SKODA 120 LSE 1980 Workshop Manual

rill
,ili
I lzz
eslo+ ol doc eql uMop MaJcs
Puo esDeJo
qllM
ll IcDd 'doc
.to1ocl.tqnl iellnDts
eql
llo /v\ercs
s6ultDog dun4
rolDn1
lo uollDcllqnl
'PaDDruDP ll
'l! MoueJ puo pDeq
lloq eq]
rapun 6u1.r 6u1;oes
aql oslD eulrrDx3 '6u1.r
6u;1oas Meu D esn
'pe6otuop es!lvrraqlo lo pelrols!p s!
1! ,l 'uo!lcos
rDlncr!c lo s!
lMoq aql
roPun 6u;.r 6u11oes eql
'uo!lDz!l!qDls sl! reuo la^el llo eql
Iceqcer
puo eu16ua aq1 dols uaql'e6o1oa;
lol 6u;1unou
retl!l l!o eql
6u!lceq3 el!q/v un: eu16ua eql
lol 'lloq
eqt uelq6lt puo
au16ua aql uo JDlloc
6uglunotu aql uo
lMoq palquassD
eql acDld
6u1.rds q11m
elogd
lsnrqt eq]
prDMol spls s!ql qllM
luausle eql u.rn1 '(e1ou
u61aro1 to slueuele
Jotlll euos
lo osDc aql
s!
qc!qlvr) e1o1d eql u!
lDas uouoq
lDuotltppD uD
qllM psp!^o.rd s1
lueuala rellll aql
ll : eto
N
'Du1ua1so; rellll I!o aq1 6u;rnp
roam a^lsDrqD o1
lcelqns s1 6u1.r 6u;1oes
,{rp
V
'lloq oqr 6ur11o1su1a.r eroloq
l!o u!
pDeq
1oq
eql ropun 6ug.r 6ulgoes eq1 d;p o1
1a6ro; lou oC
'luaulple retl!l Mou aq] puD prDMlno
6ugco; e1old
lsnJgl-eql q11r*
6u1.rds aql
l! uo
peddd;gs
6u1noq
rauD lloq eLll
llDlsuler puD
lMoq eql
uDelc
' 'lmoq
oql ulorl
6ugrds sl! tlllM .req1e6o1
uMDlpqllM eq uDc l! puD pesDelel
s!
lueuele
roll!, eql 'pe^ouer
lloq aql
qllnn 'l/v\oq
eqr
Ioano ryrg puD
lloq e:luec eq] a^oueg 'eu16
-ua eql
lo apls
puoq-1q61r
oql uo
lMoq lDclrp
-ug1Ac D ul pallDlsu!
s!
lueuola rell!+
l!o aql
lueualS jall!J
l!o lo lD/t^euau
'lro eql 1o i(1tp1ng1 ecuoqua o1
dn
l! rrlJoM
o] aui!]
Uoqs D rol unJ eu16ua oql
]al
'au16ue ploc D urorl po
aq] 6u1u1orp erole€l
6n16 u1o.16 10 -
Z/C'SL '613 '(g';
.raldoqC oes enbrol
6u!uelq6!t sl!
.ro1) u1
li 6ulrvre.rcs
uaqrrr
6n1d aq1 6u1ua1q611
-.rano r(q pDolr{} eql
dlJls o} ou
In}aJDc eB 'euo
r.lrou D qtlMl!
eco;dal'e6o1oe; u!
llnseJ o1 i;e111
s! qc!qM
e6outop
;o su61s Auo
srvroqs 6n1d u1o.tp
duns ;go aql
lo 6u1.r
6u;1oes eql
ll :
e
1o N
'l! Iceqcar puo 'ez!llqDls
la^al l!o oql
1a; 'slorvrllo
er{t IID o}u!
