lock SKODA 120 LS 1980 User Guide

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

5. Use
the MP 1'105 puller
for removing
cylinder liners from the
block. Turn the centre
bolts of the
iig to expond
the
iig iows in the
cylinder liner (ot
the top flonge of the liner)
ond pull
out the liner by turning the vwench.
6. Before removing the comshoft, lift owoy
the volve toppets. lf o
removol of the cylinder
heod is not considered, releose
the boll pins
of
the rocker orms, lift cwoy the push
rods, remove
the si'de cover of the push
rods, ond withdrow
the volve toppets.
2.5 BRAKE TEST
AND ENGINE
LUBRICATION SYSTEM DIAGRAM
Broke Tcst In view of
the very specific chorocter of
the test, especiolly with
regord to the speciol
testing eguipment,we do not intend to describe
the test procedure, restricting ourselves to
men'
tioning only the moin volues which the test is
supposed to verify. Volues indicoted in the
diogroms ore oppli'
coble to o new engine or on engine ofter o top
overhoul, which hos been
correctly run'in
by
running for o period
of obout 50 hours (2,500
km
trovelled). lf the engine is tested under other
conditions, the meosured volues must opprooch
the diogrom volues conformobly with the mech-
onicol condition of the engine.
ln diogroms, peok
performonce
volues ore
indicoted os meosured in complionce with the
CSw (Czechoslovok
Stote Standords) ond DIN
,CsNr
kwrotN'
1{J
I
20
r5t0 (Deutsche
Ingenieur Normen), i.e. with
oll oc'
cessoires reducing the gross engine
horsepower
(woter pump,
olternotor, oir
cleoner, exhoust
silencer). The
effective horsepower con
vory
with respect to the diogrom volues
within
o toleronce limit of
minus 100/s.
Every engine ofter
o top overhoul or reploce'
ment of individuol ports
of the cronk mech'
onism hos to be run'in exoctly like o
new
engine. Do
not forget to
drow your
customer's
ottention to this foct!
'",ffi15
NM
300 t000 som
t/n{a
5000 l/rnrn csilr
kwuril'
50
i
ilii Fig.2.5l2
-
Power Output ond Fuel Consumption
Diogrom -
Skodo 120 L engine
1- 3 see Fig.2.5l1
5000 t/mrn
Fig.2.511- Power Output ond
Fuel Consttmption
Diogrom -
Skodo 150
S
engine
1 -
power output, 2 -
torque, 3 -
specif ic fuel
consumPtion
k/SAE: h. p.
(SAE) 1/min :
r.P.m. Fig.2.513
-
Power Output ond Fuel Cons
Diogrom -
Skodo 120
LS engine
I
38 1- 3 see
Fig.2.5l1

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

2.6-2.7
seot in the cylinder block using o copper or
oluminium rod.
Reconditioning Recesses for
Cylinder Liner
Flonges
Before ossembling o used
cylinder block,
inspect ond cleorr thoroughly the moting
sur-
foces of the recesses for
cylinder liner f
longes.
lf chemicol ogents (petrol,
etc.) foil
to hove
the required
effect, or if the surfoces hove
been domoged
mechonicolly, use the MP 1-106
dresser, or the MP 1-157
iig with
universol guicc
rings.
Reconditioning of Comshqft Beorings
lf on oversize
comshoft is to be f itted (ex-
cessive beoring cleoronces in on otherwise
sound block), drive out the plug
on the reor
side of the cvlinder block ond reom
the beor-
ings to dimensions specif ied in the following
Toble:
-0.025To
Grind
For grir
shoft by t
between 1
'Ihe
reor
ond there
for detoils
beoring.
For grir
prepored
clomped t,
pins must
Externol Col
Nomir iourn
Stondord
1st regrin
2nd regrin
3rd regrin
Stondond comshoft
Diometer of beoring in cylinder block
mm
+0.02s
38.5
+0.021
Oversize comshoft lsg
l-
38s-
l-;- -0.041
-0.020
The numerical symbols of the beorings (
l-lll)
indicote the respective
front, centre, ond reor
beari ngs.
Close the newly
mochined bore with o new
plug ond seol
it with o dob of point.
A poor
seoling would result in oil leoking
from the
engine into the clutch.
When reboring the bore for
the comshoft,
observe the centre distonces of the cronkshoft
ond comshoft. Otherwise the timing choin will
be either too slock or too tout. For the correct
distonces see
Fio. 2.6/3. Reconditioning
of Volve Toppet Guides
lf there is on excessive cleoronce in the
guides (beorings) of the volve toppets,
it is
possible to recondition the guides
ond to re-
ploce stondord toppets by toppets
of o lorger
diometer. The centre line of the beorings
is per-
pendiculor (normol) to the seoting foce
of the
cylinder block. The relotive dimensions
of the
beoning ond toppet ore
specified in
the Toble
below: o
L_r
_-L1il I toi .ll
-t
QZt0.l -T-
zi
A'ry
@)
2.7 CRANKSHAFT
AND ITS ACCESSORIES
The cronkshoft hos three rnoin beorings ond
four cronkpin beorings. lt is o forging with sof t,
not hordened iournols. When
worn, it
must be
reground to dimensions os per
Toble for fitting
oversize big-end ond moin beoring shells
os
well os cn oversize guide
ring. Cronkshoft Beoring
(for
clutch shoft)
It will be driven or pressed
into the shoft
lubricoted with the recommended greose
with
its cover turned outword.
After its pressing-in,
odd odditionol greose
by forcing it into the
shoft bore behind the beoring.
Use the extroctor MP 1-109 for
the removol
of the
beoring. Diometer of comshoft
iournols
mm
_ =l__i tl
Volve Toppet Diometer
of Beoring
in Cylinder Block, mmToppet
Diometer
mm
Stondord
on;rsizt- 21
+0.021 21
-0.020
21.2 21.2-0.007
42 4th

