lock SKODA 120 LS 1980 Service Manual

r 2.1-t 2.3
I
I I
I
Dissssembly
ond
Reossembly of Pedols
This is usuolly not necessory. The pedols
con
be disossembled ofter removing the oxiol screw
in the pedol
pin
ond slipping off the return
spring. Do not remove the switches if it is not
obsolutely necessory -
see odiustment. On re-
ossembly, lubricote
the pedol
bush with lubri-
coting greose
of the some brond os used for the
steering linkoge -
see Chopter 7.5, por.3.
Pedol Free Trovel
Adiustment
Adjust the free
trovel of pedols
ossembled
with moster cylinders so thot the pedol piston
rod hos o
cleoronce of 0.5
to 1mm
when beoring
ogoinst the piston
heods of the
moster cylin-
ders. The free trovel of the pedol pod
should be
from 3 to 5 mm. lt
con be odiusted by rototing
the eccentric pin
on the pedol
brocket -
see
Fi9.12.111.
For the odjustment of the broke pedol
with
broke booster ond/or levelling of the broke
pedol with the
clutch pedol,
see Chopter 9.6 -
Ad justment.
Adiustment of Switches The switches con be
moved in
the ellipticol
holes of the brocket ofter loosening the fosten-
ing copscrews with ploin
woshers under their
heods. A pocking piece
should be slipped
under
the switch of the broke pedol
trovel worning
light ond the powl
of the switch pin
should be
held down under the fostening copscrew.
Ad just
the stop-light switch
so thot it
switches on the stop lights ot o pedol
trovel
of 10 to 15 mm meosured on the centre of the
pedol pod.
Adiust the pedol
trovel signolling switch so
thot the pushed-in
side push-button
pin
is
re,ecsed ot o pedol
trovel of 100 to 110 mm
mecsured on
the centre of the pedol
pod.
Press
the push
button into
the switch ofter hoving
completed the
odiustment.
12.2 ACCELERATOR PEDAL AND CABLE
The occelerotor pedol
forms o unit with its
self-lubricoting beoring ond the lever.
lt is
bolted to the f
loor tunnel. A coble possing
through the tunnel is ottoched to the pedol
lever ond the reloy
lever on the engine by
meons of clomps- The coble is protected
by
o Bowden tubing.
Pedol Removing ond Refitting
1. Loosen the clomp holding the coble on the
engine-mounted reloy lever. 2.
Remove the copscrews holding
down the
becrring with the pedol,
depress lightly the
pedol, ond lift it out of the f loor
tunnel together
with the beoring. 3. Disconnect the pedol
from the coble ofter
ioosening the clomp.
Removol ond Refitting of Bowden Tubing
ond Cqble
The Bowden tubing is
fostened to
the brocket
irr the floor tunnel by
meons of circlips. After
their removol, pull
the Bowden tubing inside
the cor. On ref
itting the tubing, lubricote it with
o low-viscosity oil (of
the SAE 20
closs). lt hos
been lubricoted with greose
in the foctory.
Fit
the clonrps so thot their longer ports (from
the
screw to their end) ore on the side of the
I evers.
Accelerotor Coble Adiustment
Adjust the coble so
thot it is not
excessively
tensioned or too slock. Loosen the clomps on
the engine side of the coble, move slightly
the
clomp toword the reloy lever,
ond tighten the
screws of the clomp.
12.3 GEAR SHIFT LEVER
AND LINKAGE
The geor shift mechonism consists of two
units: the geor
lever with its housing ond oc-
cessories, ond the geor
shifter rod
ond the
shifter lirrk with joint
(ot the georbox)
for
domping the vibrotion of the power
pock
tronsnritted to the geor
lever.
Removing Geor Lever
Housing ond Link
1. Lift owoy the mot from the floor tunnel in
the front ond reor comportment. lf seporote,
remove the individuol floor mots ofter hoving
prised out their clips with o screwdriver or
o similor tool. lf o one-piece floor
covering is
used, remove the door sill strips
on one side,
tip the seot, ond bend over the
floor covering.
2. Remove the geor
lever housing copscrews
ond prise
out the lid (next
to the clip) between
the seots. Proceed through the
operture to dls-
connect the bolted connection of the link with
the housing shifter rod.
3. Lift
owoy the housing with the lever
through the operture. Swivel the lever so thot
the shifter rod
does not protrude
over the
housing beoring thus obstructiong the removol.