se}Dr}euad
11o eql_ll!r
(a1nu1u D ,lorl lnoqo) stull
lroqs o .ro1 eu16ua
eql unu 'llo
qserl qurlt
eu!6ua aql
ll!l 'rell!l
l!o aql
puo
6npd ugolp druns
llo eql
pellDlsuler
6u;noq JaUV '(pa11anor1
sarleruol!l Jo Jeqrrnu
eql uo Dulpuedep) ouo /l^ou D qllM
lueuele
Joll!l aql ecolda: rolpuD
lmoq sl! uDelc
PUD
roll!l llo eql oslD
a^ouleu 'lno
/v\oll llo eql
lel
puo duns
l!o oql
uo.r1 6n1d
u!Dip eql e^oueu
e6uoq9 119
6nta
alog 6u1111J
t!O puo
>1c11sd!C
ltO -
L/0'91 '6lJ
'punolD
lo^al uo
pecold
oq plnoqs lDc aql 'le^al
llo aql
6urlceqc ueq6 'sllDM
aug6ue oql uorl uMop
Mol+ o] aull l!o oql
e^tgr '6utllll
JaUD Jo unr D
te1lo Alalogpauu! le^el t!o eql
lceqc lou oC
'asl'vtlcolclluD
11 6u11o1o.r
Aq 6n1d eql pa^oure: 6u1noq
lal1o
ro^oc poeq
lepu1;[c eq] ul aloq aql q6notql
l!o oqt
dn do1 'lq6leq
ulnulxDtx puD unullu!tu
s11 6u1>1.rotu seu!l eql ueomleq
1sn! eq
Plnoqs
qc!qM le^el lto eql
lcsqc o1
4c;1sd;p eql asn
le^o't l!O 6u;1ceqg
PuD ll9 dn'6u;ddo1
sfluossSccv sll cNv
lNleN3 8'9t
leqsDM usorcspu!/v eql
olu!
ISolcvle
rolDlpor eql
olu! ouolodg
X3ClUl
'6'a'(o1>1o^olsoqcazC u!) SfZSSUJIINV

I-
.'t Fig.
15.3/3 -
Oil Filter
oil f ilter bowl
witlr f ilter
element
centre-boll oil pressure
switclr pressure
oir. When driving often
on dusty roods,
ihe cleoning intervols
should
be shortened by
holf. For oir cleoner mointenonce in tropicol
re'
gions refer to
ChoPter 16.2.
Air Cleoner -
winter oPerotion
Remove the rubber
cop from
the cover exten-
sion orm ond
use it to stop the mouth of
the
orm. Fit o guide extension into
the cleored hole
in the ornr ond
insert the
corrugoted poper hose
(included in the
cor equipment) into
the
ex-
iension ond
the holder on the
intoke ond
ex-
houst monifold.
Give the
hose the required shope by
bending
it slowly ond corefully. Above
oll, ploce
it into
the holcier so thot
there is
o suff icient distonce
(wide enough to
insert o
finger) between it
crnd the exhot-tst monifold.
Tightening of
cYlinder heod bolts
The cylinder heod
bolts should be tightened
in the running-in period before
the gosket gets
settled ond then
ofter every replocement of the
gosket, i.e., ofter
obout 1,000
kilometres' For
itre tightening procedure,
s9e
Chopter
-2'16'
Check'ilg of vilve
cleoronce ofter
every tighten'
ing of tlie
cylinder heod
is o
routine procedure
which must not be omitted.
Volve Cleoronce
For checking procedures
ond odiusting volues,
refer to ChoPter 2.13.
Alternotor V'belt
Tensioning
Loosen the
nuts of the bolts
in the olternotor
f longe (fostening
it to
the engine ond
the strut)
ond'of itre
bottJ holding down
the strut on
the
olternotor, ond
swing
oside (tip)
the olternotor'
Adiust the
belt so
thot it gives
woy 10- to
15 mm midwoy between the
belt pulleys
when
depressed lightly (ot
if o- weight of obout
2 kg were opplieal with
the
finger ot this point'
LoCk the
olternotor in
this position
by tighten-
ing properlY
oll the nuts.
Belt dimensions: 9x9.5x1,0O0 mm.
To Cleon the
Distributor
The contoct breoker points, the
cover, ond
the rotor orm
of the distributor must never
be
greosy or dirty. Scrope off
ony burns on the
distributor cover.
lf you hove
cleoned the
distributor with
oetrol, do
not ref it the cover till ofter
the petrol
hos comPletelY evoPoroted.
222
oll
the greose
into the beorings. Tighten
the
cop thoioughly so
thot it connot be worked
loose by vibrotion.
Air Cleoner -
cleoning ond
replocing of
filter
element
Unclosp the cover
fostening clips
and lift
owoy the lid. Depress the
cross broce in
the
1ock6t, rotote
it
slightly to disengoge it, ond
withdrow the filter
element. Wipe
cleon the
inside of the
iocket, cleon
the filter
element or
reploce it with o new
one, ond reclose the oir
cleoner proceeding
in reverse order.
