1980 SKODA 120 LS engine

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

'i
iiiI 14. Fuse box
Centrol connection of conductors -
do not
seporote them from the bunch!
15. Direction indicotor switches, dip switch,
and horn switch
eight-pole terminol
boord
six-pole terminol boord
16. Porking light switch ond high beom feeder four-pole terminol boord
17. Switch box femole connectors 5.5 with symbols "15",
"30", ond '50"
to be
connected to symbols
"15u, "30', ond '50"
on the switch box
18. Instrument ponel
ten-pole terminol boord
six-pole terminol boord
eorthing coble with lug
'19. Heoter switch
four-pole terminol boord
20. Switch of disobility lights
six-pole terminol boord
21. Door switch, right-hond
green -
femole connector 5.5
22. Dome light,
right-hond
green -
femole connector 5.5
red -
femole connector 5.5
23. Stop switches
forked (yellow) -
femole connectors 5.5 .
red -
femole connector 5.5
white -
femole connector 5.5upper ond lower
switch
upper switch lower switch
24.Fuel gouge block -
femole connector 5.5
yellow -
femole connector 5.5
blue -
femole connector 5.5
to be connected to the respective pins
(blodes) of the some colour of the fuel gouge
25. Storter motor, reversing
lomp switch
conductors with lugs stater motor moin
terminol boord
storter motor
control switch
green -
femole connectors 5.5 heodlomp switch
26. Oil pressure
gouge,
thermometer, corburettor
iet seporotor
green -
femole connector 5.5 yellow
-
femole connector 5.5
green - telethermometer
primory element
femole connector 7.
corburettor
iet seporotor
27. lgnition coil, voltoge regulotor, olternotor,
tochometer
conductor with femole connector ond
bronching lug
femole connector-regulotor terminol 15/54
lug -
ignition coil terminol 15
blue -
femole connector 5.5,
symbol "R"
. regulotor terminol "R"
yellow -
femole connector 5.5,
symbol "M"
regulotor terminol "M"
blue -
connector "R"
. olternotor terminol "R"
yellow -
connector "M".
olternotor terminol "M"
lug terminol "+B"
conductor with
lug ignition coilterminol "1"
(tochometer operotion
)
28. Toil lomp cluster, right.hond
yellow -
femole connector 5.5 toil light
block -
femole connector 5.5 direction indicotors
red -
femole connector 5.5 stop light
green -
femole connector 5.5 reversing lomp
29. Licence plote light
conductors with femole connectors 5.5
30. Toil lomp cluster, left.hond
se point
28.
b) Connection
of free conductors
1. Storoge bottery
bottery coble positive
(*)
terminol -
storter motor
bottery eorthing strip negotive (-)
terminal -
bodywork (eorthing conductor)
2. Engine engine eorthing strip (fostening
lug) -
engine cross beorer (eorthing conductor)
3. Distributor speciol coble from distributor to
ignition
coil; end with interference suppressing
terminol to distributor
coble from distributor to ignition coil
terminol "1"
cylindricol
(pin)
connector
pressure gouge172

