engine SKODA 120L 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

Worrring
lights:
5 -
left-hond direction indicotors, green
6 -
oil pressure,
red
7 -
right-hond direction indicotors, green
8 -
broke system, red
9 -
chorging, red
10 -
fuel reserve, omber
11 -
high beom, blue
The thermometer indicotes the temperoture
of the coolont with the ignition switched on.
The optimum operoting temperoture ronge is
from 75 to 105oC. In
SfOon 105 S, this
ronge
is identified by
the green
zone of the scole.
The fuel gouge
indicotes the level
of the fuel
with the ignition switched on. The scole is
provided with divisions 0 -
r/2
-
1, i. e., empty,
holf full,
ond full
tonk.
The driver is worned by the red worning light
when thene ore less thon 5litres of fuel in the
fuel tonk.
The tochometer indicotes the speed (revol-
utions) of the engine. The
speed should
never
rise to the red zone. When chonging the geors,
on increose of speed within the ronge
of the
yellow zone is permissible.
The porking
lights come on when the switch
is thrown to the first
right-hond position.
The
Fig. 1.3/6 Switches -
port I
1 -
Porking light switch ond feeder of heodlomp
dipswitch
2 -
Horn switch, direction indicotor switch,
ond dipswitch
3 -
Switch of ouxiliory (extro)
heodlomps
4 -
Door switch 12
-
unoccupied, green -
fog lomp worning light
included in speciol
extros
13 -
unoccupied, green -
low-beom worning light
included in speciol
extros
14 -
unoccupied, red
switch switches on the heodlomps, toil lights,
ond the licence plote
light.
The heodlights, i. e. driving (high
beom) ond
dipped (low
beom), ore switched on by throw-
ing the switch to the second
right-hond pos-
ition. The switch switches on oll porking
lights
ond the heodlights
in occordonce with the pos-
ition of the switch stem-type lever: centre
position -
dipped lights,
towords the instrument
ponel -
driving lights. When the
driving lights
ore on, the blue worning light glows.
The ouxiliory heodlomps
come on ofter pull.
ing the switch knob, but only while moin
heod-
lomps ore on.
heodlomp flasher storts floshing
when
the switch lever
toword the steering
ring.
horn is sounded by depressing
the lever
the steering wheel shoft.
Fig.1.317 Switches -
port ll ond oshtroy
1 -
Switchbox ond steering lock
2 -
Switch of windscreen wipers ond
wosher
3 -
Heoter switch
4 -
Switch for on odditionol device -
not
stondord fitted
5 -
Disobility worrning light
switch -
not on
SKoDA 105 s
6 -
Heoter control
7 -
Ashtroy
The
pulling
wheel
The
toword
i
I
L 12

--
!
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

ii
i ENGINE
Model
- for Skodo 105 S ond 105
L
- for Skodo 12o L
- for Skodo 120 LS
Type
Number of cylinders
Cylinder orrongement
Cooling
Swept volume
- Skodo 105 S ond 105 L
- Skodo 12O L ond
120 LS
Bore
- Skodo 105 S ond 105 L
- Skodo 120 L
ond 120 LS
Stroke
Compression rotio
- Skodo 105 S, 105 L ond 120 L
- Skodo 120 LS
Engine power
output to CSN ond DIN
- Skodo 105 S ond 105 L
- Skodo 12O L
- Skodo 120 LS
Moximum torque
- Skodo 105 S ond 105 L
- Skodo 120 L
- Skodo 120 LS
Fuel -
recommended octone number
- Skodo 105 S,
- Skodo 120 Ls
Corburettor type
Fuel lift pump
type
CLUTCH
Type
Control
GEARBOX
Type Speeds
Geor rotios -
1st-speed geor
2nd-speed geor
3rd-speed geor
4th-speed geor
reverse geor Skodo 742.10 Engine No/l
Skodo
742.12 Engine No/2
Skodo 742.12x Engine
No/9
four-stroke, spork-ignltion,
corburettor engine with overheod volves
4 in line
pump-circuloted ontifreeze,
thermostotic temperoture control
1,046 c. c.
1,174 c.c.
68 mm
72 mm
72 mm
8.5:1
9.5:1
33.9 kW (46
h. p.)
ot 4,800 r.
P. m.
38.3 kW (52
h. p.)
ot 5,(X)0 r. p.
m.
42.7 kW (58
h. p.)
ot 5,2(X) r. p.
m.
74.5 Nm ot 3,000 r.p.m.
85.2 Nm ot 3,000 r.p.m.
90.2 Nm ot 3,250 r.p.m.
90 minimum 95 minimumduol, twostoge, downdrought
nrodel JIKOV 32 EDSR
diophrogm pump, model
JIKOV MF
dry, single-plote, with direct
disengogement
hydroulic
with helicol
spur geas
4 forword ond 1 reverse, synchrolock on the
1st-, 2nd-,
3rd-, ond 4th-speed geors
3.8
2.12 1.41
0.96 3.27
105 L ond
12O L
18

