1980 SKODA 120 LS Workshop Manual

99
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'z
(e
(p
I
(q '9
(c
(q
{o 'v
(c
(q
(o 't
(q (6

d)
e) f) choke
plunger
sticking in its
bottom
position storting worm engine
too high fuel level in floot chomber
incorrectly odiusted
idle run unstick
the plunger
or reploce it with
o new one
odjust the
floot
odiust idle
run correctlY
2.2O FUEL PUMP
Technicol DescriPtion
The model JIKOV MF 3407 fuel pump
is of
the diophrogm ond
lever type, controlled by the
round disc of the comshoft. The suction
motion
of the diophrogm is octuoted by the
lever, the
dischorge motion by the spring of
the dio-
phrogm. Fuel flows through o stroiner, o mud
trop, ond the suction volve to the delivery
volve. A priming lever is provided
for hond
priming of the fuel. The moving mechonism
is
lubricoted with oil
sploshed from the cylinder
block. Stroke of the driving disk 4
mm
Suction heod 1.5
mm
Deliveryheod. 2mm
Pump dischorge ot 2,000 strokes
per minute ond free outflowwithout
counter-pressure 30
ltrs/hr.
Mointenonce, Repoirs, Disossembly
ond Reossembly
For routine
mointenonce (cleoning
of the
mud-trop screen) see Chopter 15.3. After hoving
operoted the hond-priming lever lift it
till it
engoges sofely in its locked position.
ln the cose of o defect, inspect the diophrogm
ond check the volves for leokoge. After hoving
removed the pump
from the engine, remove the
mud trop, seporote the upper port
from the
lower port,
ond remove two screws, holding
down the thrust plote,
to lift owoy the volves.
Swill oll ports
in petrol
ond blow off with com'
pressed oir. Reploce domoged ports
with new
ones. lf necessory, remove the diophrogm from the
octuoting lever in
the lower port
of the fuel
pump (its
monufocturer recommends the dio-
phrogm to be reploced ofter obout 50,000 kilo-
rnetres with o new
one). Do not stretch the
spring of the diophrogm ond do not olter its
compression force chorocteristic in ony woy.
Do not forget to put
fibre pocking rings
underthe
volves
when reossembling the
fuel
PumP.
Put o spocer ring under the suction volve (close
to the mud trop). Fig.2.2Ol1 shows
the pos-
itions of volves ond the holding-down thrust
plote. Put the spring
of the diophrogm into
the
lower port
oi the pump
ond engoge the pin
ot
the diophrogm with the octuoting lever. Oper-
ote the hond lever
to compress the dioPhrogm
oncl hold it in position by inserting o
rod of 4.5
to 5 mm diorneter (for
exomple the
shonk of
o drill, etc.) between the octuoting lever
ond
the woll of the pump
lower
Port.
Now bolt both pump
ports
together so thot
the mud trop is on the
right-hond side when
viewing the pump from obove
ond the fostening
flonge from the front. Use spring
woshers
under the clomping bolts.
Fig.2.2011 -
Section Through
Fuel Pump
lf it is necessory to verify
the dischorge of
the pump
by o test, note the following require'
mentswhich the pump
must meet otl80strokes
per minute:
o) 15 ltrs/hr. ot f ree outf low without
fuel
counterpressure
b) minimum pressure
of 0.018 MPo (1.8
m of
woter column) ot
o zero off'toke of fuel
c) o dry pump
must drow fuel from o
depth of
1.5 m in 16 seconds.
Fuel Pump Defects ond Their Removol
1. Foulty fuel
supply
o) clogged mud trop
b) domoged diophrogm
2. Fuel pump
does not hold fuel
o) dirty or defective volves cleon it
reploce it
with o new one
wosh them in petrol,
reploce defective
volves with new ones
66

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lenl ]noq
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-e.r1nber 6
;o eOroqc
dtun4
'',' C
'.'er/
sJaqsoM 6u1ua1so
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1re
t; ,t
Fig.311- Clrrtclr -
Sectioncrl View
Alternative Diaphram
Clutch available,
Center Plate, Bearing
and arm of LP type.
68

