boot SKODA 120 LS 1980 Workshop Manual

--
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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

Remove the clip of
the
clutch throwout beor-
ing guide,
insert the MP 3-102
iig into
the guide,
open its iows, ond withdrow the
guide.
After
hcving renewed the seol ring, drive home the
guide using the MP 3-103 drift. The droin hole
in the guide
must foce
downword.
The lotest desing of the extrocting
iig hos
the type dcsiqnotion MP 3-112. Screw the
iig
bolt into
the
iig nut
inserted into the mech-
onism through the hole cleored by the removol
of the clutch releose cylinder. Jerk the
iig to
drive the guide
out of the housing.
Dismontling the Power Pock
For complete dismontling of the power pock,
remove it from the cor -
see Chopter 4.-1,
"Rernovol of Power Pock from the Cor". Then
proceed os follows:
1. Remove the front cover ond the cover of
the pinion boll beoring, the clutch releose
mechonism, ond the clip of the guide
of the
clutch throwout sleeve, i. e., oll component
ports ottoched
to both holves of the housing.
2. Remove the connecting bolts of the flon-
ges. Force oport the f longes using o screwdriverr
inserted into the chombers of the flonge feet
(lugs). Lifting owoy oll component ports
one
by one is the usuol procedure
of dismontling.
Toking oport of lorger units (pinion,
etc.) is
described individuolly
in the following
chopters.
3. Press out the beoring cups which hove
remoined in the housing ofter its holves hove
been seporoted.
Use the MP 5-107
iig supported
by the MP 5-108
iig.
Fig.4.al2 -
Pressing Out the Cup of the Topered
Roller Beoring
Using MP 5-107 ond MP 5-108
Jigs
4.5 FRONT COVER
The front cover ossembly forms
o self-con-
toined unit fitted to the georbox.
For both the
reossembly ond dismontling ploce
it on o work
bench. Assembling
Front Cover
1. Slip the rubber seol ring on the speedo-
meter beoring ossembly (beoring
with geors)
ond push
corefully the beoring, preferobly
by
o steody rotory motion, into the cover
iust for
enough to be oble to instoll the key
without
domoging the seol ring by the shorp edge of
the keywoy. For the some reoson, chomfer the edge of the
beoring bore before
instolling the beoring in
o new cover.
2. Lock the beoring in the oxiol direction by
instolling the key
ond spring woshers, ond by
screwing down the nut.
Slip the clip on
the
protruding pcrt of the beoring ond lock it olso
in the oxiol direction with o bolt, spring
wosher,
ond nut. Do not
tighten the nuts fully.
3. Instoll the oiled geor
chonge lever in the
cover while pushing
it only os for os the groove
for the seol
ring.With the lever in this position,
insent the seol ring
in its groove
ond push
forther the lever through the ring. Slip the
dust
boot on the lever ond ottoch it to the cover
with o length
of locking wire.
4. Attoch the fostening (mounting)
lugs using
copscrews ond spring woshers. There
is o right-
-hond ond o left-hond lug, ond their slots must
be turned owov from the cover.
FK 1t't4
Fig.4.5l1- Front
Cove'r Assembly
Dismontling Front Cover
Lift owoy the speedometer
beoring ofter
hoving removed the sleeve
clomping bolt ond
the key (held
down by the nut). Then
withdrow
the geor
chonge lever by simply pulling
it out.
4.6 PINION WITH GEARS The pinion
with geors
forms o self-contoined
unit to be instolled in the georbox.
Use o work
bench ond o press
fon both its ossembly onddismor
wheel sure t
Only c
wheel
m itted
drive.
4.8.
Whe
olso tl
o new
one is
Assem 1.P
the pi
the or" thrust
toworc
3-104 p
ground
the be, must t
meosul
2.S
collor I
ring ir
the grr
The rir
3.5 to I
th ickes
ond pu
speed
3.H
it the '
selecte
toword
dismor (by tol
itinp
free to
Clon
MP 3.1
Note
inner b
toining
either r
-speed
ports.