Shoke ond
top the filtet element to
rid it of
clirt porticles, oncl
blow it off ond through with
Fiq.15314
-
Lubricotor of
Woter Pump Beorings

ezz
'lloq Aellnd lleq uoqs{uDr3 eql
}o Poaq aq} ol
pe!lddD JeuuDds D esn 'au!6ue
eql 6u;urn1 .ro1
'11oq 6uldruopc
otll 6u1ua1q6g1 Iq uo;11sod slql u! rolnqlrl
:slp aql ajncss 'eu16ue
eql ol elqDc oq] uorl
leno-1rods eql Aq pelllruapl
s! ocuD^po
les eLll
o1 6ulpuodsorroc lolnqlrls!p aqt
lo uotltsod
aq1
'l1mo1s ]! urnler
puD
as!rvrlcolc lotnqllls!p
aql
alDlou 'Icolq
aql qllm
l;enllcnpuoc pelceuuoc
pod au16ue Jaqlouo ro
lcolq :epu11{c eq}
uor}
uut g
ol
t to acuDlslP
D
]D elqoc eql
lo pue
eql
plorl puo (11oc
uo11;u6; tuo.r; pDel 't'g)
re,roc
rolnqlrls!p oql
'o lno alqDc
erluec eql
llnd 't
'uo!l!u
-6! otll uo qcllMs puD
lelcoiq sl! u! rolnqlrlslp
er{l 6u1p1oq lloq 6uldtuolc agt
uesoo-l 'z
'ecuDApD par;nbal aql
lo enlDn oql ol
le^oc
roe6 6u;tu1l aql uo >1.rou 6u1u1l sq] ol e1;soddo
los s! Ae11nd
lleq UoqsluDrc aql uo
)rDr! Dultull
eql loql os
(11oqs1uo.rc) eu;6ua eqt urni '!
:sp!o tnorlllM ernpaco.rd
6u;lsnlpy (oslulod 6ug1oc1.rqn1
rolnqtrlsrC -
llt'gL '6tJ
sllog uMop-ploH rolourollv -
9i0'SL '6ll
uolloledg Jalull"^. lo] esoH
PUD
sd;13 6uluetsDJ ra^oC rauDelC rlv -
9/0'91 '6ll
oZToS
oZ Tot sl
ozl puo
1 ozl vclo)$
1 901 PUD S
901 VAO)S
(1loqs1uorc uo parnsoeu)
senlon Eulues clsDg
ecuDApV uog11u61 clsDg
;o lueulsnlpy
'slcoluoc eql lo Duluedo eql
]o lceLlc rDl
-n6uo :o1 g'g;
.raldoqC eas 'rvra:csdoc
uMop-plotl
aq1 Buluesool JelrD Japloq
]cDluoc aq1
6u1nor-u
Aq do6 oql lsnlpD puo 's1u1od
ralDarq lcDtuoc
aql ueeMleq do6
lcerloo eql
ro' g'g1-
.to1doq3
ol Jelou 'ruDc
llot{s lo}nqlr}slp
eq}
}o }l!l
lln}
eql o] eu16ua eql urnl pLrD 'turD
.ro1ol eq1 'Iro
-ssecau l! 'puD
ia^os Jolnqlllslp eql e^ouou
dogr 1u;o6 ra{Dorg
lcoluoC Du;lsnlPY
'(sttO golcedg -
Z'9L.ra1doq3 o1
reler)
6u;loeq 6u11oc;.rqn1-114s oql
ol uo
11o 1u1od-
-rnod rvrog
1o;ceds o d1.rp
puo
6ulsnoLl lolnq!rl
-s!p aql
to tuolloq
eql uorl
lloq aql
e^otuer
'uollcedsug ec!^Jas o .to
tlode.r o 6u1rvto1;o3
'(tuo11oq rolnqlrls!p eq] u! oloq orlt
q6no.rq1 tno ivrol,
lllrvr l!o snld.rns)
ap;d :e1oa:q
tcDtuoc eql
ut eloq eql q6no.rql pallddo
l!o lo
sdo.rp engl ol rnol qllr*
6u!snoq rolnq!rls!p oql
u! loJluoc 6u1tu11
;o6n;;lluac eq] elDc!rqn-l
'esoal6 LgZ tu!]D!C
qllm ro ('cte 'V
xDulleu lleqS) alo141 u61ero1
1o
sesoare -
z'gL.re1doq3 ees
-
esDor6 qrtr*
Petac
-lrqnl oq oslD uoc 'uoc
eql'6uo1o 6ugp;1s
r1a1
eq1 6u1pn1cug 's1u1od
asoqf '1u!l
loJluoc ulnncon
aql lo u1d eq1
puo
alpulds rolor aql (dorp
euo) 11o q11r*
A16u;.tods
loog 'Plotl
lllM ]lal aql
so 'ruDc
aq] aplsu!
llsl aql
Puo tuDc
aq1 6uo1o
6u;p;1s llel er{l
uo
llo qcnu
os dgtp puo 'r.u.ro
JoloJ eql PUD Je^oc
Jolnqlllslp
eq] a^oueu
rouqlrlslo oql elDclrqn'l ol

Fig.
