tow SKODA 120L 1980 User Guide

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

1-
in the
other groove.
Chose the ring olso with
regord to toleronces cvoiloble
in one closs of
the rings os mentioned in the previous
Pqro-
groph. Check the cleoronce of the geor with
the oid of o diol indicotor.
Then remove the geor
including the friction
ring in the second groove
of the shoft.
7. Ploce the lock of the 1st' ond 2nd'speed
synchron izing clutch on the bench with
its
teeth downword. lnstoll
springs in the clutch
core securing them with greose
ogoinst folling
out ond insert the clutclr core with the shorter
side of the inner heod on
top in the respective
geor. Locote bclls (dio. 1ir
in.) on the springs, com-
p,ress the springs with
the fingers or using
o suitoble rod, cnd fit
the complete core
itrto
the geor.
8. Hoving thus osembled the synchronizing
clutch lock, instoll the synchronizing ring
fronr
the opposite side of the geor.
Now threod the
lock on the oiled shoft
with the geor focing
owoy from the shoft.
9. Instoll in position the
previously selected
friction ring with its groove
focing owoy from
the shoft (toword
the geor)
ond insert the
synchronizing ring into the fitted lock of the
synchronizing clutch. Slip the oiled geor ond Fig.4.6la
-
Assembling 1st' ond 2nd-speed
Synchronizing Clutch -
lnstolling the Core
ond Pnessing in the Bolls
the previously
selected friction ring on
the
oiled shoft. 10. Slip on the 3rd -
speed geor
ond secure it
with on
orbitrorily chosen ring from the ronge
of friction rings in complionce with the poro-
groph 2. Meosure the oxiol cleoronce ond odiust
it to 0.1*0.07 mm by o repeoted exchonge of
the friction ring. Now remove the geor,
lubricote it,
slip it on
the oiled shoft ond lock it in position with the
ring with the oil groove
focing the geor.
11. Proceeding occording to porogroph 2,
insert on orbitrory friction ring into the lost
groove, slip on the 4th-speed geor
ond tighten
the pinion
nut over o pilot
collor replocing the
beoring (for
exomple of dimensions dio.
25.5/38x26 with edges of the inner
bore chom-
fered to 1x45o). Mork the side of
the pilot
col-
lor which will be
turned toword the
nut so thot
the side focing the geor
connot be domoged by
impression. Adiust the cleoronce of the geor
to 0.1+0.07 mm by o repeoted trying
on (ex-
chonge) of the friction rings. Then remove the
geor ond the ring from the shoft.
12. Assemble the 3rd- ond 4th-speed synchon-
izing clutch using the some method os when
hoving ossembled thot of the 1st ond 2nd
speed. lnsert the synchronizing ring
into the
clutch ond slip the clutch on the oiled shoft
with the short side of the lock first.
13. Instoll the selected friction
ring in the
locking position
into the groove with its
oil
groove focing owoy from the shoft. Push or top
home the key into the spline of the shoft so
thot it posses
through oll friction rings ond its
end is ot leost flush with the splined shoft end.
Fig.
4.6/3 -
Locking 1st-speed Geor in Position
(turning the ring with o drift) with the Pinion
Clompecl in MP 3-105 or MP 3111 Jig
86 Fig.
4.(