L
i g)
Excitotion of the olternotor by o current
supply outside the cor is not permitted.
Agoin the semiconductors would suffer.
h) A blown chorging worning lomp must be
reploced immediotely with o new
one. Other-
wise correct excitotion of the olternotor is
not ensured. Use o new lomp of
the some
roting (or input), i.
e., 1.5
to 2 W.
i) Be sure thot there is
o perfect
electricol
connection on the connecting terminols ond
thot the olternotor
ond regulotor
ore properly
eorthed.
i) The
olternotor is oeroted, open. Therefore
toke core when woshing the cor thot woter
or cleoning ogents do not get
into it through
the venting holes.
Removing the Alternqtor
1. Disconnect the bottery.
2. Disconnect the olternotor leods. lt will be
helpful to remember the colour of one conductor
ond its connection for reinstollotion.
3. Remove oll ports
holding the olternotor on
the engine, ond lift owoy the olternotor.
Reinstolling the Alternotor
1. Cleon oll mounting surfoces.
For the olter-
notor mounting, see Chopter 2.3, por.42.
2. With the bottery
disconnected, insert the
conductors into the respective
connectors "M,,
ond "R"
(the conductors beor the some sym-
bols), ond fosten the remoining leod with o nut.
3. Reconnect the botterv. Alternotor
Disossembly -
Repoirs
1. Screw off the belt pulley
nut ond remove
the belt pulley
ond fon.
2. Lift the brushes with o hook proceeding
through the holes in the
commutotor end
shield
ond hold them in the lifted position
by wires
inserted into the shield through dio. 3 mm holes
under the terminols uM'
ond "Ru.
3. Mork the mutuol (relotive) position
of the
commutotor ond drive end shields ond seporote
the qlternotor
ofter hoving removed its clomping
bolts. The drive end shield remoins connected
with the stotor.
This disossembly will give
occess to the
brushes ond some
of the diodes. All other
iobs,
with the exception of the renewol of the beor-
ing, should be done by experts in speciolized
repcir shops -
see the note supplementing the
following porogrophs.
Alternotor Reossembly
1. Insert the circlip into the becring bore
in
the commutotor end shield.
2. Fit the drive end shield with beoring on
the rotor shoft.
3. Assemble the stotor with the rotor ond the
commutotor end shield. 4" Tighten the olternoior with clomping bolts
ond check the rotor for free rototion while
tightening the bolts.
5. Slip the spocer on to tlre shoft,
top the
key in position,
fit the fon ond belt pulley,
ond
tighten the entire ossembly using the nut with
spring wosher.
6. Pull out wires from the commutotor end
shield which hove been used to hold
brushes
in their lifted position.
Replocement of Beorings
The used beorings ore fullyclosed ond seoled,
ond they hove been filled in the foctory
with
lubricont to lost through their entire service life.
1. Pull the beoring off the rotor
using o suit-
oble puller.
When ref itting the beoring, press
it
on to beor on the shoft
collor-
2. Before removing the drive end shield
beor-
ing, f irst drill off the heods
of the flonge rivets
ond then drive the beoring out from
the outer
side of the drive end shield using o suitoble
mondrel (drift).
On reossembly,
close the beoring with the
flonge ond rivet the flonge to the shield.
Replocement of Diodes
The use of the removoble
diode block with
the individuol
corriers of the so-colled positive,
negotive, ond ouxiliory diodes, focilitotes con-
siderobly the replccement of ony defective
176
Fig.133la
-
Alternotor -
Sectionol View

junction
with the olternoto,r occording to
Chop-
ier 13.3 ond mointoining
o constont voltoge of
tlre power
supply set within the
entire ronge
of
service speeds.
Tlre voltoge regulotor
is instolled orr the body
cross beorer, to
the right of the engine ond
beside the ignition coil.
To focilitote hondling
of its leods' especiolly
the occess to their
connections, it
is recom-
rrrended to remove the regulotor fostening
screws. For disconnecting procedures,
see
Chopter 13.3 "Alternotor
lnstollotion ond Gen-
erol lnstructions".
DK 1565
Fig.13.411- Internol
Wiring Diogrom of
Alternotol with
Voltoge Regulotor ond
Outer
Connections
Altenrotor: B, R, M -
olternotor outlets
f -
olternotor phose
windings
m -
olternotor field winding
D1,2,3, 4, 5, 6 -
moin diodes
D7, 8,9 -
olternotor ouxiliory diodes
D10 -
olternotor choking diode
Voltoge regulotor:
R, M, 15/54 -
regulotor outlets
reg -
regulotor tension winding
Rk -
boloncing resistor
Ro -
protective resistor
Rr -
odiustoble resistor
Kr -
regulotor contocts
Outer connections: K -
worning lomp (1.5
W)
S -
switch (switch
box)
B -
bottery
Checking Voltoge Regulotor
on Cor
The regulotor operotion con be offected by
loosened connections ond on imperfect eorth- ing.
lf the wsrning lomp does not go
o.ut when
driving, i. e., if it glows
ot increosed engine
speed brightly or dimly,
or if it does not stort
glowing ofter stopping
the engine ond
o new
iurning of the ignition key in
the switch box,
the voitoge regulotor
is probobly
foulty. Another
symptom of o regulotor
foilure is
o poor
chorg-
irrg of tlre bottery or its
overchorging.. lf there
is nothing wrong with the regulotor, check the
reguloted voltoge over the regulotor which
slrould reod 13.2 volts ot the
minimum ond 14.8
volts ot the moximunr. This check
in the
cor
is only tentotive ond only
o check on
the test
bench'con be considered os definite ond
bind'
i ng.
Electricol Adiustment
The voltoge regulotot- should be tested
ond
odjusted only on o test bench
in o connection
slrown in Fig. 13.412.
At o lood of some
2
onrperes, the checked
voltoge should correspond to
volues specified
in the column "Checking".
lf the checked volt-
oge is within the specified ronge, do
not odiust
the regulotor. Othenwise odiust it to the volues
specified in the column "Adiustment".
lf woter
evoporotes obnormolly from the bottery, odiust
the voltoge regulotor to the bosic volues of
"Adiustment" utilizing the lower section of
the
toleronce zone.
Fig.13.al2 -
Wiring Diogrom of
Regulotor Tested
ond Adiusted on
o
G -
olternotor
REG -
voltoge regulotor
A -
ommeter
V -
voltmeter
S -
switch
R -
lood resistor
B -
bottery DK
1566
Voltoge Test Bench
178

