1980 SKODA 120 LS Workshop Manual

1 t.1
-1
4.3
surfoces ore
sproyed with o
Protective com'
pound. The floor boords including the floor of
the boot ore covered with textile corpets while
rubber mots ore used in Skodo 105 S.
The in-
terior luggoge comportment is
lined with insu-
loting felt
sheet.
fne body finish consists of severol loyers of
speciol onti-corrosive cootings, o primer
coot,
ond o synthetic boking enomel top
coot in
colours complying with
o speciol specificotion.
14.1 BUMPERS
To Remove Front BumPer
Disconnect the
leods of the horn ond front
direction indicotors. Remove bolts connecting
the side sections of
the bumper with the wings
ond bolts of the bumper brockets, connecting
them to the wheel splosh guords. Now
the
entire bumper is free ond it con be removed.
Te Remove Reor BumPer
Proceed in the some woy with the exception
thot there ore no leods to be disconnected.
To Remove Overriders
Screw off the nut M 10 ond lift owoy the
overri der.
14.2 WTNGS
To Remove Front Wing
First remove the front bumper (see
Chop-
ter 14.1), the front door (see
Chopter 14.5), ond,
in the cose of the left-hond wing, the boot lid
Fig. 14.211- Removing Front Wing -
orrows
indicote fostening points (see
Chopter 14.3). lf the door sill is covered
with o trim moulding, loosen this moulding
portiolly. Now remove the bolts fostening the wing to
the bodywork under the sill (from
underneoth),
on the side edge of the body post,
in the chon'
nel next to the boot, ond in the forebody under
the heodlomp.
To Reinstqll Front Wing
lf the seol strip in the front
Port of the wing
is domoged, reploce it with o new one, ond
stick it on if it hos got
unstuck. Pock olwoys
o new seoling strip between the wing edge ond
the body fromework. Then instoll
the wing in
position ond locote it by tightening slightly the
connecting (fostening) bolts.
Do not tighten
the bolts firmly before hoving fitted properly
the wing.
14.3 BONNET AND BOOT LID
Removing Boot Lid
Remove the nut ond bolt of the strut ond
the screws fostening the
hinges, ond lift owoy
the complete lid.
Removing Engine Bonnet
Slip the bonnet strut out of
its guide,
screw
off the nuts of the hinge fostening bolts, ond
lift owoy the bonnet.
Reinstollotion ond Adiustment of Boot Lid
ond Engine Bonnet
Instoll the lid (or
bonnet) over
the luggoge
(or engine) comportment ond
tighten lightly
the bolts ond/or the nuts of the hinge bolts.
Moke the lid (or
bonnet) fit perfectly
with the
edges of the bodywork by shifting the hinges
in their respective holes
os necessory, ond
tighten fost the bolts ond/or nuts of the hinges-
Assemble the strut of the boot lid.
Boot Lid Releose Rod ond Engine Bonnet
Releose Coble
The releose rod of the boot lid (Fig.
1.3113)
is connected with the reloy link by meons of
o pin
ond forms on ossembly unit with the lid
locks. The
hondle of the releose rod con be
removed ofter pushing
out the pin.
The entire
ossembly con be lifted owoy ofter removing the
lid locks.
Reverse this procedure
to reinstoll the os'
sembly. Tighten the bolts of the locks lightly
ond fit the lid properly
in positlon.
Now odiust
202 c
o
o
o ir
e
tt d

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Fig.
M511-
Prising off Door Ponel
When it is roining or when woshing the cor,
woter runs down the gloss
ond penetrotes
into the inner spoce of the door. The
foil is
supposed to prevent
the forming of under-
pressure in the cor interior ond to prevent
the woter from sooking the interior trims ond
running down into the cor. Therefore,
it hos
to be stuck on by rubber cement os shown
in Figs. 14.512 ond 14.5/3 (cross hotching).
First slip the lower port
of the insulotion
(foil), the inner end, inside the door, ond
then opply o seoling compound on to
the
door inner metol-sheet ponel
ond the insu-
lotion os indicoted in the illustrotion (block
dots ) .
Close both doors
on the side to be adjusted
and visually assess which areas of each door
require re-positioning to produce
an even
contour joining
the front and rear
wing body
lines in relation to the door
heights.
With careful adjustment of hinges, satisfactory
body lines
can be obtained.
Hinges can
be moved on the door pillar in
the
following ways.
1 . Up and down after slackening bolts.
Result:
height of door in relation to door ap_erture.
2. In and out after slackening bolts. Result:
Position of
the door leading edge in
relation to bodY aPerture'
3. Shims Pt.
No. 1 13-98B9OO between
hinges and pillar
a) Shims under
both hrnges moves
the door
rearwards and
increases the gap
between
the door leading
edge and the
wing
(Front door).
b) Shims under the bottom hinge
only, will
lift the lower edge
of the door.
c) Shims under the top
hinge only, will
have the reverse effect.
It is
sometimes preferable to remove
the door
catch (On pillar)
to remove misleading stresses
being placed
on the door. This part
being re-
fitted and adjusted so
that both stages of
the lock are
working and
ensuring door is not
being stressed by
excessive tension
up or
down, in or out.
Adjust the door
catch to ensure when
the door
is closed, it will
not ride up or down'
Ensure the door does not catch the door pillar,
wing, other door etc., when both are open or
closed.
Door top half
lf you-have correctly
adjusted the
bottom half
of thb door you
may find that the window frame
top half still needs an adjustment.
Here it will be necessary to
lower the moving
window and carefully bend the
frame of the
window to match the frame
of the door'
Fig. 14.4/14
Common Areas
the Door Touches
Fig. 14.512- Front
Door lnsulotion -
":t;
hotching indicotes where
rubber cement hos to
be opplied, block dots indicote seoling
com'
pound opplicotion
204