Alternoting
cylinder No. 1
cylinder No.3
cylinder No.4
cylinder No. 2 Adjust cleoronce
on
cylinder No.4
cylinder No.2
cylinder No. 1
cylinder No.3
Fi1.2.1312
-
Volve Cleoronce Adjustment link from the choin
front side ond fit the clip
from the reor with its open end pointing in
the
direction opposite to the choin movement.
Before storting work on the volve geor,
re-
move the oil sump (engine
bottom cover to
which the timing geor
cover is bolted, the suc-
tion stroiner being ottoched to the cronkshoft
centre beoring cover) ond lock
the cronkshoft
in position
in the oxiol direction by depressing
the clutch pedol,
if removol of the entire engine
is not intended for onother purpose.
For speciol
points of the removol refer to
Chopter 2.4.
2.14 WATER PUMP
Disossembly 1. Unlock the wosher of the belt pulley
nut,
remove the nut ond pull
off the belt pulley
using
the MP 1-120 puller (o
fixturre for
Skodo MB 1000
cors) or o universol puller,
for the bolts of which
it is necessory to
cut threods M 8 in the belt
pulley holes.
By pulling
off the belt pulley,
occess will be
goined to the nuts fostening the pump
to the
engine. The some procedure
holds good
when
dismontling the pump
ofter it hos been removed
from the engine.
2. Withdrow the keyfrom
the shoft ond, using
the drift MP 1-121, drive
or press
out the shoft.
Then lift owoy the
housing plote
from the
seoting foce of the pump.
3. Remove the circlip locking the outer boll
beoring in position.
Proceeding from the reor
side of the pump
housing, drive out the boll
beorings with their spocer tube, ond remove
the
rubber seoling rring
from the housing.
Reossembly 1. Smeor the rubber seoling ring with greose
ond insert it into the pump
housing.
Use the
MP 1-123 drift to drive home the inner boll
beoring (without
sheet guord) pocked
with
greose. When opplying the drift,
fit its guide
ring into the bore for the
oute,r boll beoring.
2. Fit the gosket
on the pump
seoting foce
ond ploce
the pump plote
with its cemented-on
gosket (focing outwords from the pump)
over it.
Fosten the plote
to the pump provisionolly
with
one bolt to prevent
the gosket
from being dom-
oged during the following ossembly
iobs.
Insert the rubber seol,
wosher, ond conicol
spring into the speciol (bokelite)
seoling ring
of the pocking glond.
Instoll the spring
with
its nose
into the hole in
the bokelite pocking.
Slip the ossembled pocking glond
on the shoft
with the spring toword the shoft geor,
ond drive
the shoft home into the pump
beoring, while
supporting the beoring with the MP 1-123 drift. Fig.2
4. Fit t
shoft ond
stolling th
in positior
it with gre
sheet guor
5. Top
t
lieve the r
@@@@
DK 1240
Fig.2.1313 -
Volve Arrongement in Cylinderr Heod
Block disks -
exhoust volves
White disks -
intoke volves
Timing Choin ond Timing
Geors
Modified chain and gears
fitted since October
1979 recognised by
squared gearteeth
and chain
with split rollers.
The timing choin hos no slock odiuster (ten-
sioner). A slock choin does not substontiolly
offect the volve geor
occurocy but its operotion
is noisy. Therefore
its correct length should
be
ensured either
o) by selecting o suitoble choin from o number
of choins ovoiloble -
try it on the timing
geors, o1r
b) by replocing the stondord comshoft geor
with on oversize geor
(with greoter
toler-
onces). The comshoft geors
ore groded
in
keeping with their progressive
size (tol-
eronces) into closses A, B ond C. With the
exception of
closs A, the closs morking
letters ore stomped next
to the punch
mork.
For trying, the choin con be disconnected
to ovoid removing ond refitting of the timing
geors. To recouple the choin, insert the coupling Fig.2.1t
52