4. Tr
groovir
pinion.
friction
groover
groove!
5. On
ond fit
the nex sizes 3
84

5.5-5.7
the toe-in of the reor
wheels using olso the
MP 8-152 gouge or onother speciol gouge
ovoil-
oble in your
workshop. To
obtoin the required
shift of the holf-oxles (symmetricol
so os not
to
disturb the oxle olignment), strike ogoin the
holf-oxles with o rubber mollet
os per poro-
groph 2.
4" Retighten the slockened connections
(rodius orm bolts) ond, occording to the pro-
gress of the reossembly, olso the nuts of the
holf-oxle shoft (see
Chopter 5.2, porogroph
5).
Complete the operotion by locking the nuts.
Fig. 5.5/3 -
Checking Alignment of Reor Axle
with Cor Centre Line Using MP 8-158
Gouge 5.6 HALF.AXLE DUST BOOTS
To prevent
oil from leoking through the
ioint
gop between the dust boot ond the joint
guord
os well os ony twisting of the boot during
the oction of the rood spring, or its domoge by
contoct with other cor ports,
it is importont to
observe its correct position
on the holf-oxle. lt
should be locoted
with its
flonges focing
reor-
wqrd ond tilted upword ot on ongle of obout
45o. For better occess, ploce
the clips fostening
the dust boot to the holf-oxle ond cover with
their screws on top. With the right-hond
boot,
screw in the clip screws from the front,
with
the left-hond boot the screw on the holf-oxle
from the reor ond on the cover from the front.
Connect the dust boot flonges with hollow
rivets using suitoble pliers.
lf riveting pliers
ore
not ovoiloble, bolt the flonges togethen instol-
ling odequotely dimensioned ploin
woshers
under the bolt heods ond nuts.
5.7 HALF.AXLE SHAFT
The thrust ring of the beoring (behind
the
shoft toper) is pressed
on the shoft. lf it is ne-
cessory to renew this ring, for exomple ofter
repeoted replocements
of the beoring (see
Chopter 5.1, porogrroph
4), press
it on so
thot
it is removed 76 to 78 mm from the edge
of the
toper behind the shoft
threod.
100

wi
prl
tht
rer
oul MT
ott
rec
.a
Fig
Dis S
boll
6-1C
rubl
ovo
exomple
50,000 km ond
more, check the wheel
comber ond prepore
suitoble woshers for its
correction. 2. Jock up the cor ond support the body on
both sides to relieve the front wheels, ond
remove the wheels. 3. Proceeding from
inside the luggoge boot,
remove covers protecting
the threods of the
shock-obsorber piston
rods ond screw off the
nuts. Retoin the piston
rod by holding its flot-
tened end.
b) Operotions inside the cor
4. Remove the steering wheel, the steering
column cowling, ond detoch the steering
shoft
from the body -
see Chopter 7.8.
c) Operotions from under the cor
5. Remove the bolt of the connection of the
steering shoftwith the steering box ond releose
the shoft sleeve from the connection by pull-
ing the steering geor
inside the cor.
6. Slocken the nuts of the bottom wishbone
pins fostening the front oxle to the brocket on
the body until the woshers of the brockets ore
releosed. 7. Detoch the onti-roll bor brockets from
the
body ond disconnect the rubber broke hoses
from the front broke systems.
Before discon-
necting the hose, cleon thoroughly the hose
connector ond its surroundings to prevent
foreign motter from getting
into the broke
system. For the some reoson,
wrop the
hose
ends in o cleon rog. Toke
the some precoutions
with the disconnected broke piping.
8. Ploce o roll-o-cor
iock under the oxle ond
remove the bolts (two
on either side
of the tele-
scopic shock obsorber) fostening the oxle to
the body from obove. 9. Compress the telescopic shock obsorbers,
lower the
iock, ond
move it with the oxle from
under the cor.