I
I
t
b
c ll
e
c
tl
d n
tN'
>
\'
J I
(Il
qt3
Fig. 13.5i3 -
Vocuum Control Course -
opplicoble to both
regulotor models
copscrew fostening the distributor brocket to
the support on the engine (do
not loosen the
brocket clomping bolt).
Refit the distributor on the engine by
re-
versing this procedure. The
coupling on
tlre
shoft is osymmetricol ond it hos to engoge into
the heod of the drive shoft in the engine. To
seot properly
o new distributor
or o distributor,
the brocket of which hos
been loosened, refer
to Chopter 2.3, por.25
to 27.
Distributor Disossembly ond Reossembly
This should be done in speciolizedworkshops,
especiolly with regord
to the checking of the
mechonicol condition or o repoir
of the dis-
tributor. lt is recommended
to use o suitoble
holder for doing the moiority of the required
iobs in
o verticol position.
When reossembling
the distributor, lubricote
the sliding points
oc-
cording to Chopter 15.3
but bewore of over-
lubricotion.
Remove olso the copscrew
on the bottom of
the distributor housing ond drip some low-pour
point oil into the hole to increose the oil reserve
of the shoft
sel-lubricoting beoring -
see Chop-
ter 15.2 "Speciol
Oils".
Disossembly 1. Remove the distributor cop ond the breoker
orm.
2. Remove the coupling from the shoft (note
the relotive position
of the eccentric dogs ond
the breoker
orm).
3. Remove
the circlip from
the pivot
ond litt
owoy the breoker orm.
4. Remove
the subossembly
of the terminol
"1" (current supply to distributor).
5. Screw off the copocitor. 6. Screw
off
the retoining springs.
7. Lilt owoy the vocuum chomber (do
19t
open it, o chonge of the curve is on.improboble
d'efect; do not chonge the screw-in depth
of the
pull-rod).
' 8. Lift owoy the contoct breoker
bose plote
with pocking piece from
the housing.
g. Litt owoy the shoft with the
centrifugol
governor. -
10. lf necessory, disossemble further
the sub'
ossembly of the shoft with the centrif
ugol
governor (odvonce mechonism) ond
com.
l?;h.',0, ReossemblY
1. Reossemble the centrifugol governor
(the
weights must be free
to rotote on the pins).
2. lnstoll the reossembled shoft
with the res'
pective woshers into
the distributor housing.
3. Fit the contoct breoker bose plote
with the
f ixed contoct holder ond pocking
piece into the
housing. 4. Fit the pull-rod on
the pin
ond lock it in
position, screw down the vocuum chiomber with
the copocitor. Check the
ignition odvonce po-
sition for the first cYlinder.
5. Screw down
the retoining springs
with
shims (the
spring with
the dog opposite to
the
terminol "1"i;
the bose plote must
rotote freely
in the distributor housing.
6. Reosemble the terminol "1".
7. Fit the breoker orm
on
the pivot
ond lock
it in position. Adiust the contoct breoker point
gop (lift) ond check the
contoct
Pressure'
"
if. 'Stip
woshers on
the shoft in
the originol
sequence, slip on the coupling ond
lock
it in
position^ 9. Fit the lubricoting felt
into the hole of
the
com ond instoll the breoker orm.
10. Fit the distributor cop
in position.
11. Check the distributor operotion.
Checking A def inite indicotion of the condition of
the
distributor (during on operotionol check
os
well
os ofter o
repoir) con be obtoined by testing
the distributor on
o test stond with
o circulor
spork gop.
After o preliminory
odiustment of
the
contoc-t breoker point gop,
the stond is
used for
check i ng:
1. The contoct point
contoct ongle.
2. The spork ongulor distribution (with o
tol-
eronce of -+45
ongle minutes within
the entire
operotionol ronge).
3. The rongJ ond course of the
centrifugol
ond vocuum control. 4. The
operotion ot
moximum speed (length
of spork on spork goP -
4 mm) for o
brief period
(obout 2 minutes).
180
t
5
2tD zsa !l!
F llti
rc