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b)
Alil 1.
con
sloc
seo'
int
Fig.5.2l5
-
Pressing Boll Beoring
on Shoft
Using MP 5-112 Jig ond
lts Liner (smoller)
Fig.5.216 -
Connection of
Holf-oxles
with Rodius Arms
lorger ond one smoller, ond the forked plote),
screw down the
iig on the threod
of the shoft,
ond use
nuts to ottoch it
to the holf-oxle socketf
longe. The
iig of
the lotest design permits
its
simple fostening by engogement with
the holf-
oxle flonge (fit
the
iig ond
rotote
it to lock it
in position).
Instoll the lorger liner between the boll
beor-
irrg ond the
iig heod, ond
press
the boll
beorirrg
on the shoft by turning the iig wrench.
3. Reploce the lorger liner with the smoller
one (rest it ogoinst the
iig bolt heod), ond turn
the wrench in the opposite direction to press
the beoring into the holf-oxle socket.
Fitting Broke Mechonism ond Wheel Hub
4. Instoll the broke bocking plote
complete
with the broke
mechonism on the holf-oxle
socket, slip on the "O"
seoling ring ond the
cop with the seoling ring (with
the tightening
f in focing toword the holf-oxle), ond fosten
oll
the porrts
with bolts, spring woshers, ond
nuts.
The seoling ring should be driven or pressed
into the cop so thot the tightening lip foces the
beoring ond
iust so thot there
remoins
o gop
of
1 to 2 mm between the pocking
ond the cop
f longe.
5. lnsert the key in
the shoftwith its bevelled
end into the runout of the keywoy, smeor
the
hub neck with oil so
thot it does not
drog in
the seoling ring, ond fit the hub with the broke
drum in position.
Moke sure thot the key did
not move further olong the shoft (its
lifted end
in the keywoy would couse the hub to burst)
ond tighten
lightly the nut. Since o high
torque
is required
for finol tightening of the nut, put
off the tightening ond locking of the nut till
ofter instollotion in the cor. Then
tighten the
nut with full torque (see
Chopter 1.8),
top on
the hub to relieve
the possive
stress of the
toper, retighten to the specified torque, ond
lock the nut with o cotter pin.
Fitting Rodius Arms
6. Instoll
the spocer into the rodius
orm, fit
the knurled
woshers (with
the knurling toword
the orm)
to either side of the ellipticol holes of
the rodius
orm, ond fosten them with bolts ond
nuts not
forgetting the spring woshers. Do not
tighten the connection fully. Threod
the bolts
through the bolt holes so thot their nuts foce
into the cor ofter fitting the rodius orm to the
holf-oxle.
Fit the rodius
arm on the protruding
holf-oxle
pin ond threod
the bolt through the hole
of the
secrt. Slip
spocing tubes on the bolt ond pin
together with sheet shims with rubber liners
ond fosten
lightly (without tightening)
the
rodius orm to the holf-oxle using nuts
ond lock
woshers. Tighten
fully the connection
ofter fit-
ting the ossembly
in the cor when odiusting
the
reor wheel
olignment (geometry).
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ml
se
thr it
5tr
bo
Pock with
greose
the plostic
dust cup ond
press it over the nut till it snops home in po-
sition on the lever.
Refitting Upper Wishbones 4. When refitting wishbones
which hove
been olreody used in the cor ond which ore
rother doubtful (for
exomple,
o distortion is
suspected os o result of o crosh), inspect them
corefully ond stroighten
them, if necessory.
5. Press rubber bushes into the eyes from the
outer side. To focilitote their sliding in, dip
them in petrol
or soop
woter (suds).
Put the
bushes into the wishbone eyes with their lorger
diometer first ond push
them so for thot they
protrude from the eye by the some length on
either side. Blow off the soop woter with com-
pressed oir so thot it does no ossist the slipping
of the bush during the next operotion.
6. Slip the spocing tube on the MP 6-122 driIt,
dip the drift in petrol
or soop woter, ond, forcing
it through the rubber
bush, press
the spocing
tube into the bush.
Before pressing
it in, turn the spocing tube so
thot the
ioint of the
pockoged
bush foces the
top side of the wishbone.
7. Threod the wishbone pin
through the eye,
slip on it the cup with its dished port
focing
the bush, two wishbone brockets with the lugs
pointing owoy from the wishbone, ond the other
Fig.6.5/2 -
Pressing Spocing Tube
into
Bush Using MP 6-122 Drift cup with
its dished port
tbword the
other rubber
bush, ond threod the pin
through the other eye.
8. Push the brockets towords the eyes ond
slip two circlips on the norrowest port
of the
pin. To slip them on, hold them with their un-
connected ends on the pin
ond press
down. Use
o screwdriver to move one of the circlips into
the groove
of the pin,
ond push
the pin
with the
circlip in position
into the brocket. Clomp the
other brocket with the wishbone eye
in o vice
to compress the rubber bush, ond slip on the
other circlip. 9. lnsert the rubber deod stop into the wish'
bone.
Fig. 6.5/3- Instolling Circlip into Pin Groove
10. Reinstoll the
two ossenrbled wishbones
on the oxle body. Fit o ploin
wosher under the
spring woshers of the lug bolts. Instoll, from
obove, one 'l
mm or one 3 mm open (horseshoe)
wosher or the previously
removed woshers on
the horizontcrl bolts between the brocket ond
the oxle body lug. First tighten the horizontol ond then the ver-
ticol bolts. Fit the
cups on the wishbone pin
ond screw
down both nuts.
Refitting Lower Wishbones
11. Inspect the wishbones os per porogroph 4.
lnsert rubber bushes in
the eyes of the wish-
bone fnom its inner side. Threod the wishbone
pin through the eye, slip
on it the cup os with
the upper wishbone, then two pin
holders with
the recesses ot the inner hole focing eoch
other, onother cup, ond complete the operotion
by threoding the wishbone pin
through the
other eye. 12. Slip circlips on the wishbone pin
ond
lock with them the wishbone brockets in po-
sition. Proceed in the some monner os with the
upper wishbone (porogroph 8).
110
Rubber

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

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

nolly
emerges into spoce under the floor toword
the georbox.
lt is ottoched to the speedometer
by meons of o union nut ond to the georbox
by
o sleeve ond o screw.
It is lubricoted
with oil from the georbox
which creeps olong it due to copillory elev-
otion" Lubricote it with engine oil of o lower
viscosity dripped into its sheoth only if the
lubricotion by creeping is inodequote. When refitting
it in position, put
it into the
cor from the front, connect its
both ends, ond
then orronge it so thot it does not form ony
shorp bends ond is
not too tout. The speedo-
meter con be disconnected ofter removing
the
instrument ponel,
ond removed by pulling
it in
forword direction.
For the speedometer drive shoft possoge
under the ffoor refer to Chopter 12.7.
166

I
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I
I
t
(
(
t
l
,
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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
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