6.3 REFITTING FRONT AXLE IN
CAR
1. To reinstoll the oxle in
the cor, reverse the
procedure of its removol, i.
e., begin with the
porogroph 9 ond proceed
to the porogroph
1.
Coot the rubber
cup with greose
ot the point
of its contoct with the steering shoft.
2. While reconnecting the broke hoses, ob-
serve the utmost cleonliness ond bleed the front
wheel brokes if no other ports
of the broke
system hos been dismontled. (lf
such o dis-
montling hos token ploce,
bleed the brokes of
oll wheels ofter hoving fully reclosed
the broke
circuit). 3. Turn the wheels in the stroight oheod di-
rection before connecting the steering shoft
with the steering box. Fit the steering wheel tentotively
ond odiust the direction indicotor
switch -
see Chopter 13.17.
4. Using the steering wheel, tunn the wheels
into full lock positions
to moke sure thot the
lock ongle is correctly limited by the king pin
socket stops -
see Chopter 6.5, porogroph
36.
5. Adiust the toe-in -
see Chopter 6.1.
6.4 DISMANTLING
FRONT AXLE
No speciol instructions ore required for
dis-
montling mony of the subossemblies. Accord-
ingly, only the bosic dismontling procedure
will be
deolth with ond porticulors
will be men-
tioned only os fon
os they ore necessory for the
sequence of operotions ond the use of iigs.
Ports which con be dismontled witlrout re-
moving them from the cor ore the wheel hubs
and beorings, the broke mechonisms, steering
orms, shock obsorbers, ond the
onti-roll bor.
lf ony odditionol ports
hove to be dismontled,
remove the oxle from the cor ond dismontle it
on the stond.
Dismontling Wheel Hubs
ond Beorings
1. Dismontle the broke mechonism os per
Chopter 9.1 ond remove
the wheel hub
cop
using the MP 6-124 drog. When using the MP
6-136 pull-off
cortridge, the hub cop hos to be
prised off with o
tyre lever or o similor tool.
Now remove the costelloted nutwith its wosher
ond pull
out the hub,
ossisting the removol
with
light blows of o mollet, if necessory.
2. Toke out the inner port
of the outer beor-
ing, then the seoling ring, ond, f
inolly, the inner
port of the reor beoring (cone
with topered
rollers). Prise out the seoling ring using o
scrrewdriver. Proceed corefully olong the ring
circumference to ovoid distorting the ring which
Fig. 6.4/1 -
Removing Hub Cop Using
MP 6-124 Drog
106

7
.7-1.8
(
t
t
t
; (
(
b
tl
ir
tl
p il
o
tl
p
odiust,
if necessory, the driving dog of the di-
rection indicotor switch -
see Chopter 13.17.
Refit the steering wheel so thot its spokes
ore horizontol, lock it in position
with the nut
(for tightening torque, see
Chopter 1.8), ond
bolt down the spoke shroud.
7.8 STEERING WHEEL SHAFT AND SHAFT
BEARING
The steering wheel (column) shoft is built
up
of two ports
with the beoring in the uPPer port.
Usuolly, it is not necessory to disconnect the
two ports
of the shoft or to remove the beoring
ond steering lock. lt
con be removed from the
cor os o unit.
Removol 1. Remove the steering wheel -
see Chop-
ter 7.7. 2. Remove the screws on the lower port
of
the shoft cowling ond pull
the cowling off.After
removing two bolts, detoch the cluster switch
on the shoft from the upper port
of the shoft
cowling. 3. Remove two front screws of the upper
Port
of the cowling ond remove the cowling.
4. Disconnect the leods
from the switches
ond the switch box.
5. From under the cor, remove the bolt of the
coupling connecting the steering
column shoft
to the steering box ond detoch the dust boot
from the floor. Remove the
bolts of the shoft
beoring (from
under the shoft)
ond the bolts of
the steering lock (from
the front) fostening the
shoft to the body, ond pull
out the shoft.