15.3/8 -
Distributor Adiusting Elements
1 -
contoct holder, 2 -
rotor orm, 3- com,
4 -
distributor brocket, 5 -
distributor brocket
clomping bolt
Alwoys turn the engine clockwise to eliminote ony ploy
in the distributor drive geor
ond to
ovoid loosening of the bolt. To relieve the
com-
pression resistonce, it
is recommended to bock
off the sporking plugs.
b) Stroboscopic method:
When using this method, the volues of the
bosic ignition timing ond
the odvonce con-
trolled by the centrifugol timing control (for
its
diogrom refer to Chopter 13.5) should be odded
upwhile multiplying bytwo
the odded upvolues
occording to the diogrom. Any effect of the
vocuum control must be
eliminoted by discorr-
necting the respective hose (connecting
the
distributor vocuum unit with the corburettor).
The meosuring procedure
is indicoted by the
diognostic equipment itself.
To Adiust ldling Speed
Use the oir-correction screw (speed
cor-
rection screw). The speed decreoses when ro-
toting the screw clockwise ond increoses when
rototing it onticlockwise.
Adiust the idling speed in occordonce with
the tochometer ond within the limits specified
in the following porogroph "To
Adiust ldle
Run". The engine must be wormed-up
before
storting the odjusting procedure (see
olso the
following porogrophs) ond its ignition must be
in perfect
condition (distributor
contoct-breoker
points, sporking plug
electrodes, ond ignition
odvonce).
N o t e : For the bosic position
of the odiusting
screw refer to Chopter 2.19 - "Mointenonce
ond
Adiusting". Fig.
15.3/9 -
Air-correction Screw -
idling speed
correction screw
To Adiust ldle
Run
Acljust the contoct-breoker point
gop,
the gop
of the sporking plug
electrodes, ond
the ig-
nition odvonce. Then check
the
volve cleoronce
(if there is no cleoronce, odiust
the
volves),
cleon the oir intoke filter
element, ond moke
sure thot the occelerotor pedol link hos
the re'
quired free trovel -
see Chopter 12.2-
Use o needle to remove the plug
covering
the fost-idling screw
ond let the engine run ot
obout 2,000 r. p.
m. to ottoin on oil temperoture
of 70oC. Insert the probe
of the thermonreter
into the hole for the oil diPstick'
Now connect the
speed indicotor (tocho-
meter) ond the onolyzer of
corbon
.monoxide
(contoined in exhoust fumes). Use
the oir'cor-
iection screw (Fig.
15.3/9) to set the
speed
-r-?n
at 800 l;; t.
p. ni. cnd the fost-idling screw
(Fiq. 15.3/10) to odiust the
content of corbon
moioxide to 2*0.50/s or the oir-fuel proportion-
by-weight mixing rotio,
comporoble with
the
specif ied corbon monoxide content, to
1+.2 +$.t.
After about one minute of
the continued idle
running recheck the odiustment ond
correct it,
if necelsory. Close the hole
with the
fost-idling
screw by driving in o
new plug with
its bottom
outword.
Note: For the bosic position of
odiusting
screws refer to Chopter 2.19 - "Mointenonce
ond Adjustment".
To Lubricote Accelerotor Mechonism
Pour severol drops of oil into
the end of the
bowden coble tubing ond lubricote both
ioints
(on top ond below)- of the corburettor pull-rod
itself with obout one drop of oil. Then
depress
224

9ZZ
aqt lo lDeM
oql qll/v
AllDnPDlD sesosJceP ttlsluD
-qceu lnomorq] eql
to lo;d
A.rossaceu eql
luarulsn!PY
'llaM l!o e^eols
aql ul
lle' eql
uo
]carlp lro eql .rnod
-to '6u1
-.roaq (1nomo:ql) esoalar qclnlc
eql
lo e^eels
osDeler eql
]o lle/v l!o eqt olu! uMoP
Moll
lilM
ilo eql
qc!qM
uoJl re^el esDslal qclnlc
eql
+o
ssecer eJluec eql olul po
1o sdorp
ZL ol
OL Jnod
',rapu1lAc esDolar Llolnlc eql ]o Ja^oc el!lolDq
aql lor*o
U!l puD
6u1.rds eq1 lomo 6u1r*s uaql
'sloes rDor eql pulqeq
luaulroduroc a6o66n1
eqt
ur pJDoq
Joolt eql
,o Ja^oc
sJluec eq] a^oujeu
uollDc!rqnl
HCrnlC t'S!
reurDrls rolleinqrDC -
0L/t'gl '6!l
zrsL yo
uaarcs qllM
lMoq a6pnps -
7
.rana; 6u1tu1.rd dund -
;
uls tuDqcolA
rotoreleocv ,o uorlDclrqnl
-
6/t'gL '6!l dLun6
1111 lonJ -
LLlt'gt '6tJ
'u o !l!
