window SKODA 120 LS 1980 Workshop Manual

The child'proof
lotch
of
the reor
door.s con
be
"ng"!J Uy
tipPing down
its
lever' The doors
;;; ;" open"d'froir outside
ofter
disengoging
iunfoctin'g1 the
lotch by pulling
the
Press'
button.
Fig.1.311 Inside
Door
Mechonisms
1 -
Hondle
2 -
Lock Press-button
3 -
Drop window cronk
4 -
Door pull
5 -
Ashtroy (depending
on
reor door
outfit) Fig.
1.312
Child'Proof Lotch
INSTRUMENT PANEL
t
a
(
Fis. 1 .3/3 SKODA 1O5
Slnstrument Panel
up
to October 1978
only'I
12
/l
910
1 -
Worning light
of
left-hond direction
indicotors, green
2 -
Speedometer
3 -
Worning light
of right'hond direction
indicotors, green
4 -
High-beom worning light,
blue
5 -
Th6rmometer (of
engine cooling liquid) 6
-
Chorging worning
light, red
7 -
Oil pressure
worning light,
reo
8 -
Distonce recorder
I -
Fuel reserve worning light,
omber
10 -
Broke sYstem
worning light,
red
11 -
Fuel gouge
12 -
UnoccuPied, green

13.18 FOG
LAMPS AND
OTHER OPTIONAL
EQUIPMENT
Fog lomps
The fog lomps ore optionol equipment. When
f itting them on the cor, refer to the wiring dio-
grom while observing notionol regulotions (in-
ternotionol regulotions
hove not yet
been uni-
fied os for os individuol requirements ore
con-
cerned) ond the following informotion. In
Czechoslovokio, the Decree
No.100/1975 of the
Book of Stotutes, porogroph
51, is opplicoble. Switching
reloy
Use o switching reloy of the some design
os
for the ouxiliory heodlomps (on
cors with twin
heodlomps) or onother reloy operoting in the
some woy. Any ploce
con be chosen for its
in-
corporotion into the circuit.
Cobles For worning lomps ond the reloy
switching
circuit use cobles with o section of 0.75 mm2,
for the remoining electricol equipment 1.5 mm2
section cobles.
R,ELAY SWITCHING OF HEADLAMPS
Optionol equipment moy include on incorpor-
crted reloy for switching in the heodlomps. In
some countries (for
exomple Sweden), this
reloy is required by regulotions. For the re-
spective connections see the following wiring
diogrom.
1L7 1L7a DK 1582
Fig. 13.1812 -
Wiring Diogrom of Heodlomps
Using Switching Reloy -
odditionol incorpor-
otion into the bosic electricol equipment
( Fi9. 13.1/1)
147 -
Reloy of moin heodlomps
147o- Reloy of ouxiliory heodlomps
Heated Rear Window (1979
on)
Circuit Divide into two sections.
1. Heater switch with five positions from
left
to right. a) Heated screen b) off c) High speed
fan d) Slow speed fan e) Slow speed and
heated screen. 2. Power supply.
;;---A.i'
t..[9-+'--'o
B
A
ll
Y
5-
r369
Fig. 13.18i 1 -
Wiring Diogrom of Fog Lontps
1- Switch, 2-Fog lomps, 3- Worning lomp,
4 -
Switching reloy (A -
reloy closing circuit,
B -
fog lomps feeding circuit), 5 -
Fuse No.1 of
cor electricol equipment, 6 -
Fuse No. 4 of cor
electricol equipment, 7 -
Fuse No. 7 of cor
electricol equipment, 8 -
Fog toil light, I -
Switch of fog toil light, 10 -
Wcrning lomp
Switches Instoll them on the ouxiliory ponel
(stondord
port of the
cor) under the focio. Use
the switch
with the built-in worning lomp for the toil light.
Worning lomps Use the unconnected green
wo,rning lomp in
the instrument ponel
for fog lomps; the worning
lomp oppertoining to the toil light
is built-in
in the switch.
I
I
I
l';
196