Ref itting To ref it the steering column shoft
in the cor,
reverse the removing procedure. While reinstol-
ling the steering wheel (Chopter
7.7), do not
forget to check the direction indicotor switch
for correct function.
Use ploin
ond spring woshers under the bolts
of the steering lock
brocket. Reinstoll the shoft
beoring using spocing tubes, rubber bushes, ond
ploin woshers, ond secure the bolt of
the coup-
ling, connecting the steering
column shoft with
the steering box, with
o self-locking nut (for
tightening torque, see
Chopter 1.8).
To Disconnect Shofts
Remove the bolt
of the cross-pin
ioint con-
nection.
Connecting of Shofts
Fit o fostening sleeve on the tube
with the
shoft, dip the ring in oil ond slip
it on to the shoft end with
its wedge-shoped port
toword
the beoring, instoll the spring
ond the
ioint
socket of
the shoft bottom port.
Tighten
the
connection with the bolt with self-locking
nut
(tightening torque os per
Chopter 1.8).
The sleeve must be f irst built up if
the shoft
is refitted for the first time. Locote
both holves
of the sleeve on the tube ond fosten
them
lightly together by bending the tob of one holf
of ttre sleeve over the
other. The
sleeve must
on no occount clomp the tube tightly.
Bottom Port of Steering
Column Shoft
The shoft is provided
with cross-pin
ioints
ond connot be dismontled (token
oport). Before
fitting the shoft dust boot, smeor
it with
oil to
focilitote its slipping over the pcrrts
of the joint.
For this purpose,
it is clso odvisoble to wrop
the joint
in o plostic
foil or to moke o sleeve
with o pilot
cone.
Top Port of Steering Column
Shoft -
Beoring
Removol 1. l-ift owoy the fostening sleeve
ond check
whether the shoft rototes
freely in the tube. lf
it is not the cose, unlock the steering lock ond
press out the shoft proceedirrg
from the side
of its splined
end.
2. lf necessory, remove
the circlip of the shoft
ond lift owoy the beoring. The other beoring
hos to be driven out by topping it corefully
through the cut-outs in
the tube to ovoid domog-
ing it. 3. Remove the brocket with the steering
lock
- see Chopter 7.9.
Ref itting
1. Slip tlre beoring pocked
with greose
on to
the upper port
of the shoft, then the ring with
its wedge-shoped port
focing the beoring, ond
lock both ports
in position
with the circlip.
Press the shoft into the tube ond press-in
the
beoring (ogoin pocked
with greose)
from the
other end.
2. lnstoll the brocket with the steering lock -
see Chopter 7.9.
Shoft Beorings They hove to be thoroughly lubricoted
first,
since ofter their reossembly with the shoft od-
ditionol lubricotion is not possible.
lf there is
ony doubt concerning the greose
pocking,
re-
move the circlip f
rom the inner port
of the
beoring, toke the beoring oport, cleon it, ond
reossemble it ofter hoving pocked
it with the
recommended greose,
i. e., brond NH2 of Cze-
choslovok provenience
or one of the bronds
specif ied in Chopter 7.5, porogroph
3.
124

Shr
C
cle,
the
1
fittr
bor
(Im(
2
wit
woI
pisl
wor
the loc<(11,
3.
obo (M(
I nst
rod
the
oil' into
4.
witt
Con
prot
Inod
On f(
Inodr
oll c(
Excer
on c(
8.3 SHOCK ABSORBERS
The shock obsorbers ore of
the hydroulic,
telescopic, double-octing type of the PAL
moke.
The domping effect depends on the speed
of the
relotive movements of the oxle ond body. Doto
required for testing ond odiusting the shock
obsorbers ore given
in the following Tobles.