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t/g'tl '6!J

! Door Cotch
Retoiner
The position
of the door cotch retoiner on
the door pillor
ond/or the reor wing foce con
be odiusted within certoin limits ofter loosen-
ing its fostening screws. Adiust the retoiner
in the required position,
check the door for cor-
rect closing ond fitting
with the other ports
of
the bodywork, ond then retighten
the screws.
The door cotch must slide
on to the leodlng
surfoce of the retoiner
so thot it rests
ogoinst
it. Sometimes, it moy be necessory to ploce
o pocking piece
under the retoiner (to
prevent
the fouling of the door cotch pin).
ln such
o cose, mork the position
of the
cotch on the
bodywork, slocken the screws, ond instoll o
pocking piece under the retoiner slipping it
over the lower screws ond
tipping it into po-
sition on the upper screws. It is importont to observe the correct ongle
of the inclinotion of the retoiner leoding sur-
foce, which hos to
correspond with the incli.
notion of the beoring surfoce of the door cotch
(outer door lock). Therefore, fosten the bose
plote of the retoiner so thot its upright stiffener
is porollel
with the edge of the moulded recess
for the retoiner
on the door pillor
ond the reor
wing. The leoding surfoce of the retoiner is provided
with o friction plote.
In the cose of domoge
(excessive weor, impoct of on incorrectly od-
iusted door, etc.),
prise
off the originol friction
plote ond fit o new one. lf the friction plote is
locking or if it is excessively worn, the door is
opt to rottle.
Fi1.14.514 -
Door Cotch Retoiner
14.6 WINDSCREEN, REAR WINDOW,
SIDE WINDOWS
To Remove Windscreen ond Reor Window
Rernove the connection of the spocing Insert
ond lift owoy the spocing
insert of the glozing rubber
moulding
using o suitoble tool. Now
press corefully ogoinst the gloss from
inside
the cor ond slip the liP of the glozing
rubber
moulding step
by step over the edge of the
windscreen or window frome
olong its entire
circumference, ond finolly lift owoy
the gloss
together with the glozing rubber
moulding.
To Refit Windscreen ond
Reor Window
First cleon thoroughly the
edges of the gloss
ond of the window opening (frome).
Slip the
glozing rubber moulding over
the edges of the
g loss.
lnsert o twine with o smooth surfoce or, pre'
ferobly, o rubber insuloted coble of 2.5
to 3 mm
in diometer into the inner groove of the glozing
rubber moulding.
Fig.M.6l1- Fitting Glozing
Rubber Moulding
on o Gloss Pone
Fig.14.612 -
Inserting o Twine into
the Groove
of the Glozing Rubber Moulding
206

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prlql)
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-
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rsr y0

Reverse
the
dismontling procedure
to rein'
stoll tl-re window ond its winder. The
loterol
ploy con be odiusted by odiusting (swinging
out) the centre post
ofter hoving loosened the
respective bolts ond nuts -
see Fig. '14.6/6
ond/
or 14.617.
Use this occosion to lubricote inner door
mechonisms -
see Chopter 15.12.
Fig.14.617 -
Reor Door Control Linkoge
ond Fostening/Adiusting Screws
1 -
Inner lotch control link (short)
2 -
Reloy lever
3 -
lnner lotch control link
(long)
4 -
Inner hondle pull
rod
5 -
Fostening/odiusting screws ond nuts
of
the
centre post
(third screw in upper port
of centre post)
Repair of Window Regulator Defects
lf the windows are difficult to wind up and
down (the
maximum torque applied on the
spindle of the window regulator with the glass
installed in the doors exceeds 2.5 Nm) (1.77
tt
lbs), it is recommended that the following steps
are taken as regards both the front
and rear doors:
1. Disconnect the regulator driving plate
from
the window glass
channel. Push the glass
upward
and try the relieved regulator by turning the
regulator crank. lf the regulator does not work
smoothly (jamming,
rattling) or if
a torque higher
than O.7 Nm/(O.495 ft lbs) in front and 1.1
Nm/(0.78 ft lbs) in the rear is required for its
operation, replace the whole regulator with a new
one working satisfactorily.
2. Adjust the centre pillar position
in the door
using the jig
as per
drawing No. A1-1 5417-S.
Loosen the top screw of the centre pillar
and
retighten it while pressing
the centre pillar
against the window glass
wound up to its upper-
most position.
Loosen the bottom screw of the
centre pillar
and retighten it while pressing
the
centre pillar
against the
window glass. 5417
-
S
-l! L
3. When bolting together the regulator driving
plate with the window glass
channel make sure
that the holes in these two parts
coincide along
the whole length of the channel. lf it is not so,
move the
channel into a satisfactory position.
4. lf the regulator is
not lubricated, lubricate the
regulator cable in the
tubing with grease
and
apply oil to the regulator
crank spindle.
To Remove ond Reinstoll Reor Door Fixed
Window
Agoin remove first the door trimming. The
gloss is only inserted
into the door frome ond
supported by o bolted-down holder with o rub-
ber pocking piece.
The gloss
con be moved in
the door
covity ond withdrown through the
door frome.
14.7 TRIMMING UPHOLSTERY AND WEATHERSTRIPS
Ponel-type Trimming
This type of trimming is used for
the doors -
see Chopter 14.5, Fig.14.511- ond for
the front
ond reor window posts.
Ponel-type trimming
fostened by clips (flexible
spocing pins)
covers
olso the porcel
troy below the reor window, the
outer guideroils
of the front seots, the front
wheel orches, ond the focia. On centre posts,
the trimming is fostened by screws.
208

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