R
tr
el o
tl
Pl
e1
th
35.
Using
o meosuring rod
on which the dis-
tonces con be morked with o line, meosure the
distonce between the gouge plotes
when tunned
forwords ond reorwords (the plotes
must be
opproximotely horizontol). By turning both
steering rods, odiust the rood wheels so
thot tlre
distonce between the plotes
behind the oxle is
3 mm lorger thon the distonce in front
of the
oxle, ond lock the steering rods in
this position
by meons of nuts.
Fig. 6.5/10 -
Meosuring Front Wheel Toe-in
36. Rotote
the steering screw to check the
correctness of the steering geor
reossembly.
With the wheels in the right-hond ond left-
hond lock position
when the steering knuckle
obuts ogoinst the boss on the king pir-r
socket,
both extreme positions
in the steering
box
must be resilient,
without ony hord impocts.
lf this is
not the cose ond there is o hord
impoct, correct the odiustment by shortening
one steering nod ond lengthening
the other one.
37. Hoving odiusted the comber ongle
ond the
toe-in, retighten
o) the nuts of the eccentric pins
ond lock them
with cotter pins
b) the nuts of the upper wishbones ond lock
them with cotter pins
c) the bolts of the upper wishbone brocket
d) the nuts of the upper wishbone pins
ond
lock them by tightening the thin nuts
e) the nuts of the lower wishbones ond lock
them by tightening the thin nuts
f ) the
nuts of the boll
ioint pins (boll pins).
For tightening torques see Chopter 1.8.
38. Recheck the wheel comber, remove the
gouge, ond screw down loosely nuts ond wosh-
ers on to the protruding
ends of the lower
wish-
bone pins
in the following order: thin nut, spring
wosher, two ploin
woshers, onother spring
wosher, ond o thin nut. Fitting
Anti-roll Bor
39. Slip rubber
bushes on the centre port
of
the onti-rroll bor (close
behind the oblique bend)
ond f it on them the holder. After
hoving
threoded the other rubber bushes
on the
ends
of the onti-roll bor, instoll it in the brockets
on
the lower
wishbones, ond lock it in position
by
clomping the rubber bush by onother holder.
Secure the bolt of the holder with o spring
wosher.
Reinstolling Shock Absorbers ond Completing
Front Axle Reossembly
40. Using the spring instoller releose
the rood
spring ond then remove the instoller. Fit the
shock obsorber holder to the shock obsorber
eye ond connect them with o bolt with o costel-
loted nut. Lock the nut
with o cotter pin.
Threod the shock obsorber through the lower
wishbone ond the coil spning ond fosten it
with
bolts ond spring woshers.
41. Fill the wheel hub cop with
the recom-
mended greose
cnd drive it home
in the hub.
The greose will penetrote
into the beoring ond
lubricote it. Use the
MP 6-125 drift to ovoid
domoging the cop.
42. Screw down o greose
nipple on the bot-
tom beoring of both
king pins
ond lubricote the
enti,re oxle with the recommended greose.
Fig. 6.5/11- Driving-on Wheel Hub Cop Using
MP 6-125 Drift
6.6 STEERING KNUCKLE The steering knuckle is o unit formed by the
swivel pin,
the broke bock plote
brocket ond
guord, speciol self-lubricoting bushes, ond the
spocing tube. The right-hond ond left-hond
steering knuckle
con be identified bythe greose
nipple or nipple hole which must foce forwords.
114
5. Turning force
of box and column only. The
maximum permitted
turning force of the box and
column only (drag
link
attached to steering box
but allowed to slide freely
across idler) is 1.2kg
2.5lbs when test is carried out as in (2).
lf the force
is excessive, lubricate
universal joints
and check
thatthe drag link assembly is free to move. Repeat
test. lf still excessive remove
the steering box,
which can be removed
with the track rod still
attached.
TIME ALLOWANCE 5 mins.
6. Turning force to rotate
Steering Box input
shaft. With some form
of coupling (coupling from
'S'
type Steering Box) test the force required to
rotate the shaft; maximum prmitted
torque0.1 6kg
1.16ft lbs.
lf using an arm and spring balance as
shown the maximum force required
can be
calculated bv
160
arm length
in crn
arm length
in inches
These tests should be carried out with the
worm in the central position.
The initial force will
be 0.25 kg %lb greater
than the average pull-
force. lf excessive, remove
input shaft top bearing
cap and adjust the
bearing to give
0.OO to
0.05mm preload.