Front Shock Absorber -
see Fig.8.3/1
type PT 26x110,
Ser. No.443.621-215.000
1977-74 1 978 on
Maximum stroks llO mm 110 mm
Damping torce during
down stroke (compr€s-
sion 470N
500N
Damping force
during
upward stroke (expan-
sion) loSN
1
300N
Filling capacity lOO cc1OO
cc
Reor Shock Absorber
type T 26x175; Ser. No. 443.621.247.OO1
1977-78 1 978 on Both
types of shock obsorbers ore of similor
design, only their bottom fostening
is different
(the front shock obsorber hos o fostening eye,
the reor shock obsorber hos
o bolt ond locks
the outer protective
tube). They hove
o differ-
ent stroke, domping force, ond filling
copocity.
Removing ond Refitting When removing or refitting o shock
obsorber,
retoin the piston
rod (upper
fostening) by hold-
ing the flottened end of the threod in o sponner.
In the cose of
the reor shock cbsorber, retoin
the piston
rod in the bottom port
by holding the
heod of the bolt connecting it to the shock
obsorber cylinder.
The ossembly of the rubber bushes of the
respective shock obsorber mounting
con be seen
in Fig.8.3/1.
Access to the upper mountings of 'the
front
shock obsorbers is from the luggoge boot
(under the floor). The
threod is protected
by
o cop nut. The
mountings of
the reor shock
obsorbers ore occessible from the reor luggoge
comportment behing the reor seot bockrests ofter folding owoy the upholstery on the wheel
orch. The mounting is in the cyllndricol exten-
sion piece
in the scuttle
of the reor dosh.
Shock Absorbor Dismcntling
Dismontling is o routine procedure
beginning
with screwing out the plug
(1)
ofter the pro-
tective sleeve (tube)
hos been removed. Never
dismontle the piston
volves since there is o risk
of impoiring the domping force
by mixlng up
the volves.
o
o
*)
At o
temperoture ol 25
to 30oC,
of 100 strokes per
minute, ond
100 mm. frequency
stroke of
Fig.8.3/1 -
Front Shock Absorber -
Sectionol View
Maximum stroke
175 mm
175 mm
Damping force during
down stroke (compres-
ston, 470N
500N
Damping force during
upward stroke {expan-
sronl 950N
r
200N
Filling capacity 160
cc 160 cc
130

tr
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Broke
Shoes ond Broke Drums
When refitting
o broke shoe with o portiolly
worn lining moke sure thot it hos o thickness
sufficient to lost till the periodic
inspection
(ofter every 20,000 kilometres). The new lining
is 5 mm thick. When it is worn down to 1.5
to 'l
mm (4
to 3.5 mm when meosured
with the
shoe), the broke shoe hos to be reploced
with
o new.or
o reconditioned
shoe with glued-on
new lining. Be sure to reploce
the respective
broke shoes in both wheels to preserve
o uni-
form broking effect.
Speciol glues or cements
ond hordening ot
high temperotures
ore required when relining
the broke shoes so thot this
iob con
be done in
speciolized repoir shops
only. For informotion,
opply to the broke monufocturer -
Autobrzdy
Not. Corp., Joblonec
nod Nisou.
Broke drums are grey
cost-iron costings. Their
unequol weor
con be rectified
by mochining to
o 231 mm diometer.
No tool morks must be left
on their surfoce
which hos to be perfectly
smooth. The olignment deviotion
ond mochin-
ing toleronce should
not exceed 0.1 mm. The
moximum permissible weor is up Lo 232
mm in
diometer.
Only broke drums
with on identicol
diometer
ore permitted
to be mounted on one ond the
some oxle.
9.2 FRONT BRAKE
ASSEMBLY
Disnrontling ond Reossembly
1. Detoch
the broke fluid supply piping
from
the broke. Absolute cleonliness is o must.
Otherwise dirt ond foreign
motterwill penetrote
into the piping.
2. Renrove bolts lrolding
down the broke yoke
crnd lift owoy rlre broke
ossembly.
3. Use the MP 6-132 gouge
to set correctly
the broke (new
or repoired)
on reinstollotion.
