1980 SKODA 120 LS Workshop Manual

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2.6-2.7
seot in the cylinder block using o copper or
oluminium rod.
Reconditioning Recesses for
Cylinder Liner
Flonges
Before ossembling o used
cylinder block,
inspect ond cleorr thoroughly the moting
sur-
foces of the recesses for
cylinder liner f
longes.
lf chemicol ogents (petrol,
etc.) foil
to hove
the required
effect, or if the surfoces hove
been domoged
mechonicolly, use the MP 1-106
dresser, or the MP 1-157
iig with
universol guicc
rings.
Reconditioning of Comshqft Beorings
lf on oversize
comshoft is to be f itted (ex-
cessive beoring cleoronces in on otherwise
sound block), drive out the plug
on the reor
side of the cvlinder block ond reom
the beor-
ings to dimensions specif ied in the following
Toble:
-0.025To
Grind
For grir
shoft by t
between 1
'Ihe
reor
ond there
for detoils
beoring.
For grir
prepored
clomped t,
pins must
Externol Col
Nomir iourn
Stondord
1st regrin
2nd regrin
3rd regrin
Stondond comshoft
Diometer of beoring in cylinder block
mm
+0.02s
38.5
+0.021
Oversize comshoft lsg
l-
38s-
l-;- -0.041
-0.020
The numerical symbols of the beorings (
l-lll)
indicote the respective
front, centre, ond reor
beari ngs.
Close the newly
mochined bore with o new
plug ond seol
it with o dob of point.
A poor
seoling would result in oil leoking
from the
engine into the clutch.
When reboring the bore for
the comshoft,
observe the centre distonces of the cronkshoft
ond comshoft. Otherwise the timing choin will
be either too slock or too tout. For the correct
distonces see
Fio. 2.6/3. Reconditioning
of Volve Toppet Guides
lf there is on excessive cleoronce in the
guides (beorings) of the volve toppets,
it is
possible to recondition the guides
ond to re-
ploce stondord toppets by toppets
of o lorger
diometer. The centre line of the beorings
is per-
pendiculor (normol) to the seoting foce
of the
cylinder block. The relotive dimensions
of the
beoning ond toppet ore
specified in
the Toble
below: o
L_r
_-L1il I toi .ll
-t
QZt0.l -T-
zi
A'ry
@)
2.7 CRANKSHAFT
AND ITS ACCESSORIES
The cronkshoft hos three rnoin beorings ond
four cronkpin beorings. lt is o forging with sof t,
not hordened iournols. When
worn, it
must be
reground to dimensions os per
Toble for fitting
oversize big-end ond moin beoring shells
os
well os cn oversize guide
ring. Cronkshoft Beoring
(for
clutch shoft)
It will be driven or pressed
into the shoft
lubricoted with the recommended greose
with
its cover turned outword.
After its pressing-in,
odd odditionol greose
by forcing it into the
shoft bore behind the beoring.
Use the extroctor MP 1-109 for
the removol
of the
beoring. Diometer of comshoft
iournols
mm
_ =l__i tl
Volve Toppet Diometer
of Beoring
in Cylinder Block, mmToppet
Diometer
mm
Stondord
on;rsizt- 21
+0.021 21
-0.020
21.2 21.2-0.007
42 4th