Shim Part No. 11O-509650
Steel O.3mm
1 10-59O90O Paoer
O.2mm
1 10-590902 Paper
O.7mm
Refit the shims and gaskets
and retaining cap,
fit the rubber sealing ring
dipped in oil and f it the
thin dust cover. lf the dust cover seems strained,
install a paper
gasket
between the cap and dust
cover. Part No. 1 1O-5909O0.
Retest for torque
and check rocker
shaft end
float which should be between
O.4 and O.5mm. lf
excessive and unable to adjust by the adjusting
bolt, replace steering box after contacting
the
Service Department.
Reassemble car and check the maxtmum
permitted force at the
spoke is 2.4kg 4.5lbs.
Check that the wheel
and indicator switch is
ce ntra lised.
Rocker Shaft Nut Torque
100Nm (71
lb ft).
TIME ALLOWANCE
7O mins. (inctudes
cost of additional shims)
7. Other points
which can adversely
affect the
turning force of the
Steering mechanism:
a) excessive tension
of the ball joints.
b) Workshop
Manual 7.5.5. excessive tenston
of the drag link
arms. The force required to
move the arm should be approximately 2kg or e.g.
wrth length
of arm
6 inches
max.
permitted force
equals 1.16 x 12
6
= 2.32lbs
DUST
COVER
4.6lbs when applied to the inboard
end of the
threaded portion.
TIME ALLOWANCE -
Off Vehicte 1O mins.
lf problems
are experienced
with wheel
vibration on the front
axle it is necessary to check
the amount of weight applied to one half of the
wheel rim which should not exceed
50 grams.
You are reminded
that check A1, kingpin
adjustment, is required
to be carried ogt at each of
the six and 12,0OO mile services.
1.16 x12
UST
I
ADJ
UT LENGTH
OF ARM
118 2KG
{4.6lbs)
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
11.4-11.5
I
I
I
F
r
t'
on to the coolont tonk.
Hose
clips ore formed
either by metol strips
or lengths
of wire. When
tightening the wire clips, toke core not to
domoge the rubber of the hoses.
To Fosten Pipes ond
Hoses
A correct winding of the strip is importont
to ensure o self-locking clomping of the strip
clips -
see Fig. 11.411.
Fig.11.Al1- Diogrom showing
the threoding
of
the clip strip through
the clip closp ond
the
direction of rototion of
the tightening cotter
pin -
the diogrom hos generol
opplicobility
1 -
Strip clip,2 -
Closp, 3 -
Cotter pin
The moin pipeline
routed under the cor f loor
consists of front ond reor pipes.
They ore em-
bedded in o chonnel moulded in the floor
boords ond rest on on insuloting (polysterene)
podding. From below, they ore protected
by
o guord,
the copscrews of which ore locked
in
position by spring woshers.
Use pipe
holders (yokes) to fosten the pipe-
line to the floor. In
the front
ond reor port
of
the cor, tighten
the pipes
over the insulotion
lrod ond insert
spring ond ploin
woshers under
the nuts.
Do not use insulotion pods
for bends
forming the tronsition from
the front
ond reor
lower flot ports.
Use spring woshers under
the
heods of copscrews.
Before instolling the pipes, prepore
ouxiliory
yokes (or use lengths of wires ottoched to the
provisionolly screwed-in copscrews of the pipe-
line guord) to liold the pipes
in the moulded
chonnel in
the floor before
the finol fostening
of their guord.
The woter line runs
under the cor together
with other lines, pull-rods,
etc. For their mutuol
ref otive orrongement see Chopter 12.7. Removol
To moke the underbody occessible for hond-
ling the pipes,
ploce
the cor over o floor pit
or
on o romp. The minimum required cleoronce is
obout 650 mnr.
1. Remo.re the guords
of the pipes
ond the
fuel tonk, lift owoy the spore wheel, ond loosen
the yokes
holding the pipes
to the floor.
2. Remove droin screws to droin the coolont
from the pipes -
see the illustrotion in Chop-
ter 15.'13.
3. Remove one hose clip in the middle
of the
cor to disconnect
the pipes
(ottention -
the
remoining coolont will f low out), ond dis-
ossemble the line.
4. Disconnect the pipe
ends from the hoses,
ond detoch the pipes
from the floor or other
ports of the cor.
5. Pull out the reor pipes
possing
them core-
fully oround the vorious cor ports.
6. Pull out the front pipes.
Turn
the front
wheels into their left lock position,
disconnect
the steering linkoge from the steering
reloy
lever ond the steering knuckle orm of the
right-
hond wheel, ond push
the linkoge ogoinst the
oxle body. While removing the pipes,
rotote the
left-hond pipe clockwise (when
viewing the cor
front end), ond the right-hond pipe
onticlock-
wise.