4. Select the shims required
to fill the gop
between the end of the gouge
ond the foce of
the fostening lug.To position
correctly the
broke, insert shims
between the fostening lugs
cnd yokes. You con, however,
meosure direct
the distonce
between the fostening
lug ond the
trroke disk
ond set this distonce
in complionce
with Fig. 9.211 by odding pocking
pieces
to the
shim pock.
5. Using the respective
copscrews ond spring
'.^roshers, bolt down the yoke
to the lugs.
6. Attoch the supply hoses ond bleed
the
broke.
Replocing the Brake
Disk
A worn brol disk con be reconditioned by
grinding it to o thickness
of 7.5 mm. lf necess-
cry, reploce it with o new one 9 mm thick. The lowest
limit of thickness
of o still usoble
broke disk is 6.5 mm. The
moximum permissible
run-out of the friction surfoce is
0.15 mm.
1. After hoving lifted owoy
the broke os-
sembly, remove the wheel hub
ond then the
broke disk. 2. Reossemble the broke disk
with the wheel
hub using copscrews with spring
woshers.
3. Top
rrp or chonge the lubricont
in the
wheel
hub beorings ond reinstoll the broke ossembly
Replocing Broke Pods
The overoll thickness of o broke pod
with
new lining is 15 mm. When worn down to 7 mm
(with the lining 1.5 mm thick), the pod
is
unusoble.
Alwoys reploce
broke pods
on both ends of
the oxle of the some time so
thot their weor is
uniform. With regord to the coefficient of fric-
tion, they hove to be of the some
type ond
rnoke.
1. Suck off the hydroulic fluid from the tonk
so thot it is only holf filled.
2. Remove cotter pins
ond lift
owoy the broke
lining cover.
3. Remove the friction pod,
cleon thoroughly
the covities of the yokes, piston
ports,
ond dust
boots.
4. Fit the MP 6-134 force-off lever over the
broke disc ond drive the pistons
into the
cylinder bottoms by the presswe
of levers.
5. Ploce o new friction pod
into the broke
ossembly moking sure thot the clomp of the
thrust plote
fits into the collor of the piston
foce.
Fig.9.2l1- Front Wheel Broke Mechonism
ond Mounting (setting)
Dimensions
1 -
Broke disk
2 -
Broke
3 -
Shims
A -
Broke setting climension -
18.7+O.2
136

Reossemble the
pressure-relief
following order: dust cup, spring,
ond seol. Nicks ond burrs
ore opt to domoge
the dust
boot ond prevent
its perfect
odhesion to the
cylinder. Every boot must be odequotely pre-
stressed (topered)
so thot its seoling edge con
be in permonent
contoct with the cylinder sur-
foce. A decreosed prestress
signols excessive
weor of the dust boot or its fotigue. For the
cleoning ond lubricotion of working ports,
see
the instructions in
Chopter 9.3.
9.5 FRONT BRAKE WHEEL CYLINDERS
Wheel cylinders ore ossemblies formed
by
one cylinderwith the yoke
ond onother cylinder
with the f longe ond occessories. Fig. 9.5/1
shows the loyout. For cieoning ond lubricotion
of the working surfoces, see the informotion
in Chopter 9.3.
Dismontling
1. After hoving removed the broke pods,
disconnect ond lift owoy the interconnecting
piping, cnd then remove f our copscrews to
seporote the cylinder with the yoke
from the
flonged cylinder.
2. Pull off the retoining
ring of the dust boot
ond lift owoy the dust boot.