4. Usuolly it is not necessory to remove the
geor shift link from
the cor. lf
obsolutely necess-
ory, the link con be
disconnected only ofter
162

12.6-12.f
2. Proceeding fronr below, rernove
the fuel
tonk sheet guord
ond the guord
of the cooling
woter pipes.
3. Disconnect the pipe
of the clutclr hydroulic
line from the clutch releose hose brocket.
4. Screw out droin plugs
to droin fuel from
the fuel tonk ond ot the some time disconnect
the fuel hose from
the fuel pump.
After com-
pleting the droining, reinstoll the droin plugs
(screws) with their seoling rings.
Disconnect the tronsverse hose connecting
both sections of the fuel tonk ond stop the
open
pipes with rrubber
plugs (to prevent
the remoin-
ing fuel spilling over your
honds ond clothes
when lifting
the tonk owoy).
5. Disconnect the geor
shift link ond the
speedometer drive from the georbox -
see Chop-
ter 4.1, por.9.
6. Detoch cobles from the hond broke rocker
ond pull
them out from under the cor -
see
Chopter 9.8. 7. Droin the cooling system -
see Chopter
-15.13.
Disconnect the moin woter line in
the
rniddle of the cor. Disconnect the pipes
from
the engine (from
the hose of the thermostot
ond the pump
connecting hose) ond remove
the
pipes -
see Chopter 11.4.
8. Disconnect the hose of the fuel
tonk from
the fuel filling pipe, ond, in the upper port,
the
hose of the fuel filling line vent pipe.
9. Sever the electric connection of the fuel
level gouge
floot system under tlre right-hond
I eor seot.
10. Use o
iock to support
tl're georbox
ond
loosen tlre connection of the georbox
cross
beorer with the bodywork.
11. Loosen the copscrews fostening the fuel
tonk to the bodywork ond lower the
iock to tip
the power
pock.
Retoin the fuel tonk while ne-
nroving the copscrews, move the tonk bock-
words ond down, tip it down ond forword, ond
remove it in
this direction. 12. Should
the pipes
of the broke system ob-
struct tlre removol of the tonk, disconnet them
from the finol drive ond from broke hose brock-
ets.
Refitting Fuel Tqnk in Cor
Reverse the procedure
of the tonk removol.
Fill the cooling system with the recommended
coolont ond bleed it, odjust the hond-broke ond
the occelerotor cobles. Bleed the clutch hy-
droulic line
ond olso the reor wheel brokes if
the hydroulic broke line hos
been disconnected.
Tighten properly
oll joints
ond connections,
fosten the cobles, links, ond pipes
obsenving
their correct orrongement -
see Chapter 12.7.
Fuel Line ond lts Accessories
Filling pipe.
This is q
sheet -
metol tube ot-
toclred to
the hose on the fuel tonk by meons
of o clip, ond to
the bodywork by two holders
with o copscrew ond both o spring ond o ploin
wosher. lt posses
througlr o bushing in the side
of the bodywork. Venting line. The hose is ottoched to the fuel
tonk filler neck in the upper port
of the tonk
ond to the filling pipe
by meons
of clips. For
its possoge
through the bodywork stiffener,
see Fig. 12.714. For clips ond their tightening see
Fig. 11.4/1.
The oir-feed hose
is slipped on the filling
pipe outlet ot
the fuel tonk neck; its
loop is
inserted under the domping lining of the body-
work, ond its other end is inserted into the hole
of the filling pipe
socket bushing.
Filler neck cop -
see Chopter 1.5.
Fuel gouge -
see fuel reserve signolling
switch, Chopter 13.17.
12.7 ARRANGEMENT
OF PIPELINES, LINKS,
AND CABLES UNDER THE
CAR
The routing, fostening, etc., of pipelines,
links, ond cobles is described in
chopters deol-
ing with these ports.
They oll leove the floor
tunnel under tlre fuel tonk to
be covered by
o guold
held in position
by self-locking nuts
with ploin
woshers. The following
illustrotions
show their correct orrongement which hos to
be mointoined if incorrect function or domoge
is to be prevented.
lt is imperotive to ensure
free movement ond swing
of the geor
shift
link.
Secure the correct position
of oll ports
under
the fuel tonk by clips which hove
to be pro-
vided with sleeves preventing
domoge to Bow-
den tubings, etc. The overoll orrongement is
shown in
Fig. 12.712 ond 12.713.
Fig.
12.611- Fuel Tonk Droin
Plugs
164

'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

L
i g)
Excitotion of the olternotor by o current
supply outside the cor is not permitted.