Fig.
M511-
Prising off Door Ponel
When it is roining or when woshing the cor,
woter runs down the gloss
ond penetrotes
into the inner spoce of the door. The
foil is
supposed to prevent
the forming of under-
pressure in the cor interior ond to prevent
the woter from sooking the interior trims ond
running down into the cor. Therefore,
it hos
to be stuck on by rubber cement os shown
in Figs. 14.512 ond 14.5/3 (cross hotching).
First slip the lower port
of the insulotion
(foil), the inner end, inside the door, ond
then opply o seoling compound on to
the
door inner metol-sheet ponel
ond the insu-
lotion os indicoted in the illustrotion (block
dots ) .
Close both doors
on the side to be adjusted
and visually assess which areas of each door
require re-positioning to produce
an even
contour joining
the front and rear
wing body
lines in relation to the door
heights.
With careful adjustment of hinges, satisfactory
body lines
can be obtained.
Hinges can
be moved on the door pillar in
the
following ways.
1 . Up and down after slackening bolts.
Result:
height of door in relation to door ap_erture.
2. In and out after slackening bolts. Result:
Position of
the door leading edge in
relation to bodY aPerture'
3. Shims Pt.
No. 1 13-98B9OO between
hinges and pillar
a) Shims under
both hrnges moves
the door
rearwards and
increases the gap
between
the door leading
edge and the
wing
(Front door).
b) Shims under the bottom hinge
only, will
lift the lower edge
of the door.
c) Shims under the top
hinge only, will
have the reverse effect.
It is
sometimes preferable to remove
the door
catch (On pillar)
to remove misleading stresses
being placed
on the door. This part
being re-
fitted and adjusted so
that both stages of
the lock are
working and
ensuring door is not
being stressed by
excessive tension
up or
down, in or out.
Adjust the door
catch to ensure when
the door
is closed, it will
not ride up or down'
Ensure the door does not catch the door pillar,
wing, other door etc., when both are open or
closed.
Door top half
lf you-have correctly
adjusted the
bottom half
of thb door you
may find that the window frame
top half still needs an adjustment.
Here it will be necessary to
lower the moving
window and carefully bend the
frame of the
window to match the frame
of the door'
Fig. 14.4/14
Common Areas
the Door Touches
Fig. 14.512- Front
Door lnsulotion -
":t;
hotching indicotes where
rubber cement hos to
be opplied, block dots indicote seoling
com'
pound opplicotion
204

! Door Cotch
Retoiner
The position
of the door cotch retoiner on
the door pillor
ond/or the reor wing foce con
be odiusted within certoin limits ofter loosen-
ing its fostening screws. Adiust the retoiner
in the required position,
check the door for cor-
rect closing ond fitting
with the other ports
of
the bodywork, ond then retighten
the screws.
The door cotch must slide
on to the leodlng
surfoce of the retoiner
so thot it rests
ogoinst
it. Sometimes, it moy be necessory to ploce
o pocking piece
under the retoiner (to
prevent
the fouling of the door cotch pin).
ln such
o cose, mork the position
of the
cotch on the
bodywork, slocken the screws, ond instoll o
pocking piece under the retoiner slipping it
over the lower screws ond
tipping it into po-
sition on the upper screws. It is importont to observe the correct ongle
of the inclinotion of the retoiner leoding sur-
foce, which hos to
correspond with the incli.
notion of the beoring surfoce of the door cotch
(outer door lock). Therefore, fosten the bose
plote of the retoiner so thot its upright stiffener
is porollel
with the edge of the moulded recess
for the retoiner
on the door pillor
ond the reor
wing. The leoding surfoce of the retoiner is provided
with o friction plote.
In the cose of domoge
(excessive weor, impoct of on incorrectly od-
iusted door, etc.),
prise
off the originol friction
plote ond fit o new one. lf the friction plote is
locking or if it is excessively worn, the door is
opt to rottle.
Fi1.14.514 -
Door Cotch Retoiner
14.6 WINDSCREEN, REAR WINDOW,
SIDE WINDOWS
To Remove Windscreen ond Reor Window
Rernove the connection of the spocing Insert
ond lift owoy the spocing
insert of the glozing rubber
moulding
using o suitoble tool. Now
press corefully ogoinst the gloss from
inside
the cor ond slip the liP of the glozing
rubber
moulding step
by step over the edge of the
windscreen or window frome
olong its entire
circumference, ond finolly lift owoy
the gloss
together with the glozing rubber
moulding.
To Refit Windscreen ond
Reor Window
First cleon thoroughly the
edges of the gloss
ond of the window opening (frome).
Slip the
glozing rubber moulding over
the edges of the
g loss.
lnsert o twine with o smooth surfoce or, pre'
ferobly, o rubber insuloted coble of 2.5
to 3 mm
in diometer into the inner groove of the glozing
rubber moulding.
Fig.M.6l1- Fitting Glozing
Rubber Moulding
on o Gloss Pone
Fig.14.612 -
Inserting o Twine into
the Groove
of the Glozing Rubber Moulding
206