Connect o com-
pressed oir supply (or
the broke moster cylinder)
ond use it to force the piston
out of the
Fig. 9.5/1 -
Front Broke Wheel Cylinder c/w
Broke Pods
volve in the
spring plote,
Fig. 9.312 -
Secondory Piston Cup Mounting
Fixture for dio. 12 mm
Moster Cylinder
(1 -
guide bush, 2 -
clomping ring)
Fig. 9.3/3 -
Secondory Piston Cup Mounting
Fixture for dio. 22
mm Moster Cylinder
(1- guide
bush, 2 -
clomping ring)
9.4 REAR BRAKE WHEEL
CYLINDER
'l-he wheel cylinder requires procticolly
no
servicing. Whenever removing
the broke drums,
exomine the rubber dust boots.They hove
to be
perfectly tight, flexible,
ond undomoged. When
replocing them, exomine the inner surfoce of
the wheel cylinder ond the surfoce
of the piston.
Fig. 9.4/1 -
Sectionol View of Wheel
Cylinder
138

1 t.1
-1
4.3
surfoces ore
sproyed with o
Protective com'
pound. The floor boords including the floor of
the boot ore covered with textile corpets while
rubber mots ore used in Skodo 105 S.
The in-
terior luggoge comportment is
lined with insu-
loting felt
sheet.
fne body finish consists of severol loyers of
speciol onti-corrosive cootings, o primer
coot,
ond o synthetic boking enomel top
coot in
colours complying with
o speciol specificotion.
14.1 BUMPERS
To Remove Front BumPer
Disconnect the
leods of the horn ond front
direction indicotors. Remove bolts connecting
the side sections of
the bumper with the wings
ond bolts of the bumper brockets, connecting
them to the wheel splosh guords. Now
the
entire bumper is free ond it con be removed.
Te Remove Reor BumPer
Proceed in the some woy with the exception
thot there ore no leods to be disconnected.
To Remove Overriders
Screw off the nut M 10 ond lift owoy the
overri der.
14.2 WTNGS
To Remove Front Wing
First remove the front bumper (see
Chop-
ter 14.1), the front door (see
Chopter 14.5), ond,
in the cose of the left-hond wing, the boot lid
Fig. 14.211- Removing Front Wing -
orrows
indicote fostening points (see
Chopter 14.3). lf the door sill is covered
with o trim moulding, loosen this moulding
portiolly. Now remove the bolts fostening the wing to
the bodywork under the sill (from
underneoth),
on the side edge of the body post,
in the chon'
nel next to the boot, ond in the forebody under
the heodlomp.
To Reinstqll Front Wing
lf the seol strip in the front
Port of the wing
is domoged, reploce it with o new one, ond
stick it on if it hos got
unstuck. Pock olwoys
o new seoling strip between the wing edge ond
the body fromework. Then instoll
the wing in
position ond locote it by tightening slightly the
connecting (fostening) bolts.
Do not tighten
the bolts firmly before hoving fitted properly
the wing.
14.3 BONNET AND BOOT LID
Removing Boot Lid
Remove the nut ond bolt of the strut ond
the screws fostening the
hinges, ond lift owoy
the complete lid.
Removing Engine Bonnet
Slip the bonnet strut out of
its guide,
screw
off the nuts of the hinge fostening bolts, ond
lift owoy the bonnet.
Reinstollotion ond Adiustment of Boot Lid
ond Engine Bonnet
Instoll the lid (or
bonnet) over
the luggoge
(or engine) comportment ond
tighten lightly
the bolts ond/or the nuts of the hinge bolts.
Moke the lid (or
bonnet) fit perfectly
with the
edges of the bodywork by shifting the hinges
in their respective holes
os necessory, ond
tighten fost the bolts ond/or nuts of the hinges-
Assemble the strut of the boot lid.
Boot Lid Releose Rod ond Engine Bonnet
Releose Coble
The releose rod of the boot lid (Fig.
1.3113)
is connected with the reloy link by meons of
o pin
ond forms on ossembly unit with the lid
locks. The
hondle of the releose rod con be
removed ofter pushing
out the pin.
The entire
ossembly con be lifted owoy ofter removing the
lid locks.
Reverse this procedure
to reinstoll the os'
sembly. Tighten the bolts of the locks lightly
ond fit the lid properly
in positlon.
Now odiust
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