1980 SKODA 120 LS Workshop Manual

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I 5.7*
1
5.8
sell-lubricoting type
but the greose is intended
to rid the beorings of ony moisture which moy
get to them post
the seols in certoin circum-
stonces. Apply the greose
gun
till the lubricont
seeps post
the upper rubber cuP.
Front Wheel Toe-in
For meosuring
ond odiusting the toe-in, see
Chopter 6.1.
Fliminqtion of
King Pin PloY
Remove the coter pin
of the king pin
nut ond
rotote the nut to the next cotter pin
hole pos-
ition. lf the ploy
is not elinrinoted ond no
friction sets in with the nut in this position,
continue rototing it
until this condition is
ochieved -
see Chopter 6.5, porogroph 21. Lock
the nut in the f irrol position
with the cotter pin
Fig. 15.712 -
King Pin Hold-down
cnd Adjusting Ntit
Note: irr the list
of servicing (mointenonce)
iobs,
I,he porogroph on "Checking
Front ond Reor
Wlreel Brokes" includes
o) inspection of the broke-shoe lining ond its
replocement, if necessory
b) in the cose of the front broke, the cleoning
ond inspection of the protective (dust) cups
of pistons octing on the broke pods (shoes),
in the cose of the reor broke, the inspection
of the wheel cylinder dust cups (boots),
ond
in both coses the replocement of domoged
ports.
i5.8 BRAKE SYSTEM
Broke Fluid Tonlk -
filling
The brake f luid tonk is instolled in the boot
{inoin luggcrge comportment)
cnd closed with Fig.
15.8/1 -
Broke Fluid Tonk
o screw cop. lt serves
olso the r:lutclr lryrlrotrlic
control systenr. Keep the brqke fluid level withirr tlre ronge
of the moximum filling, i.
e., not lower
thon
10 mm below the "MAX"
mork or so high thot
it just
covers the pcrtition
woll of the tonk
which con be seen on looking inside the tonk.
Observe obsolute cleonliness when filling
in
the broke fluid through the screen in the tonk
filler neck. Refer to
Chopter 15.2 for recon'r.
mended broke fluid bronds. For broke fluid hondlinq precoutions, see
Chopter 9.9.
Brqke Fluid Chonge
The broke f luid obsorbs otmospheric humidity
ond the chcnge of its properties
is opt to offect
broking ond even bring obout corrosion of some
ports of the broke system.
The time period,
in which these chonges
con
toke ploce,
connot be defined with ony pre-
cision. Therefore forestoll troubles ond chonge
the broke fluid in the broke ond clutch system
every few yeors (preferobley
two to three
yeors ) .
Suck out the old f
luid from
the tonk, fill in
fresh fluid, ond remove the bleeding screws
one
ofter onother to let the old fluid be forced out
by the fresh
one from oll bronches of the broke
line to the clutch -
see the broke ond clutch
bleeding procedure.
Broke Bleeding Air con get
into the hydroulic system
of the
brokes either due to lock
of the broke fluid in
the tonk (low
level) or when removing
or dis-
montling some ports
of the hydroulic line. lf
there is o smoll omount of oir in the hydroulic
system, the pedol broke feels "spongy"
ond the
broke efficiency decreoses. Ingress of o lorge
228