Broke
fluid:
- clossificotion
- brond filled-in in the foctrY -
FUEL TANK
Locotion Fuel cleoning (filtrotion)
CHASSIS LUBRICATION
TyPe
ELECTRICAL EQUIPMENT
Eorthing
Roted voltoge
Service voltoge
lgnition
Storoge botterY .
Alternator PAL Magneteton
Voltoge regulotor
Distributor
lgnition coil
Storter motor
Sporking plugs -
see ChoPter 137
BODYWORK
Type Seoting copocity
Luggoge comportments, coPocitY
H e oter
FILLING CAPACITIES
Engine -
Skodo 105 S, 105 L
ond 120 L
Skodo 120 LS
Georbox ond
finol drive cose
Steering box
Broke system
ond clutch
Cooling system
Fuel tonk SAE J
1703C
SYNTOL HD
190
suspended under
floor boord of cor reor holf
stroiner in fuel tonk,
fuel filter, ond stroiner
in corburettor
self-lubricoting beori
ngs,
by greose nipples;
wheel
greose
negctive pole
12 volts
14 volts repocking
with greose
beorings pocked
with
bottery (coil)
type
type AKUMA 6N 37 -
12 volts, 37 ompere-hours
14V 35 amps 1976-79
1O5/12O
L
14V 42 amps 1979 on
1O5/12O
L
14V 42 amps 1976-79
120 LS
14V 55 amps 1979 on
120
LS
type PAL Mogneton, 14 volts
type PAL Mogneton
with centrifugol timing
device ond vocuum unit
type PAL Mogneton, 12
volts
type PAL Mogneton, 12
volts
0.66 kilowotts (0.9
h. p.)
oll-metol, closed, four'door,
chossisless body
5 occuponts
0.40 mi (0.28
rn: moin luggoge comPortment for
q lood of obout
0 kg, 0.12 mr interior luggoge
comportment for
o lood of obout 10 kg)
hot-woter heoter
with fon, fed with woter
from
the engine cooling sYstem
4 litres moximum -
2.5 litres minimum
of engine oil
4.6 litres moximum -
3 litres minimum
of engine oil
2.5 lities of geor
oil (2 litres when
chonging oil)
0.16 litres of gecrr oil (obout
0.25 litres when
topping up)
O.4A titres of broke f
luid (f
illing for tropicol
regions, etc. see ChoPter 16.2)
12.5 litres of
ontif'reeze
38 litres 1.8 Tt(
BC
1. Ap
von ized
out o sL
2.tti
Threo
ENGINE
Connecti
Nut of c
Nut of c
Nut of vr
Nut of fr
Nut of c
Nut of si Nut of c'
Cylinder Bolt of c
Flywheel
Bolt of cr
Oil sump
Oil sump
Droin plu
Bolt of ft
Bolt of oi
Socket ol
Oil pressr
Sporking
CLUTCH Connectir Generol
20 Bolt
foste

