1980 SKODA 120 LS ABS

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35.
Using
o meosuring rod
on which the dis-
tonces con be morked with o line, meosure the
distonce between the gouge plotes
when tunned
forwords ond reorwords (the plotes
must be
opproximotely horizontol). By turning both
steering rods, odiust the rood wheels so
thot tlre
distonce between the plotes
behind the oxle is
3 mm lorger thon the distonce in front
of the
oxle, ond lock the steering rods in
this position
by meons of nuts.
Fig. 6.5/10 -
Meosuring Front Wheel Toe-in
36. Rotote
the steering screw to check the
correctness of the steering geor
reossembly.
With the wheels in the right-hond ond left-
hond lock position
when the steering knuckle
obuts ogoinst the boss on the king pir-r
socket,
both extreme positions
in the steering
box
must be resilient,
without ony hord impocts.
lf this is
not the cose ond there is o hord
impoct, correct the odiustment by shortening
one steering nod ond lengthening
the other one.
37. Hoving odiusted the comber ongle
ond the
toe-in, retighten
o) the nuts of the eccentric pins
ond lock them
with cotter pins
b) the nuts of the upper wishbones ond lock
them with cotter pins
c) the bolts of the upper wishbone brocket
d) the nuts of the upper wishbone pins
ond
lock them by tightening the thin nuts
e) the nuts of the lower wishbones ond lock
them by tightening the thin nuts
f ) the
nuts of the boll
ioint pins (boll pins).
For tightening torques see Chopter 1.8.
38. Recheck the wheel comber, remove the
gouge, ond screw down loosely nuts ond wosh-
ers on to the protruding
ends of the lower
wish-
bone pins
in the following order: thin nut, spring
wosher, two ploin
woshers, onother spring
wosher, ond o thin nut. Fitting
Anti-roll Bor
39. Slip rubber
bushes on the centre port
of
the onti-rroll bor (close
behind the oblique bend)
ond f it on them the holder. After
hoving
threoded the other rubber bushes
on the
ends
of the onti-roll bor, instoll it in the brockets
on
the lower
wishbones, ond lock it in position
by
clomping the rubber bush by onother holder.
Secure the bolt of the holder with o spring
wosher.
Reinstolling Shock Absorbers ond Completing
Front Axle Reossembly
40. Using the spring instoller releose
the rood
spring ond then remove the instoller. Fit the
shock obsorber holder to the shock obsorber
eye ond connect them with o bolt with o costel-
loted nut. Lock the nut
with o cotter pin.
Threod the shock obsorber through the lower
wishbone ond the coil spning ond fosten it
with
bolts ond spring woshers.
41. Fill the wheel hub cop with
the recom-
mended greose
cnd drive it home
in the hub.
The greose will penetrote
into the beoring ond
lubricote it. Use the
MP 6-125 drift to ovoid
domoging the cop.
42. Screw down o greose
nipple on the bot-
tom beoring of both
king pins
ond lubricote the
enti,re oxle with the recommended greose.
Fig. 6.5/11- Driving-on Wheel Hub Cop Using
MP 6-125 Drift
6.6 STEERING KNUCKLE The steering knuckle is o unit formed by the
swivel pin,
the broke bock plote
brocket ond
guord, speciol self-lubricoting bushes, ond the
spocing tube. The right-hond ond left-hond
steering knuckle
con be identified bythe greose
nipple or nipple hole which must foce forwords.
114