Reverse
the
dismontling procedure
to rein'
stoll tl-re window ond its winder. The
loterol
ploy con be odiusted by odiusting (swinging
out) the centre post
ofter hoving loosened the
respective bolts ond nuts -
see Fig. '14.6/6
ond/
or 14.617.
Use this occosion to lubricote inner door
mechonisms -
see Chopter 15.12.
Fig.14.617 -
Reor Door Control Linkoge
ond Fostening/Adiusting Screws
1 -
Inner lotch control link (short)
2 -
Reloy lever
3 -
lnner lotch control link
(long)
4 -
Inner hondle pull
rod
5 -
Fostening/odiusting screws ond nuts
of
the
centre post
(third screw in upper port
of centre post)
Repair of Window Regulator Defects
lf the windows are difficult to wind up and
down (the
maximum torque applied on the
spindle of the window regulator with the glass
installed in the doors exceeds 2.5 Nm) (1.77
tt
lbs), it is recommended that the following steps
are taken as regards both the front
and rear doors:
1. Disconnect the regulator driving plate
from
the window glass
channel. Push the glass
upward
and try the relieved regulator by turning the
regulator crank. lf the regulator does not work
smoothly (jamming,
rattling) or if
a torque higher
than O.7 Nm/(O.495 ft lbs) in front and 1.1
Nm/(0.78 ft lbs) in the rear is required for its
operation, replace the whole regulator with a new
one working satisfactorily.
2. Adjust the centre pillar position
in the door
using the jig
as per
drawing No. A1-1 5417-S.
Loosen the top screw of the centre pillar
and
retighten it while pressing
the centre pillar
against the window glass
wound up to its upper-
most position.
Loosen the bottom screw of the
centre pillar
and retighten it while pressing
the
centre pillar
against the
window glass. 5417
-
S
-l! L
3. When bolting together the regulator driving
plate with the window glass
channel make sure
that the holes in these two parts
coincide along
the whole length of the channel. lf it is not so,
move the
channel into a satisfactory position.
4. lf the regulator is
not lubricated, lubricate the
regulator cable in the
tubing with grease
and
apply oil to the regulator
crank spindle.
To Remove ond Reinstoll Reor Door Fixed
Window
Agoin remove first the door trimming. The
gloss is only inserted
into the door frome ond
supported by o bolted-down holder with o rub-
ber pocking piece.
The gloss
con be moved in
the door
covity ond withdrown through the
door frome.
14.7 TRIMMING UPHOLSTERY AND WEATHERSTRIPS
Ponel-type Trimming
This type of trimming is used for
the doors -
see Chopter 14.5, Fig.14.511- ond for
the front
ond reor window posts.
Ponel-type trimming
fostened by clips (flexible
spocing pins)
covers
olso the porcel
troy below the reor window, the
outer guideroils
of the front seots, the front
wheel orches, ond the focia. On centre posts,
the trimming is fostened by screws.
208

l4.l
l-14.12
has two anchoring points.
The seat belts have
anchoring bolts
on the size 7/16-20 UNF-2A'
In f ront, the anchoring threads
are easily
accessible being provided
on the door posts
(remove only one of the pair
of pins
covering the
thread), on sills
below the posts,
and on
the sides
of the'floor tunnel
behind the front seats'
Anchoring points
for rear seat belts are shown
in the illustation. For the seat
belt of the person
sitting in the
middle, the threads are under the
seat cushions and rather removed from each other
(A3). For the seat belts of persons
occupying the
butside places
the threads are also under the
cushions, nearer to the centre (A2),
in the body
sides close to the cusions (82),
and in window
pillars (C2). These latter threads can be found by
touch in the point
of intersection of the plane
passing about 165 mm
above the
rear window
parcel tray and in parallel
with the door frame at a
distance of about 85 mm. To gain
access to
them,
it is necessary to cut through the trimming.
We must stress that for the fitting of points A2
and A3, the bolts should not protrude
beyond the Fig.M.11l2
-
Lower Anchoring Points
14-12 FACIA
l-he focio cctl be rentoved otter unsct-ewlllg
the nuts of its peripherol bolts ond
ofter lifting
owoy the instrument ponel -
see Chopter '13'15'
It is olso necessory to
remove the steering
wheel with the shroud of
the steering wheel
shoft (see
Chopters 7.7
ond
7.8), ond the heoter
control ponel
(see ChoPter 11.0).
The bolts holding down the focio
ore occess-
ible ofter removin! the
instrument ponel
ond
the heoter control ponel, ond
ofter swinging. out
the glove
box. To swing
out the glove
box,
open its lid ond loosen tlre screws of its
stops'
Fig. 14.1111 -
Upper Anchoring Point
captive not more
than 1lz mm or there is every
likelihood of damaging the
fuel tank.
The depth of the nut from the mounting face
is
15 mm.
Child seat fixing
Follow the seat belt manufacturers instructions
as to the spacing of the belt straps.
The straps can be mounted to the rear parcel
shelf if the mounting holes are drilled 30 mm from
the front engine bulkhead. The
sound deadening
trim in the engine compartment
will need to be
lowered to fit the spreading plate
and nut.
Be careful when drilling the shelf, not to
scratch the rear screen. Fig.
14.1211 -
Focio Mounting Points
14.13 WATER LEAKS
To determine the
source of
a water leak
proceed in a progressive
manner.
1. Determine area
water finally rests'
2. lf possible follow
water trace to
source'
3. lf hot, remove carpets and clutter'
4. Dry car inside
and out'
5. Us'e a sprinkler rather
than
a hose jet'
6. Start on the
underside of
the vehicle and
work up. Do not
do any adjustments or
sealing until after the
first test.
7. When"you have
finished adjustments and
sealing RE
TEST.
212