-sod pelcol sl! ul aulotl slcrl3
]l lirl sprorvrdtt
ra^al aql 11nd uaql '.rarra1
6uttuud aq1 6utlonlco
Iq lenl gllrrr
dund eq1 er,u1.rd 'Arossecau
;;
'a>;ol aqt +o tnu aql
6u1ualq6r1
{q uorllsod ut lMoq aq}
arnoes 'lMoq
eql otru!
lDas eql LlllM
]l llDlsLreJ puo
1o.r1ad u! uearos
eql qsDM 'lDes
puD ueercs aql 6u1pn1cu!
lMoq
aql ADMD 1l!l puD
lMoq aql
to Luolloq aql
]D
(puoq lanoc) a>1oA aqt
lo 1nu eql
'ro {cDB
lmog a6pnlg
dun4
lanl uDelC
ol
'sseceJ anllcadsa.r
aqt olu! ig6nus s1l
l! loql os Mercs
6n1d eq1
]o plo
aq] qllM
l! llDlsuler puD
loas uo-paddtls
aql qllM
Marcs 6n1d aql uo
11 acu;d
uaql 'llo
ll Molq
puo
;ol1ed u!
ll llrMS 'tau1ol1s
aq1 {omo
llll 'lalur
lanl eLll
lD /v\arcs 6n1d
aqr e^oueu
,teulorls ,ollernqloc uoalc ol
'6ugqn1 uepMoq
eq] olu! requn'
lro aql
Ar.roc po.r-;1nd
aq1
1a1
01 soru!1
lDle^os ;opad lolo.relacsD
aql AlMols
6n1d ctlsold D
ql!M
Pasolc
sl 1l ol ssecco -
rnrrarcs 6ur1p;-1so1 -
0llt'91 '6!l

friction focing. lnodequote
ploy
results irr o too
short free trovel of the clutch pedol
ond on
olmost immediote clutch disengogement. Access
to the releose
cylinder con be goined
os de-
scribed in the previous porogroph
on clutch
lubricotion. Hold the rod protruding from
the
relose cylinder ond force
from it corefully the
releose lever, ogoinst which it is restingi
the
lever con be relieved by disengoging the ten-
sion (pull-off
) springs.
ln service, the forcing-off
must be ot leost
2 mm. Adiust it to 4
to 5 mm by odiusting the
length of the rod. After hoving
loosened the nut
on the rod
of the releose cylinder, rotote
the
releose finger to obtoin the correct rod
length.
Then retighten the nut, thus locking the releose
f inger in its position
on the rod.
lf the ploy
is correctly od justed,
the f ree
trovel of the
clutch pedol
pod should ronge
from 40 to 50 mm. lt should not be ollowed to
drop below '!0
to 15 mm. lf the described od-
justing procedure foils to bring the required
result, it is necessory to odjust the clutch
mech-
onism in occordonce with
informotion con
toined in Chopter 3.2.
Bleeding the Glutch Hydroulic System
The movement of the clutch pedol
is trons-
mitted hydroulicolly to the clutch releose cylin-
der. The couses ond symptoms of penetrotion
of oir into the hydroulic
system (similor
to the
broke hydroulic system) ore described in detoil
in the section deoling with brokes. The pro-
cedure of bleeding the clutch is the some os
wherr bleeding the brokes -
see Chopter 15.8.
Fig. 15.411-
Adiusting Elements of
Clutch
Control Mechonism
I -
releose cylinder rod, 2 -
releose cylinder,
3 -
releose lever, 4 -
bleed screw 15.5 GEARBOX
AND FINAL DRIVE UNIT
Checking Oil
Level ond Topping'up
Oil
Renrove the centre cover ol the
f loor boord in
the luggoge comportment behind the
reor seots.
Pull off the filler neck cop ond use
the dipstick
to check the oil level. With the diPstick inserted
into the neck up to its seoling ring, the oil level
should be obout 8 mm obove the upper line'
For this check, the cor
should be ploced
on
level ground.