Agoin the semiconductors would suffer.
h) A blown chorging worning lomp must be
reploced immediotely with o new
one. Other-
wise correct excitotion of the olternotor is
not ensured. Use o new lomp of
the some
roting (or input), i.
e., 1.5
to 2 W.
i) Be sure thot there is
o perfect
electricol
connection on the connecting terminols ond
thot the olternotor
ond regulotor
ore properly
eorthed.
i) The
olternotor is oeroted, open. Therefore
toke core when woshing the cor thot woter
or cleoning ogents do not get
into it through
the venting holes.
Removing the Alternqtor
1. Disconnect the bottery.
2. Disconnect the olternotor leods. lt will be
helpful to remember the colour of one conductor
ond its connection for reinstollotion.
3. Remove oll ports
holding the olternotor on
the engine, ond lift owoy the olternotor.
Reinstolling the Alternotor
1. Cleon oll mounting surfoces.
For the olter-
notor mounting, see Chopter 2.3, por.42.
2. With the bottery
disconnected, insert the
conductors into the respective
connectors "M,,
ond "R"
(the conductors beor the some sym-
bols), ond fosten the remoining leod with o nut.
3. Reconnect the botterv. Alternotor
Disossembly -
Repoirs
1. Screw off the belt pulley
nut ond remove
the belt pulley
ond fon.
2. Lift the brushes with o hook proceeding
through the holes in the
commutotor end
shield
ond hold them in the lifted position
by wires
inserted into the shield through dio. 3 mm holes
under the terminols uM'
ond "Ru.
3. Mork the mutuol (relotive) position
of the
commutotor ond drive end shields ond seporote
the qlternotor
ofter hoving removed its clomping
bolts. The drive end shield remoins connected
with the stotor.
This disossembly will give
occess to the
brushes ond some
of the diodes. All other
iobs,
with the exception of the renewol of the beor-
ing, should be done by experts in speciolized
repcir shops -
see the note supplementing the
following porogrophs.
Alternotor Reossembly
1. Insert the circlip into the becring bore
in
the commutotor end shield.
2. Fit the drive end shield with beoring on
the rotor shoft.
3. Assemble the stotor with the rotor ond the
commutotor end shield. 4" Tighten the olternoior with clomping bolts
ond check the rotor for free rototion while
tightening the bolts.
5. Slip the spocer on to tlre shoft,
top the
key in position,
fit the fon ond belt pulley,
ond
tighten the entire ossembly using the nut with
spring wosher.
6. Pull out wires from the commutotor end
shield which hove been used to hold
brushes
in their lifted position.
Replocement of Beorings
The used beorings ore fullyclosed ond seoled,
ond they hove been filled in the foctory
with
lubricont to lost through their entire service life.
1. Pull the beoring off the rotor
using o suit-
oble puller.
When ref itting the beoring, press
it
on to beor on the shoft
collor-
2. Before removing the drive end shield
beor-
ing, f irst drill off the heods
of the flonge rivets
ond then drive the beoring out from
the outer
side of the drive end shield using o suitoble
mondrel (drift).
On reossembly,
close the beoring with the
flonge ond rivet the flonge to the shield.
Replocement of Diodes
The use of the removoble
diode block with
the individuol
corriers of the so-colled positive,
negotive, ond ouxiliory diodes, focilitotes con-
siderobly the replccement of ony defective
176
Fig.133la
-
Alternotor -
Sectionol View

I
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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

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s
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t
(
(
t
l
,
t
T c
R
L D
v Ir
1' 2
3
orotely
(
screen the other one) . With lef t
directionol heodlomps,
the borderline deviotes
towords the other
side.
lf the heodlomps ore neorer to the woll thon
the soid
5 metres, decreose the meosure indi-
coting the
deviotion of the light ond
dorkness
bordeiline from the
height of the heodlomps
obove the ground in the
direct proportion to
the
decreose of
tfre distonce, for
exomple when
plocing the cor 2.5 metres
from the woll, de-
creose the deviotion bY holf.
Light proiections "A"
ond "B"
correspond to
the spocing of heodlomPs on
the cor ond they
hove the following dimensions:
Heodlomps, dio. 160
mm 1,030
mm
Duol heodlomps, dio.
130 mm 1,114
mm
Auxiliory heodlomps, dio.
130 mm 790 mm
When odjusting the heodlomps, the cor must
be empty ond the
tyres must be correctly in-
floted. Hologen heodlomps should
not be left
switched on for too long o period os they build
up heot if not cooled by heod-on
oir blost when
driving. For lhe odiustment of
heodlomPs ore intended
screws in their fromes. The screws
ore occess'
ible ofter the removol of the side ports
of the
grille. Remove the copscrews of the corners
ond push
the grille
oside.