6.
Complete the pump
ossembly by fitting
the
Stouffer lubricotor filled with
the recommended
greose.
2.15 ROCKER SHAFT AND ROCKERS
Assembly (on
Skodo 105 engine)
1. Instoll the lock ring, ploin
wosher, ond
spring wosher on the ro6ker shoft
with both
ends plugged.
Smeor the shoft with oil, fit the
rocker (with
its orm with the thrust foce de-
flected toword the next ossembled ports),
the
shim, the rocker support, ond the other
orm
def lected toword the support, i. e. the complete
rocker unit of cylinder
No. 1.
2. Then slip the spring,
the rocker, the sup-
port, the shim,
ond the next rocker, i.e.
the
complete rocker unit of cylinder
No.2, on the
shoft.
3. Threod on the spring ond, using the mirror
orrongement of the ossembled
rocker units,
instoll the rocker
units of the remoining
two
cylinders. Use o lock ring supplemented
with
o ploin
ond o spring wosher
to lock the os-
sembled ports
in position.
The rocker support of the cylinder No.4 must
be provided
with on oil hole
to provide
for the
supply of oil to the rocker shoft.
4. Compress
the springs
by holding down the
rocker orms ond lubricote
oll loterol contoct
surfoces with oil.
Assembly (on Skodo 120 L
ond 120 LS engines)
The rocker shoft is provided
with two od-
ditionol rocker supports fitted from
the outside
of the rocker units (the
shoft is longer), re-
plocing woshers obutting
on the lock rings.
For
the rest, the ossembly is identiccl
with the pro-
cedure described in porogrophs
1 to 4 obove.
NJote: Rocker orms
on the Skodo 120 LS en-
gine ore shorter (18.5
mm) thon those on the
Skodo -120
L ond Skodo 105 engines,
in order
to obtoin o higher rotio.
Disossembly
Remove the lock ring from the shoft
end ond
strike off the
entire volve nocker geor
from
the
shoft.
2.16 CYLINDER HEAD, VALVES
AND
SPRINGS
The cylinder heod is o costing of speciol grey
cost iron. The volve seots ond guides
ore cost
ond mochined directlv in tlre heod. The volves ore of different
diometers, the intoke volves
being lorger. Outer (exhoust)
ports
ore single,
oll remoinlng ore doubled, i.e. bifurcoted
ond
bronching to two volves in odioining
cylinders.
The centre exhoust port
bronches to the cyl.
inders No.2 ond 3, the neighbouring
intoke port
to the cylinders No. 1 ond 2, ond No. 3 ond 4.
The cylinder heod con be hondled
in the cor os
o unit. Of the individuol
iobs, only
the reploce-
ment of volve springs,
cotters, ond cylinder
heod bolts con be corried out with the engine
in. position in the cor. For oll the remoining
iobs, the
cylinder heod hos to be removed
from
the cor.
To remove
the volve springs,
screw out
the
sporking plugs ond, using o tommy
bor with
o curved end (steel
bor of obout 5 mm dio-
meter), broce
the volve to prevent
it from
sliding down into the combustion
chomber.
To Remove
Cylinder Heod from Engine
1. Let
the engine cool down before removing
the cylinder heod to preclude
worping of its
beoring surfoce.
2. Droin
the coolont into o cleon vessel (see
Chopter 15.13), detoch oll ports
connecting the
cylinder heod to the vehicle,
ond remove
oll
ports which ore likely
to obstruct the removol.
3. Remove the oir cleoner,
lift owoy
the
cylinder heod cover, ond remove
the nuts ond
bolts holding down
the cylinder heod (on
en-
gines of Skodo 120 L
ond 120 LS cors, two
bolts olso hold down
the end rocker
shoft sup-
ports) reversing the order of the numbers
in-
dicoted in Fig. 2.1611.
By pulling
the exhoust
monifold, disengoge the
cylinder heod ond lift
it owoy.
To Refit Cylinder
Heod on Engine
. 1.
Locote the cylinder heod gosket
on o per-
fectly cleon surfoce of the cylinder
block (cleon
Fi1.2.1611- Tightening Diogrom of Cylinder
Heod Bolts ond Nuts
For tightening torques see Chopter
1.8 the
cylinc
the oilwo,
structed c
Releose
once odjur
heod. lf nr
the rocker
2. Swin<
down the
porogroph
opply the
liminory o
the sequ€
(Fig. 2.16/
shoft suppr
3. Adjus
ter 2.13,
re
cleoner, rer
tighten oll
Cylinder Hr
Disossem
heod on o r
o support i
it does
not
o iob from
t
An exomple
1. Remove
the cosing
control, end
geor ofter
supports.
Fig.2Je
For holding
c
bolt M 8 scrt
rocker-shoft st
1 -
MP 1-113
v,
2 -
MP 1-114
v
Itl
I
I
/\.
-
( 3 r--{ 4)
\-/
\II
l
/
,/
t___v'
?,3
"'@-:lO
54