After hoving topped up the oil,
woit obout 2 minutes (while
oil flows from the
georbox proper
into the finol drive ond its level
is stobilized), ond then recheck
its level-
Fig. 15.5/1 -
Tronsmission Unit Filler Neck
Fig. 15.512 -
Tronsmission Unit Droin
Plugs
ond Inspection Plug
1 -
georbox droin plug,
2 -
finol drive droin plug,
3 -
inspection plug,
4 -
switch of reversing lcmps
(except SKoDA 105 S)
ffi
;rt'i,*
tiiffi
ii.! i;
br'ill
226

LZZ
uo!lDc!Jqnl
u!d 6u!) rol sslddtN osDere -
LILgL '6lJ
aql lo eJD s6urrDeq aql
ecu!s uo!lDstrqnl
lou
sr osDer6
lo uollDc!lddo eql
;o asod:nd
eq1
'eprs reql!e uo e1dd1u asoe:6 euo sr
eratl
l- rD:)
aql repun lrroJ] olq!ssoccD eJD selddru ilsno.rt)
su16 6u1; lo uollDcllqn'l
'ecuDJoalc 6u1:oaq eql
lo truaulsnlpo
puo asoer6
lo lunoruD pallnbe;
eql Jol'LVpuogZ
o1 77 sqdolBorod 'g'g
reldoqc ol puD qnq
leoqM
eql lo lD^oruer rol
t'g .raldoqc eqt ol Jeleu
'asoar6 plo eql po^ouar
6u1noq rouo osoe.r6 qsa.r1 qlll
s6ulrDeq eq]
1codey 'elxD
eql urorl
sqnq
leaqM aql
enouau
s6ulroeg leeq/v to uollDclrqn'l
'gZ ol g7
sqdorDorod 'g'g
.ra1doq3 ees
's6u1loeq leeqrl'rto eouoloelc aql 6u;lsnJpo.ro3
luals!xe-
-uou I;locglcord aq plnoqs
luaus^our eer]
V
'I1e1oure1;o dn 1r ;1nd puo
uMop
1g qsnd
ro uMop
puo dn
leeqM eq1 6ulrvrs
puD
loc eql dn >1co1-
ecuDJDelC 6u;roeg laaq1
31XV INOUJ I'91
'JAID/!| put)
frlp Aq
palralto
Alasranpo erD slulol 6u1rae1g
'g'l puD g'2 sleldoqC oss -
asoar6
qsorl q]!M s6ug.roaq eq1
lcod puo
l;a1o1pauru1
ueql Meuar 'pe6ouop
a:o iaql ,l 'uo!l!puoc
:o; sdnc 6ug;oas Jeqqnl eq] eu!uJDxe 'uosDes
ploc eql
lo lesuo eql
lD l1;orcedsa'i11ouo1soccg
'uo!lDc!rqnl 6u;1o1nqo slDleru 6u;.roaq 6u11oc
-!rqnl-,les r.l]!rvt peurl
a.ro s1u1o! 6u1leels
11yalog
6u1111J xog 6ut:aelg -
L/g'gL '6!J
'g'7 raldoqc oql u! peu!oluoc suo!]cnrlsu!
ql!ivr ecuoproccD ut es!rrtsl!l Aold Iuo eloultu!l:l
r:ol1gsod u! lcol puD
ruaql
lceuuoJar '(g'l
lat
doqC aes) asoa.rti rll!M sluto! 6u1.raals oloo!Jqnl
'J)oJ IoDJI eql
uor1 spo-r 6ultaels
lceuuocs!(l
An14 a6o4u;1 6u;ree1g
lo uollDultullf
'paltnbel se dn do1 '/l^oleq
umoqs
se pojnlcelnueuJ
lclls dlp
qrlinr,
la^al llo lceqS
'6n1d aq1 lno Melos
l(oq outlaels eql
lo 6n;d
nne:cs
aql ol lsocce uteb ol
leeu/vl eleds
eq] a^otuou
-T-- 9t
+ J_ I
t
t-J
I e!l .MoJcs
uollcadsul aq]
s6n1d ulorp io 6u1ua1q6ll
puD
6u11oes aq1
xog 6upealg
ur
llO dn butddol
9NrU33rS 9'9t
puD
ro] 6n1d ugorp dr.uns
;go uo
elou aql ol raleu
l! Iceqc
puD ez!ltqDls
le^31 lro eLll
141 u1o6y 'eloq
aqt
dots Ilalo!peuu.r! puD
eloq uoglcadsul eqt olu!
it tcalu! noA
1oq1 u! Molaq
uorl oslD
llo qllM
pell!i oq uoc
llun uolss!ulsuD.r1
.rervrod
eq1
'pez!llqDls
sor{ 1! JaIJD
le^el lro eql
)caqc '(suol1cnr1s
-u! dn-6ugddol puo
6u;1caqo e^oqD
aql ees)
lceu rell!l aql
q6norql
l!o qserl
'o sarl!l
z u!
ll!l
puo s6n1d peuDelc
lllca;led u! Mercs
ueql 'lno
Moll l!o llo lol puo
s6nld ulorp eq]
Marcsun
e6uoqS 1;9
'ajnPasolcl Du!)caqc
puo dn-do1 aql
loeda: 'aloq
eql ,o lno seuoc
i1o ou 'larennoq
';;
'lno
Moll 11o snldlns
1a-1
'selnulu o/v\l lnoqD JeuD
ll Jenocun
PUD 'eloq
sLll dols 'eloq
aql olu!