r
5.9-15. r
2
Dismontle the housing, remove
old greose,
cleon the individuol ports,
opply fresh greose,
ond reossemble the housing. Sook the felt rings
on the links (pull-rods)
in engine oil.
15.10 WHEELS AND TYRES, SNOW
CHAINS
Tyre Inflotion, Boloncing
ond lnterchonge
of Wheels
The procedures ore outlined in
Chopters 10.1
through 10.3. Snow
choins ond their use ore
deolt with in Chopter 10.6.
Wheel Toe-in -
see Chopter 16.1.
Shock Absorbers -
see Chopter 8.3 "Shock
Absorbers ".
15.11 ELECTRTCAL EQUTPMENT
Checking electrolyte level ond topping up --
see Chopter 13.2.
Sporking plugs -
electrode gop
odiustment,
etc. -
see Chopter 13.7.
Stqrter motor -
exqminqtion ond renewol of
brushes, etc. -
see Chopters 13.11 through 13.14.
lgnition timing, odiustment of contoct breoker
point gop, distributor lubricotion -
see Chop-
ter 15.3.
15.12 BODYWORK -
UNDERBODY
Woshing ond Mointenonce
The visible ports
of the body qre
f inislred in
o hord synthetic boking vornish, the remoining
ports in synthetic vornish.
The underbody is sproy-cooted
with o plostic
compound -
for detoiled informotion, see Chop-
ter '14.9.
Follow the
usuol procedures
when
woshing, cleoning ond polishing
the cor, ond
observe the specific instructions for
the use of
woshing ond cleoning preporotions,
issued by
their monufocturers.
All lights with the exception
of heodlomps
hove cosings of plostic
moteriols qnd
they
should be cleoned onlywith woteror shompoos.
When hosing down the corr
cover the voltoge
regulotor of the olternotor ond
the ignition coil
to protect
them ogoinst sploshing with woter,
ond do not
sproy woter direct on
the door lock
ond the lid covering the fuel
tonk filler neck.
Woshing ond Core of Underbody
Mechonisms
The underbody mechonisms
ore protected
with o synthetic vornish which stonds
well the
usuol woshing procedures.
Protect oll rubberports
ogoinst direct contoct with speciol chemi-
col solvLnts or limit the durotion of this
contoct
to o minimum before
o complete woshing off of
the solvents with woter (by
hosing down, etc.)'
Keep the oil cooler, if fitted on
the cor, in
cleon'condition. Hose
it down when woshing
the cor, ond if dirt still
sticks to the cooling
surfoces, use some of the detergents.
Bodywork Lubricotion
Routine mointenonce includes the
lubricotion
of door hinges ond limiters, hinges
ond releose
mechonismi of the engine bonnet ond boot lid,
the releose mechonism of
the spore wheel,
ond
the leveroge of windscreen wipers. Lubricotion
of inner dolor mechonisms is
included in
speciol
mqintenonce. Lubricote oll occessible mechcnisms
with
high-quolity greoses which
do not
dry, do not
oxldize, ond protect
the mechonisms ogoinst
corrosion for o long time. Oil is
not suitoble due
to its short-time efJect. Any greose con
be used
to lubricqte the
door limiters ond
the front
seot
slide roils.
Lubricotion of SporeWheel Corrier
Bearings-
Remove the spore wheel,
cleon the hinges, ond
opply oil on iheit
upper sides. In oddition, rub
in greose of ony brond.
Lubricotion of Windscreen Wiper
Leveroge -
Remove the cover of the
ioint (o
plostic cup),
f ill it with greose, lubricote the
ioint, ond
rein-
stoll tlre cover.
The Lubricotion of
Inner Door Mechonisms
is possible only
ofter removing the
door ponel
ond the inner 'door
mechonism. Use
only re-
commended greose brcnds.
Lubricote
the bowden
coble of thJwindow wind-up mechonism
with
Fig.15.1211- Lubricotion
of Windscreen Wiper
Leveroge Joint -
ioint cover
230

17.7 COMPLETE
CAR
T &:* MP 8-101 Cement
syringe
MP 8-102 Rodiotor fon hub puller
MP 8-152 Toe-in gouge
MP 8-157 Comber gouge
MP 8-158 Reor oxle olignment check gouge
MP 8-159 Check gouge
for underbody (front)
MP 8-160 Check gouge
for underbody (reor)
MP 8-161 Window frome moulding fitting fixture