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

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

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

r
t
i
5. Prc
scri bed
rods onc
4th spee
fork rod,
irr the b
6. lnsl
guide bu
cover inr heods. S
tob wos
edges of
F it thr
stri ki ng
weoker s
ing forks 7. Tigl
the forks fork rod
the strik
function
Reverse-:
Fig
-1 - Rever
2-1st-o
3-3rd- o
4 -
Rever
8. Inst
press-f ittr
verse-spe
inside th
through t
Turn tl'
end foces
lock it in
hole. Tigl
Pinion Ar
9. Instc
ing ond,
r
_-_-- -
. i\:r,,,
\. 43
Fig. A.1l'l -
Power Pock
1 -
engine with mounting, 2 -
georbox/f inol
drive with
mounting, 3 -
reor oxle (holf-oxles),
4 -
rodius orms
retighten it using the recommended torque
(Chopter 1.8) ond screw down the clinch nut.
lf necessory, top up engine oil, f ill the cooling
system witlr on qntifreeze,
bleed the broke sys-
tem, ond
odiust the hond broke.
For the fosten-
ing of broke hoses (routing)
see Chopter 9.7.
4.2 ASSEMBLING
GEARBOX
Generolly, the reossembly
p'rocedure
depends
on the extent, to wlrich the unit hos been token
oport. For betterunderstonding,
we sholl des-
cribe the procedure
ond peculieorities
of reos-
sembly of o completely
disossembled unit.
Gear Chonge Mechonism
. 1.
Clomp the right-hond holf of the housing
(when viewed from the flonge securing
it to
the engine) in the MP 9-101 stond
com-
plemented with the MP 3-101 georbox
rock, ond
check the housing for completeness.
2. Instoll
circlips on the striking fork rods
of
the reverse
ond 1st ond 2nd speed. The ring
with the lower
nose is to be fitted
on the 1st--
ond 2nd-speed rods.
3. lnsert the reverse speed
striking fork rod
into the housing
so thot the inserted
end pro-
trudes slightly from its guide,
slip on it the
striking fork with the longer
side of its heod
first,- ond push
the striking fork rod through
the fork
ond the end of the guide
os for os=it
will go. 4. Fit tlre
MP 3-109 jig
into the free holes for
striking fork rods (both pins
of the
iig), ond
proceeding through the hole in its side ond
using o stick or o length of wire, push
the lock
pin into the housing
os for os it will go.
Proceed
in the some monner for
inserting the next pin
(use one pirr
of the
iig). Shift
it
iust so thot
the centre lrole remoins free for inserting
the
striking rod.
Puslr the lock pin
into the end
guide of the strikirrg
fork rods olso os for os it
will go. The
iig is not required
for
the instol-
lqtion of this pin.
Fig.4.2l1- Clomping Georbox Housing in Stond
Using MP 3-101 Rock
Fig.4.212 -
Locking Striking Fork Rods in
Position bv Meons of Lock
Pins ond Bolls
78 Fig.4.2l3
-
Instolling Lock Pins Using
MP 3-109 Jig