Heodlomp Assembly
o) The fundomentol fostening
Port of
circulor
heodlomps is the
so-colled support plote
(rec-
tongulor plote)
ottoched to the bodywork by
copscrews with lock woshers. The
heodlomp
housing is bolted to this suPPort plote by bolts
with nuts ond lock woshers. One of the bolts holds
down olso the
lug of the eorthing coble-
The inner frome,
forming the
odiusting element
of the heodlomp insert, is ottoched
to the
hous'
ing by two speciol odiusting screws
ond two
tension springs. The heodlomp insert
is ot'
toched to
the bezel by
three copscrews.
There is one left-hond ond
one right-hond
support plote.
Both should
be mounted with the
oriow ond the word "TOP"
upwords. With
the
exception of the ouxiliory heodlomps, the
heod'
lomp inserts ore different for
the left-hond ond
the right-hond troffic. The leods
enter the hous-
ing through o
rubber grommet.
When r-eplocing the insert, remove
the bezel
copscrews. After
hoving fitted o new insert, it
is necessory to reodiust the
heodlomps.
Front Direction Indicotors
The right-hond ond
left-hond direction indi-
cotors ore undisossembloble units
(the
lomp
fostening sockets (locks) ore
mounted in the
direction towords the cor longitudinol centre
line). They ore fostened to their brockets in the
bumper with o nut ond o ploin ond
o lock
wosher.
Toil Lomp Cluster
The lomp cluster is on undisossembloble unit
fostened to
the bodywork by
nuts with ploin
woshers ond the
respective bolts.
Scrope off
the enomel ot the
top bolt used for holding
down the eorthing coble.
For the sequence
of the individuol lomps ond
their bulbs see Fig. 13.111 ond the respective
porogroph on bulbs.
Fig. 13.812 -
Adiusting ond
Fastening Screws of Right-hond Heodlomps -
their locotion
on
left-hond he-odlomps is their
mirror ref lection
1 -
Sidewoys odiusting screw
2 -
Height odiusting screw
3 -
Fostening screws
182

1 3.9-1
3.10
13.9 HORN
It is situoted behind
the left'hond port of
the
front bumper. To
remove it, disconnect the
leods ond remove the
fostening screw. heor
the ormoture being ottrocted (o
cleor ond
loud click). Now continue to
switch the bottery
on ond off
while rototing
corefully ond
sloryly
the screw "1"
onticlockwGe till
the
horn sounds'
iune it by rototing the odiusting.:cr9ry slightly
clockwise or
bock.-After hoving
odiusted (tuned)
ih" honn, secure
oll
odiusting ports with
o
dob
of point.
12
volts
4 omperes
Operoting
voltoge
Moximum current demond
Horn Adiustment
Before odiusting (tuning) the
horn, clomp it
firmly by th'e brocket ond
tighten thoroughly
oll screws "4"
ioining the
horn cover
with the
housing ond the dioPhrogm.
1. The horn is "hoorse"
- Using o screwdriver
rotote slowly the screw "1"
clockwise to odiust
the current demond
till the tone is cleor.
2. The horn sounds weokly -
Using o screw-
driver, rotote the screw "1"
slowly onticlockwise
to decreose the current demond
till the tone is
loud ond cleor.
3. The horn does not sound ot oll-Proceeding
through the operture in the front cover, loosen
the nut "2"
using o socket
sPonner. Then
insert
o screwdriver ond rotote
the odiusting screw
clockwise till it
beors lightly on the core. Then
bock off the screw by 1lz
or moximolly 3/a
of
o turn to odiust the distonce
of the ormoture
from the core. Hold the screw in this position
with the screwdriver ond
tighten firmly the nut
by rototing it clockwise. After hoving
connected
the bottery (of
the specified voltoge), you
will Fig.
13.9/1 -
Sectionol View
of Horn ond
o View
of Reor
Adiusting Screw
13.10 STARTER MOTOR
This is o series motor for
intermittent oper-
otion with on
electromogneticolly engoged
pinion. -@
c@c
Specif icotions
TyPe Roted outputStorting torqueSpeed for roted output
Voltoge ocross terminol
No-lood storting current
Direction of rototion
Number of pinion
teeth/modulus .
Contoct spring pressure PAL-Mogneton
12 V/0.8
h.
p. -
443'115'142'070
0.66 kw (0.e h.