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901-L (

2.7.-2.8
Guide Rings Regrinding of the foce of the front
cronkshoft
web results in
on increosed (oxiol) ploy
of the
shoft. Reploce therefore the originol guide
ring with
on oversize one. Oversize guide
rings ore fitted exclusively
to
the regrround loterol
foce of the cronkshoft web.
Stondord size rings
should be olwoys fitted
to
the thrust ring side (next
to the timing geor).
Thrust Ring
lf the thrust ring under the cronkshoft timing
geor (sprocket)
obutting ogoinst the guide
ring is worn to on
extent
which mokes domoge of
the guide
ring likely, reploce it
with o new one
or regrind it.
The moximum permissible
regrinding is, how-
ever, to o thickness of only 3.75 mm.
Cronkshoft Moin Beoring Shells
Fit the cronkshoft moin beorings (shells)
occording to the respective nominol diometer
of the cronkshoft
iounnols. The shells
ore not
provided with o diometer symbol so thot they
hove to be checked for
the respective woll
thickness with o micrometer.
2.8 FLYWHEEL WITH GEAR RING
Boloncing -
Removol ond Refitting
A new flywheel ossembly is o
stoticolly bo-
lonced unit, its moximum permissible residuol
out-of-bolonce weight being '10
gcm. The finol
lf one of the
shells
is worn or domoged, o ll
cronkshoft moin beoring shells must be reploced without foil !
For the respective correlotion of the cronk-
pins ond connecting rod
big-end beorings see
Chopter 2.11. dynomi<
ism shr
sembfed
Thus
sitioq of
shoft be
from o
1
When
rnork on
zero line
ond prol
mork op
cylinder
the rem<
gcm sin
mosses (
concentr
cronksho
holes rot
wheel ir
interf erel
For thi
on the r
sition, i.
cronksho
fore the
When
one or wl
follows:
1. Fit .
residuol o
olly offec
2. The
bolonce r
hos o hig
correctior
once. lt
occording
porogroph
Chopter 1
bending t
To Reploc
Reploce
worn or d,
ring, toke
the interfr
sion). The
prime impr
ossembly
storter mo
The gec
removed b
port pod
cr
MP 1-153. I
ing the ge
it off. The
monufoctut
When ur
front foce
ond drill
o
Fig.2.8l1- Morking
Correct Position of
on Cronkshoft (prior
to removing theFlywheel
f lywheel)
Motching
Cronkshoft Main Beorings with Journols
Nominol cronkshoft mmiournol
diometer Thickness
of beoring
shell woll
mm Toleronce limit
of woll thickness
mm
dio. 55 dio.54.75
dio. 54.50 dio.54.25
dio. 54 stondord
1st regrinding
2nd regrinding
3rd regrinding
4th regrinding 1.497
1.622
1.747
1.872
1.997
-
0.007
44

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eq plnoqs
usl
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DK 626
Fig.2.911- Morking of Cylinder Toleronce
Closs
Grode the rebored cylinder liners in the some
monner while
odding the number of the re-
spective rebore before the designotion of the
Dio. 68 (stondord)
68.25 (1st
rebore)
68.50 (2nd
rebore)
Dio.72
Fig.2.912 -
Outside Dimensions of Cylinder
Liner
Cylinder bore 68 mm
Cyf inder bore 72 mm toleronce
closs occording to the clossificotion
toble, for exomple dio. 68.25
1A, dio.
68.50 24.
However, only cylinder liners of o nominol dio'
meter of 68 mm con be rebored. Worn liners of
72 mm nominol diometer hove
to
be reploced
with new ones. For the cylinder liner otrd pistotr
ossembly
see Chopter 2.12.
Check the diometer (bore)
ot o temperoture
of 20oC which must be constont for both the
cylinder liner ond gouges.
Mochining (Reboring)
Cylinders
For mochining (reboring),
the cylinder should
be clomped only in the oxiol direction to
preclude ony distortion
ond deformotion of its
bore. Depending on the mochine
used for
reboring, moke o
centering heod to be centred
68.00 68.01
68.02
68.25
68.26 68.27
68.50 68.51
68.52 +
0.009
72.OO 72.O1
72.O2 + 0.009
Fig.2.9/3 -
Mochining the Cylinder
1- cylinder liner, 2 -
centering heod, 3- clomp.
ing plote, 4 -
clomping bolts, 5 -
cutting tool
A
B
c
1A
1B
1C
2A
28
2C
AB
c
dio. D :75f7
dio. D:76t7
46
Groding of
Cylinder Liners
According to Diometers ond Toleronce
Closses
Nominol diometer mm Toleronce
ond I
rebore closs I IDiometer
mm Diometer
toleronce

