1980 SKODA 120 LSE ignition

'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

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

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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

Fig.
15.3/8 -
Distributor Adiusting Elements
1 -
contoct holder, 2 -
rotor orm, 3- com,
4 -
distributor brocket, 5 -
distributor brocket
clomping bolt
Alwoys turn the engine clockwise to eliminote ony ploy
in the distributor drive geor
ond to
ovoid loosening of the bolt. To relieve the
com-
pression resistonce, it
is recommended to bock
off the sporking plugs.
b) Stroboscopic method:
When using this method, the volues of the
bosic ignition timing ond
the odvonce con-
trolled by the centrifugol timing control (for
its
diogrom refer to Chopter 13.5) should be odded
upwhile multiplying bytwo
the odded upvolues
occording to the diogrom. Any effect of the
vocuum control must be
eliminoted by discorr-
necting the respective hose (connecting
the
distributor vocuum unit with the corburettor).
The meosuring procedure
is indicoted by the
diognostic equipment itself.
To Adiust ldling Speed
Use the oir-correction screw (speed
cor-
rection screw). The speed decreoses when ro-
toting the screw clockwise ond increoses when
rototing it onticlockwise.
Adiust the idling speed in occordonce with
the tochometer ond within the limits specified
in the following porogroph "To
Adiust ldle
Run". The engine must be wormed-up
before
storting the odjusting procedure (see
olso the
following porogrophs) ond its ignition must be
in perfect
condition (distributor
contoct-breoker
points, sporking plug
electrodes, ond ignition
odvonce).
N o t e : For the bosic position
of the odiusting
screw refer to Chopter 2.19 - "Mointenonce
ond
Adiusting". Fig.
15.3/9 -
Air-correction Screw -
idling speed
correction screw
To Adiust ldle
Run
Acljust the contoct-breoker point
gop,
the gop
of the sporking plug
electrodes, ond
the ig-
nition odvonce. Then check
the
volve cleoronce
(if there is no cleoronce, odiust
the
volves),
cleon the oir intoke filter
element, ond moke
sure thot the occelerotor pedol link hos
the re'
quired free trovel -
see Chopter 12.2-
Use o needle to remove the plug
covering
the fost-idling screw
ond let the engine run ot
obout 2,000 r. p.
m. to ottoin on oil temperoture
of 70oC. Insert the probe
of the thermonreter
into the hole for the oil diPstick'
Now connect the
speed indicotor (tocho-
meter) ond the onolyzer of
corbon
.monoxide
(contoined in exhoust fumes). Use
the oir'cor-
iection screw (Fig.
15.3/9) to set the
speed
-r-?n
at 800 l;; t.
p. ni. cnd the fost-idling screw
(Fiq. 15.3/10) to odiust the
content of corbon
moioxide to 2*0.50/s or the oir-fuel proportion-
by-weight mixing rotio,
comporoble with
the
specif ied corbon monoxide content, to
1+.2 +$.t.
After about one minute of
the continued idle
running recheck the odiustment ond
correct it,
if necelsory. Close the hole
with the
fost-idling
screw by driving in o
new plug with
its bottom
outword.
Note: For the bosic position of
odiusting
screws refer to Chopter 2.19 - "Mointenonce
ond Adjustment".
To Lubricote Accelerotor Mechonism
Pour severol drops of oil into
the end of the
bowden coble tubing ond lubricote both
ioints
(on top ond below)- of the corburettor pull-rod
itself with obout one drop of oil. Then
depress
224

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