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r
5.9-15. r
2
Dismontle the housing, remove
old greose,
cleon the individuol ports,
opply fresh greose,
ond reossemble the housing. Sook the felt rings
on the links (pull-rods)
in engine oil.
15.10 WHEELS AND TYRES, SNOW
CHAINS
Tyre Inflotion, Boloncing
ond lnterchonge
of Wheels
The procedures ore outlined in
Chopters 10.1
through 10.3. Snow
choins ond their use ore
deolt with in Chopter 10.6.
Wheel Toe-in -
see Chopter 16.1.
Shock Absorbers -
see Chopter 8.3 "Shock
Absorbers ".
15.11 ELECTRTCAL EQUTPMENT
Checking electrolyte level ond topping up --
see Chopter 13.2.
Sporking plugs -
electrode gop
odiustment,
etc. -
see Chopter 13.7.
Stqrter motor -
exqminqtion ond renewol of
brushes, etc. -
see Chopters 13.11 through 13.14.
lgnition timing, odiustment of contoct breoker
point gop, distributor lubricotion -
see Chop-
ter 15.3.
15.12 BODYWORK -
UNDERBODY
Woshing ond Mointenonce
The visible ports
of the body qre
f inislred in
o hord synthetic boking vornish, the remoining
ports in synthetic vornish.
The underbody is sproy-cooted
with o plostic
compound -
for detoiled informotion, see Chop-
ter '14.9.
Follow the
usuol procedures
when
woshing, cleoning ond polishing
the cor, ond
observe the specific instructions for
the use of
woshing ond cleoning preporotions,
issued by
their monufocturers.
All lights with the exception
of heodlomps
hove cosings of plostic
moteriols qnd
they
should be cleoned onlywith woteror shompoos.
When hosing down the corr
cover the voltoge
regulotor of the olternotor ond
the ignition coil
to protect
them ogoinst sploshing with woter,
ond do not
sproy woter direct on
the door lock
ond the lid covering the fuel
tonk filler neck.
Woshing ond Core of Underbody
Mechonisms
The underbody mechonisms
ore protected
with o synthetic vornish which stonds
well the
usuol woshing procedures.
Protect oll rubberports
ogoinst direct contoct with speciol chemi-
col solvLnts or limit the durotion of this
contoct
to o minimum before
o complete woshing off of
the solvents with woter (by
hosing down, etc.)'
Keep the oil cooler, if fitted on
the cor, in
cleon'condition. Hose
it down when woshing
the cor, ond if dirt still
sticks to the cooling
surfoces, use some of the detergents.
Bodywork Lubricotion
Routine mointenonce includes the
lubricotion
of door hinges ond limiters, hinges
ond releose
mechonismi of the engine bonnet ond boot lid,
the releose mechonism of
the spore wheel,
ond
the leveroge of windscreen wipers. Lubricotion
of inner dolor mechonisms is
included in
speciol
mqintenonce. Lubricote oll occessible mechcnisms
with
high-quolity greoses which
do not
dry, do not
oxldize, ond protect
the mechonisms ogoinst
corrosion for o long time. Oil is
not suitoble due
to its short-time efJect. Any greose con
be used
to lubricqte the
door limiters ond
the front
seot
slide roils.
Lubricotion of SporeWheel Corrier
Bearings-
Remove the spore wheel,
cleon the hinges, ond
opply oil on iheit
upper sides. In oddition, rub
in greose of ony brond.
Lubricotion of Windscreen Wiper
Leveroge -
Remove the cover of the
ioint (o
plostic cup),
f ill it with greose, lubricote the
ioint, ond
rein-
stoll tlre cover.
The Lubricotion of
Inner Door Mechonisms
is possible only
ofter removing the
door ponel
ond the inner 'door
mechonism. Use
only re-
commended greose brcnds.
Lubricote
the bowden
coble of thJwindow wind-up mechonism
with
Fig.15.1211- Lubricotion
of Windscreen Wiper
Leveroge Joint -
ioint cover
230

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Mau D qllM
'c1a P1nbt1
,o pu!l elqolrnsun
uo
ql!M paqslualde-r 6ttteq
iq palorouelop ssalun 's:oaA
t, or
Z sr
6ur11r;
eql lo al!l
ec!^les aql 'Jerrolsns
oLl] ql!M
luetu
-aal6o logceds o uodn
JeMol Jo
C.9Z- o]
uMop
sarnloladuel lua!quJD Jol
szaalj!luD pasoq-
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Pell!] s!
ua]sAs
aq1 'l.ro1col
eql ul '.rool
eq1 lnoqDno:ql uats{s
eql ul pesn
s!
luDlooc lutod-6utzaall r'rrol
V
dfrvsH cNV t lfls^s eNI100c tl'gt
'vL'tL
raldoq3 aes -
reqsDn1 uearosPu!nA 6utlltl
'sloc!u€qc
eql ]o secoll
;1o Aoano
qsDM 'pa^oual
uaaq
soq lods JD]
eql le1;o A1e1o!pauul 'Jalourer
-ro1 logceds o Jo 'eulluedlnl
'euasoJel
ul padd;p
qlolc D qlrvr
Apoq oql uor, slods .tol a^oued
stods ro1 6ulnoueg
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eql ssnDc
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6uguoelc lolcadg 'doos
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lo s-le^oc
puo
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1to autDuo