metre), ond the
relotion of 1
kpm :9.806
Nm is'
opplicoble. When opplied to tightening
torques
of bolts ond nuts, use the relotion
10 Nm :
: 1 kpm.
d) The unit of power (output) tW'
(wott)
reploces the former "h.p."
(horsepower) ond
the relotion
of t h. p.:
735.499 W is opplicoble.
For procticol purposes,
o multiple of kW (kilo-
wott :
1,000 wotts) is used, i. e., t h. p. :
:0.736 kW.
e) The
unit of pressure "Po"
(poscol) or, in
proctice, MPo (megoposcol :
1,000,000 poscols)
or kPo (kiloposcol :
1,000 poscols)
reploces the
former "bor"
ond "kglcmz",
ond the following
relation is opplicoble: 1 MPo: 10 bors :1O.2
kg/cm2 (kp/cm2).
For current meosuring
of tyre
pressure etc., use the relotion: 100 kPo :
1 bor:
:1kglcm2 (kp/cm,) :1
otm.
1.10 GENERAL INSTRUCTIONS
With the exception of o few
speciol pro-
cedures or ossembly techniques
mentioned in
the respective section of
this monuol,
every
removol ond refitting (disossembly
ond re-
ossembly) should be governed
by the following
generol principles:
o) Use suitoble tools ond especiolly tubulor
box sponners which couse the leost domoge
to nuts ond bolt heods.
b) During disossembly note corefully how
the ports
hove been ossembled. This knowledge
is involuoble for correct reossembly.
c) Cleon ports
in trichloroethylene or tech-
nicol petrol.
They do not contoin substonces
(esoeciolly leod) which horm
the skin os motor
petrol does. Current bronds of seoling com-
pounds con be removed with denoturoted
ol-
cohol or scroped off. For o speciol
seoling
compound see the note ot the end of this
chopter.
Avoid contominotion of self-lubricoting
metol
beorings with ony degreosing
ogent os this
would unfovourobly offect their self-lubricoting
properties.
Cleon ports
of the broke ond clutch hydroulic
system with olcohor.
d) Lubricote
oll ports
moving on or in
eoch
other before their ossembly. Operoting lubri-
conts do not spreod eosily on dry surfoces,
the
ports ore not properly
lubricoted, ond friction
oreos ore opt to get
domoged. Coot the os-
sembled ports with the lubricont which is used
to lubricote them in operotion. When lubricoted
with oil, dip
the ports
in motor oil, the f luidity of which mokes
it
especiolly suitoble for
this
purpose. Use greoses
ond hydroulic f luid bronds
specified in the Toble
of Recommended Lubri-
conts.
e) Use new cotter pins
ond metol lock
woshers if you
ore not convinced of the perfect
condition of the old ones which could breok
ond leove the joints
unsecured. Moreover, there
is o risk
of the broken ports
domoging other
functionol ports.
f) Cleon new ontifriction beorings (boll,
rol-
ler, ond topered roller beorings) of preserving
greose using kerosene.
Preserving greose is not
suitoble for lubricotion ond it mixes bodly with
I ubriconts.
g) Some of the joints
hove to be tightened
with o moximum occurocy to the specified
tor-
ques listed in the previous
chopter.
h ) 'Ihe
permissible rototion unbolonce is spe-
cified for some of
the rototing ports,
usuolly in
gcm (gromcentimetres). A well boloqced port
con be stopped in
ony position
if it is
instolled
so thot no rototion resistonce
octs on it. With
the exception of dynomic boloncing, the ports
ore usuolly tested on on ouxiliory shoft ploced
on the
edges. The
unbolonced port
moves from
the deflected position
with its heoviest (i.
e.
unbolonced) port
downword. The
volue of un-
bolonce con be determined
when fostening
o weight corresponding to the permissible
un-
bolonce to the opposite side
of the unbolonced
port. lf the port
does not move when deflected
or if it moves with this weight downword; the
unbolonce is within the recommended limits.
The weight of the testing weight sholl be
de-
termined by dividing the volue of the permis-
sible unbolonce by the distonce of the weight
from the rototion
centre of the port.
i) Even slightly domoged seols ond pockings
must be reploced with new ones
Note: In the foctory,
the speciol seoling
compound
of the "Velvonton
C" brond is used for seoling
the engine reor
cover on the cylinder block, the
moting surfoces of the georbox housing holves,
ond the guide
of the clutch releose beoring.
This seoling compound is mode
on the bose
of o polyurethone
plostic ond it
corresponds to
"Hykemor", "Reineplost", "Curil
K" ond similor
compounds. lt con be removed from the ports
by scroping ond woshing with ocetone, butyl-
ocetone or chlorinoted solvents, for exomple
chloroform (trichloromethone)
ond corbon tetro-
ch loride.
24

ENGIN
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c
;
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ir
33
46_
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32. 5'
3t-
4/
ENGINE

ENGINE
CYLINDER HEAD ASSEMBLY
Gr__53a- @ -54
a--&J
3oa
"3q;' 25
2t
66
/62
:> €}\
8- -60
)^\ 0-cl
I
38---\
64 ow,,, l\ '39
|
l2