P.)
12.25 Nm (1.25
kgm)
'1,000 r. p.
m. moximum
9.5 V moximum
65 A moximum
onticlockwise (left'hond)
912.5
e.3 N (0.ss0 ks) +100/6
"30"
of roted output
Mointenonce The mointenonce consists of periodicol
in'
spections ond repoirs or replocement of foulty
ports:
o) brushes
b) brush springs
c) commutotord) storter pinion ond idler
e) self-lubricoting beorings The brushes
must
be sufficiently long
ond
they must slide
freely in
their-cells, their
press-
ure springs must hove o
sufficient thrust,
the
commutotor must not
show ony
domoge, ond
it
must be
free of dust ond dirt.
Cleon the
commu-
totor with olcohol, petrol or
trichloroethylene,
ond let it dry before closing it
ond switching
on the storter motor. A
burnt or mechonicolly
domoged commutotor must
be repoired or
re'
ploceJ immediotely. A commutotor in
good con'
dition hos o brownish red
hue.
184

(
1
z
Strike the
slip-over ring off the circlip
(towords the motor windlng). Open the circlip
ond pull
it off the shoft together with the re-
leosed ports.
8. lf necessory, re-turn the commutotor ond
scrope or mill out the insulotion between the
lominotions. "Mikonit"
should be 0.4 to 0.8 mm
below the octive surfoce.
Note: The
switch connot be further token
opat. lf
defective, lt hcs to be reploced with
o new one. When cleoning ports
of the storter
motor, do not dip the ormoture or the pinion
with the idler into petrol
or onother degreosing
ogent.The some opplles to the end shieldswith
beorings. By dipping them in o degreosing
ogent, the beorings become procticolly
worth-
less"
Storter Motor Reossembly 1. Lubricote the hellx of the ormoture shoft
with greose -
see Chopter 15.2 'Lubriconts
of
foreing mokeu ond fit the pinion
with the idler
ond the slip-over ring in posltion.
Fit the
circlip
into the groove
in the shoft, ond drive the slip-
on ring over it. The pinion
with the idler must
move freely olong the shoft.
2. Slip the respective
woshers on the shoft in
their originol sequence (corrier
ring, distonce
ring, fibre ring, distonce ring) ond insert the
ormoture with the engoging lever
into the drive
end shield. 3. Suspend the switch
ormoture into the
pre-engoging lever ond bolt down the switch
lightly. Fit the lever pin
into the drive
end
shield ond lock it in position
with the retoiner.
4. Tighten the copscrews of the switch
ond
fit the stotor on the drive
end shield.
5. Instoll the respective
woshers into
the
commutotor end shield in
their originol se-
quence (the dished wosher with its centre
focing the shield, then the ploin
wosher, the
toothed wosher, ond the drive wosher).
6. Fit the commutotor end shield with lifted
brushes on the shoft (in
the position
occording
to the recess
for the excitotion outlet ond the
notch) ond screw in the clomping bolts.
7. Instoll the brush interconnecting strip ond
bolt it down together with the field winding
outlets to the positive
brush holders, lower the
brushes. 8. Fit the Insuloting strip in position
ond bolt
down the cover. 9. Test the storter mottr.
Diognosing Storter Motor Defects in Cor
o) lf the storter motor refuses
to operote, look
first for on interrupted connection between
the bottery ond
the storter
motor, the engine
eorthing ond the storter
motor, or the engine
eorthing ond the bottery. lf these connec-
tions ore in order (current
flows to the ter' DK
1575
Fig. 13.10/3 -
Storter Motor Testlng Connection
minols u30"
ond "50"
with switched on
ignition), stort looking for o foilure of the
storter motor switch. Even in this instonce,
the couse con be o fully dischorged or foulty
bottery.
b) lf the storter motor
continues running
even
ofter the ignition key hos been switched in
the switch box from the position "START",
it hos to be stopped without ony deloy by
disconnecting the bottery (using
its eorthed
pole).
c) lf the storter motor hos no power
to cronk
the engine, stort with switched-on heod-
lights. A
morked dimming indicotes c poorly
chorged bottery.
Tentotive Checking of
Storter Motor
Outside Cor
Connect the terminol "30'of
the storter
motor to o properly
chorged bottery ond incor'
porote on ommeter with o wide
meosuring ronge
into the circuit -
see Fig. 13.10/3.
Stort the
engine (feed
current to the terminol "50").
The
volue of the current ot idling speed must
not
exceed 65 omperes (not
considering the peok
ot
the first momentous deflection).