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Nominol
diometer
mm Gudgeon
pin
diometer mIn Pin
bore
in piston
nl
n] Connecting
rod
smoll-end bore
(br-rsh diometer)
mm
20
20.0s 20
-
0.003
20.0s --
0.003 -
0.004
zu - o.o1o
,o 05, 3 3?3 2a
13 33?
,o os
13
33?
Toble
ofMotching GudgeonPins
to Pistons ond
Smoll'end Bushes The
cler
should be
cleoronce
the rings
2.11 COn
The con
o brorrze
b
beoring sh
in the big
Before r
for compli<
weight, ol
ond motch
shoft.
For its
<
ter 2.12.
To Check
Connecti
weight gror
foctory, ligl
yellow poi
Should the
during stor
been fitted
determ ined
remove o c
smoll ond t
the smoll
r
in the
engi
(+2 gr.).
When re
odjust its w
connecting
DK 63:
Fig
'l - boloncing
2 -
numericol
GUDGEON
PIN
Tlre gr-rdgeon pin
is cr slight interference f it in
the piston-
lts cleoronce in the
connecting rod
smoll-end bush is:;pecified in
the Chopter
"Connecting Rocl ".
The steel gudgeon pin
is lrollow ond hos
c rronrinol cl iometer of 20 ntnr,
replocement pitts
l.rovirrg; o nominol dionreter of
20.05 mnr. When
f itting on oversize gudgeon
pin with 20.05 mm
nomincl diometer, the bore
toking the pin must
be reomed to dimerrsions
specif ied irr the re-
spective l-oble.
PISTON RINGS
To ensure their correct function, they must
be f itted in the correct position, they
must hove
no or onlv c minimum cleoronce clong
their
r:ircumference, o smqll
cleoronce in
the gops'
ond tlrey mLrst rrove freely in the piston
grooves.
DK 1436
Fig.2.1Ol3 .-
Seqerence ond
[Jlethod ot Fitlingl
Piston Rings
( Mork Positioning).
Fronr top to bottom: chromium-ploted compres-
sior.r rinq, bevelied compression ring,
spring
locrded exponding oil control ring
Fit the {irst ring in cny orbitrory position
(its cylindricol chromium-ploted peripherol
port
is chomfered on either side,
focilitoting identi-
f icotion), the second, bevelled ring with
the
lettering 'TOP"
or onother mork
on top, ond
llre oil lontrol ring with its
outer shorp
edge g>ointirig
dowtrword. lf
tl-rere is
ony doubt os
to
the coriect selection of
the rings, check them
for proper seoling in
the cyli.nder.before os-
rurbty. ltrsert tlre ring into
the cylinder ond
level it by pLrshing
home the piston heod' In
the cose of
o used cylinder, insert
the ring
obout 20 ntin
below the
top edge of the cylinder
lirrer, i. e.
o plcce rvhere the
cylinder. liner
is
olreodv worn, while checking for
the right
clecronce in the piston
groove ond for the
correct gcrp in the
cYlinder bore.
For ri"ngs
thot hove not
been run-in,
the
fol'
lowirrg circumferentiol gop or
contoct cleoronce
with rlgord to
the cvlinder liner
is permissible:
none foi the chromir-rm-ploted compression
ring,
two in c totol ronge
of on ongle of
35 degr' for
the bevellecl compression ring
ond the oil
control ring. Lcrger
contcct cleoronces olong
the circumTerence denote
either on
incorrect
selection of
the ring, for exomple the
ring
does
not correspond to
the cylinder bore, or
on
excessive weor
of the cylinder liner.
Check the ring gop cleorcnce using
feeler
goLrges- For new
compressiol
lngs, this
gop
.leo"ronc" should
be
0.25 to 0.40 ntm, for
new
oil corrtrol rings
0.20 to 0.35 nrnr. The
nloxinrtlttt
oernrissible cleoronce
of
worn rings is 1mm'
48
105 r20
'.;iA
'!.t l
\Lt { .,
x),:=
s!-9
f:ig.2.1A14 -
Checkinq Pi.;ton Ring
Gop