2.2-2.3
threods. Fill the etrgine with oil ond the cooling
systenr with on ontifreeze, ond
bleed them.
2.3 REASSEMBLING THE ENGINE
The reossembly procedure depends
on the
extent to which the engine hos been
dis-
rnontled. For better understonditrg, o
reossembly
of o conrpletely disnrontled
engine is described
in the following
porogrophs.
lnspection of
Cylinder Block
1. Clomp the thoroughly cleoned
cylinder
block into the MP 9-101 stond with the engine
corrier type MP 1-101 ond check it for complete-
ness -
see Chopter 2.6. Fit the
block with its
lugs on the engine corrier pins
ond use the side
bolt for ltolding it down.
DK 1188
Fig.2311- Cylinder Block Fostened on the
Assenrbly Stond by lVleons of the MP 1-10-l
Corrier
2. Rernove the pressure
relief volve, moke
sure thot the boll contoct {oces ore cleon,
ond
refit the cleoned volve. Forr
f itting o new volve
see Chopter 2.6.
3. Remove the cronkshoft beoring
covers ond
tlre i;ylinder block reor cover.
To Refit the Cronkshoft
4. Force the beoring shell lrolves with the
fingers into the cronkshoft beoring bores so thot
the shell lip snops home into the slot (cut-out)
in the block ond so thot the shells do not pro'
trude over the beoring surfoces for the beoring
covers, ond lubricote them with engine oil. Be
r;ure to fit shells motching the cronkshoft
i":urnols -
see Chopter 2.7.
5. Slip the oiled guide
ring on the cronkshcft
"vith oil grooves
pointing
toword the cronkshoft
'.veb ond {it the cronkshoft with the pressed-on
boll beoring (see
Chopter 2.7)
into the shell. 6.
Inscrt the
beoring shell
holf ir-rto
the cover
of the beoring No.-l
os described in
porogroph
4,
ond fit the cover with the
recess for the guide
ring turned outword. Proceeding from
the front
of lhe block, slip
on the next guide ring with
the oil grooves pointing
owoy from the block so
thot itJ
lip engoges ogoin into
the slot in the
cover. Coot the ring
with oil ond slip on the
thrust ring. Fit the MP -1'112
thrust collor on the
cronkshofi ond
tighten the
beoring slightly
using the belt
PrrlleY bolt.
7. Instoll the next
two beorirrg covers
corl'l'
plete with beoring shells
ond lightly
tighten l.he
cover nuts.
Press the cork
seol
into the
reo'r
cover moking
sure thot it
f its the groove
snugly
ond slightly bverlops the lower
seoting surfoce'
Before titting the cork seols,
compress them
for
o while in o vice to distort them. Insert the
distorted seols in the grooves
or gops between
the cover qnd
the cylinder block
where they
will expond onci provide
for perfect seoling.
lnsert tob woshers under
the nuts of the
beoring covers
ond while tightening the rruts
check their correct position so os
to enoble
o subsequent correct locking
of the nuts.
Fig.2.312 -
Meosuring Cronkshoft Ploy
1 -
Thrust collor, type
MP 1 112
2 -
Diol indicotor in o
speciolly mode yoke
8. Rotote the cronkshoft severol times ond
using o mollet top the covers ond both shoft
ends to ensure o correct bedding
of the covers
ond cronkshoft guide rings.
9. Tighten the belt pulley nut
to clomp the
thrust ring, ond
rotote ond force
off
the cronk-
shoft to
check its ploy. The
cronkshoft must
be
free to rotote but
without ony
noticeoble ploy.
lf there is o noticeoble ploy, recheck
its volue
ond odiust it by replocing the guide ring with
o new one. The
moximum ploy
should not ex-
ceed 0.10 mm, the recommended minimum ploy
being 0.04 mm. 10.
F
speciol
end onr Drive
suchr o
be turnr
cover. I
ever, tf
the cyl
speciol note in
11. Ti
the tigh
in the
covers. hoving
does no
must ro
Then lo,
woshers
ond nut
To Refil
12. R
greose i
it with i
o flywhr
engine,
with rec
under tt
Chopter
bending
shoft og
powl ins
For flyw
Fig.2.3l3
Using thr
Screw
holes, for
con be ur
further o1
the hondr
30