FR|C
lf the f
it is odvi
8.5 mm th
When r
the frictio
ond only r
complicot
After hr
the plote
if necessc
recheckinl
quired.
70 Fig.3.4l1
-
IAP 2lol
Assembly Plote with Clutch