Reinstollotion Reverse the dismontling procedure
when re-
instolling the woter line. While connecting the
steering linkoge, poy
ottention to the condition
of boll pin
seoling cups (fit
new cups if the old
ore domoged). Fill in the recommended
coolont
ond bleed the cooling system.
11.5 COOLANT TEMPERATURE CONTROL
Throughf low Thermostot
This thermostot shuts off the inlet of the
coolont into the rodiotor
during the engine
heoting-up period. lt is mounted on the engine
- see Chopter 2.3, por.
30.
The thermostot operotes within the following
volues:
it begins to open ot 80+2"C
it is fully open ot 90+4oC
its lift ot full opening
11 mm
When closed, it
is permitted
to let poss
o nroximum
of 0.5 litres
of coolont per
minute,
ond it must not be closed by o bock pressure
of 0.16 MPo (1.6
kg/cm2).
When removing the thermostot by rototing
tlre rivet in the volve disk, breok owoy sedi-
I i
i 152
1 3.1 6-t 3.1
7
focio ofter removing two
copscrews ol-l the
ponel bottom. lt moy
be olso necessory to pull
off the heoter control push
buttons.
c) Switch of disobility worning lights
For fostening see
informotion sub
b). -l
he
switch operotes only
when connected to the
direction indicotor ticker.
d) Dipswitch, direction indicotor, horn, wind-
screen wiper, ond winscreen wosher switch
ox 1568
instolled on
the steering
fostened to
the reduction
with shoft
beorings ond to
steering wheel shoft
shroud.
Fig.
13.16/1 -
Switch Box with Steering Lock -
the orrows indicote the copscrews (M
3.5)
holding down the switch box in the steering
lock housing
disengoging the shoft from
the bodywork -
see
Chopter 7.8, porogrophs
1 to 5 -
without, how-
ever, disengoging the shoft from
the steering
box. The switch box con be removed
ofter loosen-
ing two copscrews on the steering lock hous-
ing (see
illustrotion).
Reverse this procedure
when refitting the
switch box. Turn
the key ond
the key hole of
the switch box into the left-hond extreme pos-
ition (STOP),
instoll the switch box in the
steering lock,tighten the copscrews ond secure
them with o dob of point.
13.17 SWITCHES OF LAMPS
AND WARNING
SYSTEMS, DIRECTION INDICATOR
TICKER, RECEPTACLE
For the wiring of these electricol devices
refer to Chopter 13.1 -
Electricol Equipment
Connections ond Wiring Diogrom -
ond for
their operotion to Chopter 1.3.
All the devices ore expendoble ond they hove
to be reploced with new units if defective.
All the switches ore of the contoct type,
speciol types ond exceptionol connections ore
mentioned in the following text.
o) Switch of porking
lights ond heodlights
(feeder of chonge-over
switch
of these
lights)
The switclr is fostened to the instrument
ponel by o nut with o wosher under the push
button. When instolling the switch,
turn it so
thot it engoges in the locking slots. The push
button con be removed
by pulling
it off ond
refitted bv pressing
it down.
b) Heoter switch
This is fostened in the some monner
os the
switch sub o). Access to the switch
body con
be goined
by removing the centre ponel
of the This switch
is
column shoft ond
sleeve of the tube
the top port
of the
Removol: Remove the steering wheel
ond the bottom
port of the shroud -
see Chopter 7.8.
The switch
con be releosed from the shoft ofter loosening
the screw in the driver ond the removol of the
driver (
if the switch is equipped with
such
driver), ond the loosening of the
screw in the
yoke on the switch bottom right-hond side.
Loosen or remove the fostening screws of
the
shroud ond lift owoy the top port
of the shroud-
lf you
intend to remove olso the
steering
geor, do not loosen the screw
on the switch
bottom right-hond side but the screw on the
left-hond side, ond lift
owoy the switch
together with the reducit-tg
sleeve on the steer-
ing wheel shoft tube.
Refitting ond Adiustment
Reverse the described procedure when
re-
fitting the switch. lf the cor is equipped with
:" outomotic
direction
indicotor concelling
Fig. 13.1711- Adiusting Elements of
Directiorr
lndicotor Self-concelling Device
1 -
Centering pin
of the left-hond
switch or
mork on the switch foce, 2 -
Boss on the bush
foce, 3 -
Driver
194
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
tificotion
number, or in
words. For exomple
Mobiloil 30 is on oil in the SAE 30 viscosity
closs, Mobiloil Speciol belongs to the SAE
10 W/30 closs. We quote
the viscosity closs
symbol of oils identified
in this woy in brockets
following the oil brond (trode
nome).