The storter motor must run noiselessly,
smoothly, ond the pinion
must move smoothly
into ond out of the rest position
(engoge
ond
diesengoge). The engoged pinion
must not ro-
tote direct on the foce of the slip-on ring. The
run-out of the storter motor must not lost longer
thon 8 seconds ofter the disconnection of the
switch from the current supply.
Inspect the brush pressure
springs. The
brushes must
beor on the commutotor by ot
leost two thirds of their surfoce ond they must
move freely in their cells.
The ormoture should hove o noticeoble oxiol
cleoronce (ploy)
not exceeding 0.7 mm.
At
o slight rototion of the pinion
in the direction
of the storter motor rototion,
the idlor must
slip
freely.
186

1 3.10-t
3.1 1
13.11 WINDSCREEN WIPER
Technicol Description
The rotory windscreen wiper consists of the
wiper motor
with o geor
cosing, o lever system
driving the wiper orms, ond two wiper orms
with wiper blodes.
The two-pole wiper motor
with permonent
mognets is o two-speed
unit with self'lubri'
coting beorings. The geor
cosing comprises onepicyclic
geor
ond on outomotic self-porking
device. The shoft runs in self'lubricoting beor'
ings, the geors
being lubricoted with greose
pocked into the geor
cosing. The lever system
(leveroge) includes self-lubricoting
ioints ond
beorings.
Windscreen wiper
tyPe -
for left-hond steering .
- for right-hond steering
Roted voltoge
Roted current PAL 443.122
-
081.071
PAL 443.122 -
076.071
-12
volts
4 omperes ot high speed,
2.5 omperes ot low speed
60 ot high speed (minimum)
20 (minimum)
to 50 (moximum)
ot low speed
15 cycles per
minute (minimum)
onticlockwise -
for left-hond steering
clockwise -
for right-hond steering
Wiping
cycles per
minute
Difference of cycles between speeds
Direction of
rototion when viewing
the output
shoft
I
i
f1
llr
fi.,
il
lr
l Removol
ond
Refitting
According to the
noture of the required re-
poir, remove either only the motor with the geor
cosing after hoving disconnected the pullrod
from the cronk, the cronk from the geor
cosing,
ond the geor
cosing from the brocket, or remove
the complete unit
ofter removing the wiper orm
beorings -
see wiper orm drive.
When ref itting
the windscreen wiper unit,
observe the
ossembly position of the
wiper
cronk -
see the following porogroph "Motor
ond
Geor Cosing". For position
of the wiper
orms
(blodes), see the porogroph 'Wiper
Arms". ln-
stoll the brocket into the body bulkheod ond
fosten it in position
with the nut, using o rub-
ber ond o flot wosher.
Cleoning ond Repoirs
When disossembling the windscreen wiper
motor, do the following jobs:
1. Reploce worn brushes ond use petrol
to
cleon motor ports
ofter blowing the dust out of
the brushes; moke sure thot the brushes move
freely in their cells. 2. lf the commutotor is
dirty, cleon it
with
petrol, if it is domoged, re-turn ond polish
it.
3. During cleoning, the self-lubricoting beor-
ings must not come into contoct with the
cleoning (degreosing)
ogent (petrol,
etc.). They
should be lubricoted
only with o low-pour-point
oil dripped into the cut-outs of the
cup retoining the boll beoring ond
the felt. Use only os much
oil os the felt con hold.
4. For the epicyclic geor
in the geor
cosing
use greoses
specif ied in Chopter 15.3 -
either
of foreign
moke or of
Czechoslovok moke -
re-
commended specificolly
for windscreen wipers.
MOTOR AND GEAR CASING
Ports of the motor
with the geor
cosing (or
geored motor) is the wiper brocket,
the pro.
tective housing, ond the driving cronk. When
instolling the wiper, put
the housing
on the
motor with the geor
cosing ond clomp it from
below. Bolt down the brocket using ploin
woshers under the bolts. Fosten the motor
eorthing coble under one
of the bolts.
Fosten the cronk in position
using o nut
ond
o spring wosher while observing its ossembly
position:
o) with wipers for left-hond steering-toword
the right-hond side
of the motor ond deflected
13o downword from
the oxis porollel
with the
centre line
of the motor;
b) with wipers for right-hond steering
toword the left-hond side of the motor ond de-
f lected 17" downword from the oxis porollel
with
the centre line
of the motor.
Dismontling the Geor Cosing 1. Remove three screws ond lift owoy the
cover.
188

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