llo lo lunoulD-
llDuls D
1c'elul 'dn
6ulddol puD
le^el l!o eql
6u!lceqc
Jol pesn oslD
aq uoc eloq
uo;lcadsu; eq1
e19t
yo
t'l-
I EtJ St sluloft
6u;raa15

I 5.7*
1
5.8
sell-lubricoting type
but the greose is intended
to rid the beorings of ony moisture which moy
get to them post
the seols in certoin circum-
stonces. Apply the greose
gun
till the lubricont
seeps post
the upper rubber cuP.
Front Wheel Toe-in
For meosuring
ond odiusting the toe-in, see
Chopter 6.1.
Fliminqtion of
King Pin PloY
Remove the coter pin
of the king pin
nut ond
rotote the nut to the next cotter pin
hole pos-
ition. lf the ploy
is not elinrinoted ond no
friction sets in with the nut in this position,
continue rototing it
until this condition is
ochieved -
see Chopter 6.5, porogroph 21. Lock
the nut in the f irrol position
with the cotter pin
Fig. 15.712 -
King Pin Hold-down
cnd Adjusting Ntit
Note: irr the list
of servicing (mointenonce)
iobs,
I,he porogroph on "Checking
Front ond Reor
Wlreel Brokes" includes
o) inspection of the broke-shoe lining ond its
replocement, if necessory
b) in the cose of the front broke, the cleoning
ond inspection of the protective (dust) cups
of pistons octing on the broke pods (shoes),
in the cose of the reor broke, the inspection
of the wheel cylinder dust cups (boots),
ond
in both coses the replocement of domoged
ports.
i5.8 BRAKE SYSTEM
Broke Fluid Tonlk -
filling
The brake f luid tonk is instolled in the boot
{inoin luggcrge comportment)
cnd closed with Fig.
15.8/1 -
Broke Fluid Tonk
o screw cop. lt serves
olso the r:lutclr lryrlrotrlic
control systenr. Keep the brqke fluid level withirr tlre ronge
of the moximum filling, i.
e., not lower
thon
10 mm below the "MAX"
mork or so high thot
it just
covers the pcrtition
woll of the tonk
which con be seen on looking inside the tonk.
Observe obsolute cleonliness when filling
in
the broke fluid through the screen in the tonk
filler neck. Refer to
Chopter 15.2 for recon'r.
mended broke fluid bronds. For broke fluid hondlinq precoutions, see
Chopter 9.9.
Brqke Fluid Chonge
The broke f luid obsorbs otmospheric humidity
ond the chcnge of its properties
is opt to offect
broking ond even bring obout corrosion of some
ports of the broke system.
The time period,
in which these chonges
con
toke ploce,
connot be defined with ony pre-
cision. Therefore forestoll troubles ond chonge
the broke fluid in the broke ond clutch system
every few yeors (preferobley
two to three
yeors ) .
Suck out the old f
luid from
the tonk, fill in
fresh fluid, ond remove the bleeding screws
one
ofter onother to let the old fluid be forced out
by the fresh
one from oll bronches of the broke
line to the clutch -
see the broke ond clutch
bleeding procedure.
Broke Bleeding Air con get
into the hydroulic system
of the
brokes either due to lock
of the broke fluid in
the tonk (low
level) or when removing
or dis-
montling some ports
of the hydroulic line. lf
there is o smoll omount of oir in the hydroulic
system, the pedol broke feels "spongy"
ond the
broke efficiency decreoses. Ingress of o lorge
228

6ZZ
't'zl reldDr{c
ees -
JDc eql uoJl l! e^oueJ ol AJDSSocau s!
l!
6ulsnop relel rDee
elDclrqn-l oI
WSINVHC3W :IoNVHC UV39 6'9t
'8'6
:a1doq3 ees 'suollcnJlsu!