Oils designoted by o doubled viscosity closs
symbol ore the so-colled multigrode oils. Their
complionce with viscosity clossificotion is ex-
pressed by the symbol before the froction line
progressively to the clossificotion expressed by
the symbol behind the froction line. Thus,
for
instonce, the SAE 10W/30 oil hos the properties
of the sAE 10w, sAE 20w120,
ond sAE 30
closs.
Czechoslovok oils
Motor oil M6 AD (SAE
30), M4AD (SAE
20W/
20), Mogul Super SAE 20W50,
Mogul Speciol
SAE 2OW/30
Modit Oil SAE 30 (M6
AD), Modit Oil SAE
2OWl2O (M4AD), Modit Oil Speciol
SAE 10W/
30, Modit Super SAE 10W/40
Foreign oils
Agip: Agip F. 1 Motor Oil HD SAE 10W/20,
2OWl30, 4Ol5O; Agip F. 1
Super Motoroil
10w/40,20wl50
BP: Energol HD SAE 40, 30, 2OW (2OW|?O),
10W; Super Visco-Stotic 10Wi30, 10W/40,
20wt20
Costrof : Costrol 40,
30, 20Wl2O, '10
W; Costrolite
(SAE 10W/30), XL (SAE 20W/50);
GTX
(SAE 10w/50)
Mobil: Mobiloil 40, 30, 2OWl2O,
10W; Speciol
(SAE 10W/30); Speciol 20W/50; Super (SAE
10w/so)
Shef l; X-100 40, 30, 2OWl20,
10W; Super (SAE
10w/so)
Other oils of foreign moke con be used if equi-
volent to the listed bronds, for
exomple, Avio,
Esso, Heno (Optimol
LD), INA (Delto TLX),
Noftogos (Golox GTX, Omnio) etc.
GEAR OILS -
type E. P. (high-pressure)
I Viscosity j Ambient
Lubricoting noint
I closs
! temperoture
sAE 140*) -r50
to +15 oC
Georbox/f inol
drive SAE
90
*35 to -15
oC
* 5 to -30oC
SAE 80
teering box SAE 90 throughout
the yeor Czechoslovok
oils
PP 90 (SAE
90) geor
oil; PP 80 (SAE 80)
geor oil
Foreign oils
Agip: F. 1 Rotro 140; 85/90; 75Wl8O
BP: Geor Oil 140
EP; 90 EP; 80 EP
Costrol: Hypoy B 140; B 90; B 80
Mobil: Mobilube GX 140; GX 90; GX 80
Shell: Spirox E. P. 140; E. P. 90; E. P. 80 W
Other geor
oils of foreign moke con be used
if equivolent to the listed oils.
SPECIAL OILS
Distributor beorings (service inspection)
Czechoslovok moke -
ON 1 low'pour-point oil
Foreign moke -
for exomple, Shell Clovus 17
ond similor oils
GREASES -
use throughout the yeor
Woter pump
Czechoslovok moke -
SP 4 sooP greose,
NH 2
or A4 motor greose
Front wheel beorings, geor lever
brocket
Czechoslovok moke -
SP 4 or NH 2 soop greose
King pins
Czechoslovok moke -
A 00 motor greose
Inner door mechonisms, locking mechonisms
Czechoslovok moke -
SP 2-3 soop greose*)
Clutch releose beoring
Czechoslovok moke -
SP 4 or NH 2 soop
greose* )
Steering tinkoge boll
ioints, cronkshoft
beoring
Greoses listed in the porogroph
on greoses
of
foreign moke
Greoses of foreign moke:
Agip: F.1 Greose 30; BP: Energreose L2; Costrol:
Costroleose l. M.; INA: Automost Speciol;
Mobil: Mobilgreose MP;
Shell: Retimox A,
ond other greoses
equivolent to
the listed
ones.
BRAKE FLUID
To SAE J 1703C Specificotion
ln Czechoslovokio -
SYNTOL HD 190 broke fluid
Abrood -
SYNTOL HD 190, Pentosin
Super Fluid,
Mobil Hydroulic Broke Fluid, ATE Blou, BP
Broke Fluid, STOP SP 19
r) Greoses of foreign moke should be preferred.
220
*)
Not used
in Czechoslovokio
17.5
FRONT AXLE MP
5-114 Wheel shoft pilot
toper
MP 5-116 Seoling ring drift
MP 5-151 Pinion odiusting gouge
MP 5-152 Wheel
hub puller
MP 6-150 Front oxle ossembly broclket
MP 6-105 Steering orm drift