69
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zt-tt

Turn
the flonge
on the centering
orbor so thot
the longer, cylindricol port
foces the clutch,
push it ogoinst the friction plote
hub, ond olign
the ends of the levers to touch the flonge.
A deviotion from the ploneness
of 0.1 mm
is
permissible. Use feeler gouges for checking
this deviotion.
lf it is not possible
to odiust the out-trovel of
the clutch releose levers to o volue given
by the
length of the flonge cylindricol port
due to
excessive weor
of the friction plote, odiust to
the next higher volue.
Clinch nuts on the
odiusting nuts bocked off up to the end of the
threod ore o worning of o weor limit which pre-
cludes ony further odiustment
of the clutch.
4. After hoving reossembled
the engine with
o new or odiusted clutch,
check ond, if necess-
ory, odiust the cleoronce between the releose
levers ond the throw-out beoring -
see Chop-
ter 15.4.
3.3 CLUTCH DISMANTLING
Owing to its simplicity,
it is not necessory
to
describe in detoil the dismontling
of the clutch,
but some speciol feotures
deserve ottention.
1. lf the friction plote
ond clutch cover ore
intended to be re-used, mork their relotive
positions using centre punch
morks to preserve
the originol bolonce of the ossembly.
2. To dismontle
the clutch, it is
necessory to
compress the clutch cover to relieve the stress
of the releose lever bolts. For this purpose
use
the MP 2-101
ossembly plote
shown in Fig.3.4/1.
After screwing off the releose lever nuts ond
compressing the clutch cover,
the clutch is
reody for dismontling.
3.4 CLUTCH REASSEMBLY
1. Locote
the clutch pressure
plote
on the
MP 2-101
ossembly plote
ond fit springs
on the
cylindricol bosses. Before fitting
the springs, it
is odvisoble to check them for
complionce with
the volues specified
in the following Toble.
Toble of Clutch Springs
Lood
Length of spring in mm
lin -rrr"ltp1
Mounted length
31.55'10+36
(s2t3.6)
Length of compressed spring 29.5
I 580 (59) 2.
Instoll retoining plotes
on the clutch
springs ond fit the clutch cover with releose
lever springs in position.
Assemble the clutch
cover with the pressure plote,
observing the
morks indicoting their relotive positions.
When
ossembling new pot'ts,
their positions
ore of no
consequence.
3. Slip o 4.5 mm high pod
over the ossembly
plote bolts (the
plote
con be used
for Skodo
1000 MB ond Skodo 100 cors os well,
ond by
using pods
of different heights, the plote
con be
odopted for different
types of clutches), fit the
yoke of the
iig on
the plote
bolt ond compress
it by screwing down the nut till the bottom port
rests on the pod.
When compressing the clutch
cover toke core thot the projections
of the
pressure plote
ore correctly centered in
the
cover slots to prevent
o distortion of the clutch
cover.
4. Slip the bottom ends of the releose levers
under the springs instolled in the cover ond fit
them with their longitudinol
slots on the sup-
ports. Slip odiusting woshers on the bolts of the
pressure plote ond screw down the nuts with
their cylindricol port
focing the woshers. Then
odjust the height of the releose levers with
these nuts so thot their ends touch the shoulder
of the yoke
bottom port.
The difference of the
lever height should not exceed 0.'l mm. This
odiustment olso sets the recommended
distonce
of the levers from the pressure
plote
beoring
surfoce.
Use clinch nuts for locking the odiusting nuts
in position,
put
supporting clips under the re-
leose f ever ends os shown in Fig.3.111 ond3.212,
ond slocken the nuts of the ossembly plote.
The
clips ore useful when fitting the clutch to the
f lywheel since it is not necessory to overcome
the tension of the clutch springs.
To Check Adiustment ond Bolance
The described od justment
of the releose levers
in the
iig is
the most occurote, the ossembly Fig.3
Dim
plote be
simulotin
For on<
porogropl
The cl
with the
friction ;
ports of '
clutch on
To bol
centering
pressure
the chips
lf thesr
boloncing ing holes
in o circk
4mmofr
between
fostening
3.5 FR|C
lf the f
it is odvi
8.5 mm th
When r
the frictio
ond only r
complicot
After hr
the plote
if necessc
recheckinl
quired.
70 Fig.3.4l1
-
IAP 2lol
Assembly Plote with Clutch

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The
clutch moster
cylinder is port
of the
ossembly of the broke moster cylinder ond
pedols. For the odiustment of the pedol
free
trovel, etc. see Chopter 12.1.
Pipeline ond Hoses
The rigid port
of the pipeline
comprises
speciol steel pipes,
the some os those of the
broke system. However, they hove o diometer
of 6 mm os compored with the 5
mm diometer
pipes of the broke system. For
their servicing,
repoirs, ond replocement see Chopter 9.7.
The flexlble port
of the clutch hydroulic
line comprises o high-pressure broke hose.
No
speciol position
or fostening ore recommended.
I N
Il'
I
til
lt
h .t*
: i'*
;::
..:tn
., i oilfl
Fig.3.612
-
Clutch Moster Cylinder
1 Sectionol
View
72