pallDlep rol 'selqDO
erll ueyor.ls ol A.rossecau sr
11 '6ugsoercep
sr icuelcl;le eIDJq aql puD
ellssecxa seuoc
-eq le^Drl eql
ll 'salqDc
elDrq aql lo 6u1qc1er1s
puD roeM 6u1u11 elorq 6u1ssa.r6o:d eq] qllM
sesD€Jcu! re^el alDrq puDq
eql
lo la^DJl eeJJ
luaulsn!py elorg
puDH
6u1g 6u1ua1so3
dn3 1sn6 +o elold 6u11uno61
-
t/8'gl'6tJ
'dnc lsnp eql
puD
repulllc
leeqM eql uo
uogllsod sll olul auoq 6u1.r eql
acJol otr lene1 6ulpuodxa aq1 u1o6o asn puo
6u1.r
eq] ol uo
t/8'91 '69
ut uMoqs 6tl
aqr ilddy
'6ug: 6ulualsDl eql erluec puD
llDlsu! puD
rp!nll e)DJq qllM
ll looc 'uorlgsod
u1 dnc
lsnp
aq] Jo a6pa :aq1o eql
pallll
6u;noq reUV 'ra^el
6urpuodxa tel-g dU1; eql 6ulsn .rapu1lic
leeqM
aql otrur uolsrd eql acrol puo
uolsgd eql uo
dnc lsnp Meu
eql
llDlsul uaql 'spod
e)Drq )srp
luorl aq]
uo 6u11co suolsld
;o sdnc
lsnp pa6o
-uop e^ouer puD
6ur.r 6ugualsDl eLll
]jo aslrd
sdn3 (1sn6)
en;1celord uolsld 6ugcoldeg
'1-'6 :a1doq3 ol Jelei 'lDMauer
r!oql
;o Allssacau
eql puD
uorl!puoc r!sql 6ugsses
-so ro3 'qnq
leeqM eqt 6u!^oLuer reUD
pau;oD
s! sooqs elDJq eql o1 sseccD -
elxD lDeu
'sdnc lsnp
eql rvreusr 'a6ou.rop
lselqDr;s eql
Jo uo!lDc!pu! Auo
lV 'uo!]!puoc
.ro; sdnc lsnp Jleq] eurmDXa
puo 'spod
aq] uo 6u11co suolsld
aq+
'o sa3D+
-rns 6uturolpo eqf uDelc 'auJrl
aulos eql ]V
'sr:orlrsod
1ou16;.to rtaql u! spod
alDrq pesner
ltler 01
erns eB '6u1u1g
elo:q lo 1Dltneuar
;o Alrssecau
puo uolllpuoo eql 6u rssasso ueLlM
,, spDd
elDJ€,, 7'6 reldoqC ol Jelar -
alxD luot j
6u;u;1 e{DJg lo lD/v\eueu puo
uollDulruoxf
ETDJB
elxv luorl Jo Mercs
6utpealg -Zlg'gL '6lJ
'p!n tl
e)Drq qsarl
lluo asn :JrD
;o u; 6ur>1cns
luenard
ol aur!l poo6
u; dn
]r dol
puD
luDl eqt ul
le^al prnll
a)Drq eqt qcloM '6u1pea1q
6u1.rn6
'slseqM rnoj llo ]o sa)orq
eq1 siorvr;o peelq
ol
fuosseceu sl
1l 'eull
eql llo prnll
a>lorq eq] u!
pe6.rer,uqns aqnl oq]
lo pus
aql qllM
e;qgssod so
q6rq so.rol aql ploq
ol aJoo alol'.rol sso;6 eql
u1 paD.reuqns
eqn] oql
lo pue
eqt uo.rl 6u1doc
-sa dols selqqnq rlo
llll e:npecord
stql
loedag
'uosrad JeqlouD jo
acuols!ssD eql peeu
ll!M
nol 'paue1q611
{11n; uaeq soq Mercs 6u;peelq
eql raUD A;uo pasoaler
eq plnoqs
lopad aql sV
'Mercs aqt uetq6psr puD 'lopad
alorq aq1 A11n;
sserdep 'MeJcs
eq] uesool MoN 'MeJcs
6ulpaepq
eql o1 pelcauuoc
eqnl aql
]o Pua aql
l! ul
o6rauqns puD p!nll
eloJq aql qlrm I11otl.tod '.tol
ssol6 o Alqora;a.rd 'lesse^
uDalc D ll!J 'uotlcau
-uoc asoq aql e^oqD s! se)orq roer 3ql
]o loql
'(Zlg'gt '613
oes) esoq alDrq eql pulqeq
pelocol
sr selorq luor+ eq]
,o qcoe
]o MeJcs
Burpaalq
eLlI'aqnl raqqnr D ql!M
11 acoldar
puo
Marcs eql
;o doc reqqnr
oql aloueu 'secolJns
luacolpo
aql puD
.rapulli{c
leeqM sql
lo Melcs
6u;pealq
eql uDelc ueql puo'IuD]
3qt u! ptnll
eIDJq
aq1 dn do1
1sr;; 'selorq
aql 6ulpaalq ueqM
'lcella 6ur>1o.rq lo ssol
elelduoc o
puD le^Drl arlue s1g
1noq6noq1 ;opad eloiq eql
jo uorloD
,,A6uods,, D u! stlnse't
JtD
lo lunouD
6'S1-8'gl

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