(
1
z
Strike the
slip-over ring off the circlip
(towords the motor windlng). Open the circlip
ond pull
it off the shoft together with the re-
leosed ports.
8. lf necessory, re-turn the commutotor ond
scrope or mill out the insulotion between the
lominotions. "Mikonit"
should be 0.4 to 0.8 mm
below the octive surfoce.
Note: The
switch connot be further token
opat. lf
defective, lt hcs to be reploced with
o new one. When cleoning ports
of the storter
motor, do not dip the ormoture or the pinion
with the idler into petrol
or onother degreosing
ogent.The some opplles to the end shieldswith
beorings. By dipping them in o degreosing
ogent, the beorings become procticolly
worth-
less"
Storter Motor Reossembly 1. Lubricote the hellx of the ormoture shoft
with greose -
see Chopter 15.2 'Lubriconts
of
foreing mokeu ond fit the pinion
with the idler
ond the slip-over ring in posltion.
Fit the
circlip
into the groove
in the shoft, ond drive the slip-
on ring over it. The pinion
with the idler must
move freely olong the shoft.
2. Slip the respective
woshers on the shoft in
their originol sequence (corrier
ring, distonce
ring, fibre ring, distonce ring) ond insert the
ormoture with the engoging lever
into the drive
end shield. 3. Suspend the switch
ormoture into the
pre-engoging lever ond bolt down the switch
lightly. Fit the lever pin
into the drive
end
shield ond lock it in position
with the retoiner.
4. Tighten the copscrews of the switch
ond
fit the stotor on the drive
end shield.
5. Instoll the respective
woshers into
the
commutotor end shield in
their originol se-
quence (the dished wosher with its centre
focing the shield, then the ploin
wosher, the
toothed wosher, ond the drive wosher).
6. Fit the commutotor end shield with lifted
brushes on the shoft (in
the position
occording
to the recess
for the excitotion outlet ond the
notch) ond screw in the clomping bolts.
7. Instoll the brush interconnecting strip ond
bolt it down together with the field winding
outlets to the positive
brush holders, lower the
brushes. 8. Fit the Insuloting strip in position
ond bolt
down the cover. 9. Test the storter mottr.
Diognosing Storter Motor Defects in Cor
o) lf the storter motor refuses
to operote, look
first for on interrupted connection between
the bottery ond
the storter
motor, the engine
eorthing ond the storter
motor, or the engine
eorthing ond the bottery. lf these connec-
tions ore in order (current
flows to the ter' DK
1575
Fig. 13.10/3 -
Storter Motor Testlng Connection
minols u30"
ond "50"
with switched on
ignition), stort looking for o foilure of the
storter motor switch. Even in this instonce,
the couse con be o fully dischorged or foulty
bottery.
b) lf the storter motor
continues running
even
ofter the ignition key hos been switched in
the switch box from the position "START",
it hos to be stopped without ony deloy by
disconnecting the bottery (using
its eorthed
pole).
c) lf the storter motor hos no power
to cronk
the engine, stort with switched-on heod-
lights. A
morked dimming indicotes c poorly
chorged bottery.
Tentotive Checking of
Storter Motor
Outside Cor
Connect the terminol "30'of
the storter
motor to o properly
chorged bottery ond incor'
porote on ommeter with o wide
meosuring ronge
into the circuit -
see Fig. 13.10/3.
Stort the
engine (feed
current to the terminol "50").
The
volue of the current ot idling speed must
not
exceed 65 omperes (not
considering the peok
ot
the first momentous deflection).
The storter motor must run noiselessly,
smoothly, ond the pinion
must move smoothly
into ond out of the rest position
(engoge
ond
diesengoge). The engoged pinion
must not ro-
tote direct on the foce of the slip-on ring. The
run-out of the storter motor must not lost longer
thon 8 seconds ofter the disconnection of the
switch from the current supply.
Inspect the brush pressure
springs. The
brushes must
beor on the commutotor by ot
leost two thirds of their surfoce ond they must
move freely in their cells.
The ormoture should hove o noticeoble oxiol
cleoronce (ploy)
not exceeding 0.7 mm.
At
o slight rototion of the pinion
in the direction
of the storter motor rototion,
the idlor must
slip
freely.
186

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

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