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8.3 SHOCK ABSORBERS
The shock obsorbers ore of
the hydroulic,
telescopic, double-octing type of the PAL
moke.
The domping effect depends on the speed
of the
relotive movements of the oxle ond body. Doto
required for testing ond odiusting the shock
obsorbers ore given
in the following Tobles.
Front Shock Absorber -
see Fig.8.3/1
type PT 26x110,
Ser. No.443.621-215.000
1977-74 1 978 on
Maximum stroks llO mm 110 mm
Damping torce during
down stroke (compr€s-
sion 470N
500N
Damping force
during
upward stroke (expan-
sion) loSN
1
300N
Filling capacity lOO cc1OO
cc
Reor Shock Absorber
type T 26x175; Ser. No. 443.621.247.OO1
1977-78 1 978 on Both
types of shock obsorbers ore of similor
design, only their bottom fostening
is different
(the front shock obsorber hos o fostening eye,
the reor shock obsorber hos
o bolt ond locks
the outer protective
tube). They hove
o differ-
ent stroke, domping force, ond filling
copocity.
Removing ond Refitting When removing or refitting o shock
obsorber,
retoin the piston
rod (upper
fostening) by hold-
ing the flottened end of the threod in o sponner.
In the cose of
the reor shock cbsorber, retoin
the piston
rod in the bottom port
by holding the
heod of the bolt connecting it to the shock
obsorber cylinder.
The ossembly of the rubber bushes of the
respective shock obsorber mounting
con be seen
in Fig.8.3/1.
Access to the upper mountings of 'the
front
shock obsorbers is from the luggoge boot
(under the floor). The
threod is protected
by
o cop nut. The
mountings of
the reor shock
obsorbers ore occessible from the reor luggoge
comportment behing the reor seot bockrests ofter folding owoy the upholstery on the wheel
orch. The mounting is in the cyllndricol exten-
sion piece
in the scuttle
of the reor dosh.
Shock Absorbor Dismcntling
Dismontling is o routine procedure
beginning
with screwing out the plug
(1)
ofter the pro-
tective sleeve (tube)
hos been removed. Never
dismontle the piston
volves since there is o risk
of impoiring the domping force
by mixlng up
the volves.
o
o
*)
At o
temperoture ol 25
to 30oC,
of 100 strokes per
minute, ond
100 mm. frequency
stroke of
Fig.8.3/1 -
Front Shock Absorber -
Sectionol View
Maximum stroke
175 mm
175 mm
Damping force during
down stroke (compres-
ston, 470N
500N
Damping force during
upward stroke {expan-
sronl 950N
r
200N
Filling capacity 160
cc 160 cc
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Broke
Shoes ond Broke Drums
When refitting
o broke shoe with o portiolly
worn lining moke sure thot it hos o thickness
sufficient to lost till the periodic
inspection
(ofter every 20,000 kilometres). The new lining
is 5 mm thick. When it is worn down to 1.5
to 'l
mm (4
to 3.5 mm when meosured
with the
shoe), the broke shoe hos to be reploced
with
o new.or
o reconditioned
shoe with glued-on
new lining. Be sure to reploce
the respective
broke shoes in both wheels to preserve
o uni-
form broking effect.
Speciol glues or cements
ond hordening ot
high temperotures
ore required when relining
the broke shoes so thot this
iob con
be done in
speciolized repoir shops
only. For informotion,
opply to the broke monufocturer -
Autobrzdy
Not. Corp., Joblonec
nod Nisou.
Broke drums are grey
cost-iron costings. Their
unequol weor
con be rectified
by mochining to
o 231 mm diometer.
No tool morks must be left
on their surfoce
which hos to be perfectly
smooth. The olignment deviotion
ond mochin-
ing toleronce should
not exceed 0.1 mm. The
moximum permissible weor is up Lo 232
mm in
diometer.
Only broke drums
with on identicol
diometer
ore permitted
to be mounted on one ond the
some oxle.
9.2 FRONT BRAKE
ASSEMBLY
Disnrontling ond Reossembly
1. Detoch
the broke fluid supply piping
from
the broke. Absolute cleonliness is o must.
Otherwise dirt ond foreign
motterwill penetrote
into the piping.
2. Renrove bolts lrolding
down the broke yoke
crnd lift owoy rlre broke
ossembly.
3. Use the MP 6-132 gouge
to set correctly
the broke (new
or repoired)
on reinstollotion.
4. Select the shims required
to fill the gop
between the end of the gouge
ond the foce of
the fostening lug.To position
correctly the
broke, insert shims
between the fostening lugs
cnd yokes. You con, however,
meosure direct
the distonce
between the fostening
lug ond the
trroke disk
ond set this distonce
in complionce
with Fig. 9.211 by odding pocking
pieces
to the
shim pock.
5. Using the respective
copscrews ond spring
'.^roshers, bolt down the yoke
to the lugs.
6. Attoch the supply hoses ond bleed
the
broke.
Replocing the Brake
Disk
A worn brol disk con be reconditioned by
grinding it to o thickness
of 7.5 mm. lf necess-
cry, reploce it with o new one 9 mm thick. The lowest
limit of thickness
of o still usoble
broke disk is 6.5 mm. The
moximum permissible
run-out of the friction surfoce is
0.15 mm.
1. After hoving lifted owoy
the broke os-
sembly, remove the wheel hub
ond then the
broke disk. 2. Reossemble the broke disk
with the wheel
hub using copscrews with spring
woshers.
3. Top
rrp or chonge the lubricont
in the
wheel
hub beorings ond reinstoll the broke ossembly
Replocing Broke Pods
The overoll thickness of o broke pod
with
new lining is 15 mm. When worn down to 7 mm
(with the lining 1.5 mm thick), the pod
is
unusoble.
Alwoys reploce
broke pods
on both ends of
the oxle of the some time so
thot their weor is
uniform. With regord to the coefficient of fric-
tion, they hove to be of the some
type ond
rnoke.
1. Suck off the hydroulic fluid from the tonk
so thot it is only holf filled.
2. Remove cotter pins
ond lift
owoy the broke
lining cover.
3. Remove the friction pod,
cleon thoroughly
the covities of the yokes, piston
ports,
ond dust
boots.
4. Fit the MP 6-134 force-off lever over the
broke disc ond drive the pistons
into the
cylinder bottoms by the presswe
of levers.
5. Ploce o new friction pod
into the broke
ossembly moking sure thot the clomp of the
thrust plote
fits into the collor of the piston
foce.
Fig.9.2l1- Front Wheel Broke Mechonism
ond Mounting (setting)
Dimensions
1 -
Broke disk
2 -
Broke
3 -
Shims
A -
Broke setting climension -
18.7+O.2
136

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