1980 SKODA 120 LS Workshop Manual

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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

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12.6-12.f
2. Proceeding fronr below, rernove
the fuel
tonk sheet guord
ond the guord
of the cooling
woter pipes.
3. Disconnect the pipe
of the clutclr hydroulic
line from the clutch releose hose brocket.
4. Screw out droin plugs
to droin fuel from
the fuel tonk ond ot the some time disconnect
the fuel hose from
the fuel pump.
After com-
pleting the droining, reinstoll the droin plugs
(screws) with their seoling rings.
Disconnect the tronsverse hose connecting
both sections of the fuel tonk ond stop the
open
pipes with rrubber
plugs (to prevent
the remoin-
ing fuel spilling over your
honds ond clothes
when lifting
the tonk owoy).
5. Disconnect the geor
shift link ond the
speedometer drive from the georbox -
see Chop-
ter 4.1, por.9.
6. Detoch cobles from the hond broke rocker
ond pull
them out from under the cor -
see
Chopter 9.8. 7. Droin the cooling system -
see Chopter
-15.13.
Disconnect the moin woter line in
the
rniddle of the cor. Disconnect the pipes
from
the engine (from
the hose of the thermostot
ond the pump
connecting hose) ond remove
the
pipes -
see Chopter 11.4.
8. Disconnect the hose of the fuel
tonk from
the fuel filling pipe, ond, in the upper port,
the
hose of the fuel filling line vent pipe.
9. Sever the electric connection of the fuel
level gouge
floot system under tlre right-hond
I eor seot.
10. Use o
iock to support
tl're georbox
ond
loosen tlre connection of the georbox
cross
beorer with the bodywork.
11. Loosen the copscrews fostening the fuel
tonk to the bodywork ond lower the
iock to tip
the power
pock.
Retoin the fuel tonk while ne-
nroving the copscrews, move the tonk bock-
words ond down, tip it down ond forword, ond
remove it in
this direction. 12. Should
the pipes
of the broke system ob-
struct tlre removol of the tonk, disconnet them
from the finol drive ond from broke hose brock-
ets.
Refitting Fuel Tqnk in Cor
Reverse the procedure
of the tonk removol.
Fill the cooling system with the recommended
coolont ond bleed it, odjust the hond-broke ond
the occelerotor cobles. Bleed the clutch hy-
droulic line
ond olso the reor wheel brokes if
the hydroulic broke line hos
been disconnected.
Tighten properly
oll joints
ond connections,
fosten the cobles, links, ond pipes
obsenving
their correct orrongement -
see Chapter 12.7.
Fuel Line ond lts Accessories
Filling pipe.
This is q
sheet -
metol tube ot-
toclred to
the hose on the fuel tonk by meons
of o clip, ond to
the bodywork by two holders
with o copscrew ond both o spring ond o ploin
wosher. lt posses
througlr o bushing in the side
of the bodywork. Venting line. The hose is ottoched to the fuel
tonk filler neck in the upper port
of the tonk
ond to the filling pipe
by meons
of clips. For
its possoge
through the bodywork stiffener,
see Fig. 12.714. For clips ond their tightening see
Fig. 11.4/1.
The oir-feed hose
is slipped on the filling
pipe outlet ot
the fuel tonk neck; its
loop is
inserted under the domping lining of the body-
work, ond its other end is inserted into the hole
of the filling pipe
socket bushing.
Filler neck cop -
see Chopter 1.5.
Fuel gouge -
see fuel reserve signolling
switch, Chopter 13.17.
12.7 ARRANGEMENT
OF PIPELINES, LINKS,
AND CABLES UNDER THE
CAR
The routing, fostening, etc., of pipelines,
links, ond cobles is described in
chopters deol-
ing with these ports.
They oll leove the floor
tunnel under tlre fuel tonk to
be covered by
o guold
held in position
by self-locking nuts
with ploin
woshers. The following
illustrotions
show their correct orrongement which hos to
be mointoined if incorrect function or domoge
is to be prevented.
lt is imperotive to ensure
free movement ond swing
of the geor
shift
link.
Secure the correct position
of oll ports
under
the fuel tonk by clips which hove
to be pro-
vided with sleeves preventing
domoge to Bow-
den tubings, etc. The overoll orrongement is
shown in
Fig. 12.712 ond 12.713.
Fig.
12.611- Fuel Tonk Droin
Plugs
164

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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

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