the
pipes) The
greoter portion of
the f illing
will 'flow
out through the
outlets ond
this will
suffice in the
event of
droining before dismon'
tling the engine.
3.-Uncouple the
hoses from
the engine line
in the engine boy -
See Fi1.15.131A. Proceeding
from und6r the vehicle, pull
the hoses
behind
the cross beorer of
the georbox,
ond let the
liquid flow
from the hoses.
4. Remove the
droin plug of
the cylinder
block ond, if necessory, free
the out'f low using
o length of wire,
etc.
N ot e : In oll, obout 85 0/0
(10.5 litres) of the
coolont will f low out,
ond the difference should
be reckoned with when
refilling the
system-
All ontifreezes ore
to o certoin extent hormful
to the skin. lt is therefore necessory to
protect
oneself qgoinst
contoct with
the liquid, es-
peciolly the eyes (do not touch them
with Fig.15.13/4
-
Heoter Line on
Engine
ond Droin Plug
1 -
droin plug
2 *
pump ond heoter connecting line
3 -
thermostot ond
heoter connecting lirre
fingers soilded witlr
the liquid). Wosh
ony
stolns off the skin os quickly os possible with
soop woter etc.
Rinse the stoins off
the vor-
nished cor bodY with woter.
Fridex-Spolqno Antifreeze
As clreody mentioned, the cooling system is
f illed with this liquid,
or with o solution
of its
concent'rote with
soft
woter, in the
foctory.
For the preporotion of this solution
olw.oys
use soft ond cleon woter. In the following
toble,
its concentrotion in
dependence on
its freezing
resistonce is indicoted. Alternotively, the
con-
centrotion con be determined from
the density.
Fig.15.1312 -
Cooling System
Bleed Cock
Fig.-15.13/3 -
Fuel Tonk
Droin Guord
Sheet ond
PiPe
Plugs Densit
I ot
+20'
I
i
-- I 1.029
; t.oqs I 1.055 1.O57
1.062
| 1.067
I
i 1.074
i 1.080
I
Volume
Ports
Fridex Spolono
i Woter
21 1
38 1
44 47
I
53 -1,5 ity
ot +20 oCFreezi
ng
point "C
-10 -20
-25
-27
-30
-35
-40 -45
-60
79
2
62 '1,5
56 53 1
47 4I
232

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a6o4 suo;6er
;oc1do.r1 rol
luaudtnbf z'gL
suo;6a.r locldorlqns .rol
luaurd;nb3 t'gt
rNSWdrnc)l 'lvlf,3ds'9
]

16.1
-
16.2
16.1 EQUTPMENT FOR SUBTROPTCAL
REGIONS
Stondord equipment of
cors for subtropicol
regions where the temperoture
does not exceed
+40oC, or where
increosed
cooling efficiency is
required generolly:
1. Copper rodiotor (copper
lominotions) for
oll types. 2. Oil cooler for oll types,
the some
os thot
fitted in the stondord
12O LS
model.
3. Cost finned
oil sump for oll types includ-
ing occessories (longer
oil pump
suction
stroiner ond longer oil dipstick), like thot fit-
ted in
stondord 120 L ond 120 LS models.
4. Oil temperoture signolling
telethermometer
(125+3'C) in cor type S 120 t-S.
The primory
element is mounted in o speciol connection fit-
ted to the oil cooler outlet. The worning lomp
on the instrument ponel
is red
ond without
o symbol (the
instrument ponel
hos o different
wiring for the connection of the worning lomp
to the terminol boord).
The coble of the primory
element is con-
nected to the terminol "10"
of the terminol
boord "111"
(morking occording to wiring dio-
grom in Fig. 13.1/1).
The
coble is led out ot
the engine together with
cobles to the engine
temperoture gouge
ond the oil pressure
switch.
16.2 EQUTPMENT FOR TROP|CAL
REGTONS
Stondord equipment of cors for tropicol re-
gions where the temperoture does not exceed f
50 oC,
or where on
extro high cooling
ef-
f iciency is required generolly:
1. Copper rodiotor (copper
lominotions) for
oll cor types.
2. Oil cooler for
oll types like thot fitted
in
stondord S 120 LS mod6l. The bolt
connecting
the rodiotor hose of the outlet from the engine
timing geor cover to the rodiotor hos, however,
no by-poss holes.
3. Cost finned
oil sump
for oll cor types -
refer to Chopter 16.1, porogroph
3.
4. Oil temperoture signolling telethermometer
(125+3oC) for types 120 L
ond 120 LS.
For
loyout see Chopter 16.1, porogroph
4.
5. Thermostot with o nominol opening tem-
peroture of +75oC for oll
types.
6- Increosed volume of coolont (storoge)
tonk -
4 litres for oll types.
7. Fr-rel pump
with o longer priming
lever.
It is instolled on the engine on two insuloting
pcrd s
Mointenonce of oir clecner:
The stondord oir cleoner filter element (the
some for oll cor types) must be
chonged in
dust-loden environments ofter every 2,000
kilo-
metres. On dusty roods in deserts, this element
must be inspected doily ond reploced doily, it
necessory.
Keep the coolont level
ot obout the middle
of the tonk or only slightly obove the middle.
The totol
volume is 13 5 litres opproximotely
234