1980 SKODA 120LE boot

Reossemble the
pressure-relief
following order: dust cup, spring,
ond seol. Nicks ond burrs
ore opt to domoge
the dust
boot ond prevent
its perfect
odhesion to the
cylinder. Every boot must be odequotely pre-
stressed (topered)
so thot its seoling edge con
be in permonent
contoct with the cylinder sur-
foce. A decreosed prestress
signols excessive
weor of the dust boot or its fotigue. For the
cleoning ond lubricotion of working ports,
see
the instructions in
Chopter 9.3.
9.5 FRONT BRAKE WHEEL CYLINDERS
Wheel cylinders ore ossemblies formed
by
one cylinderwith the yoke
ond onother cylinder
with the f longe ond occessories. Fig. 9.5/1
shows the loyout. For cieoning ond lubricotion
of the working surfoces, see the informotion
in Chopter 9.3.
Dismontling
1. After hoving removed the broke pods,
disconnect ond lift owoy the interconnecting
piping, cnd then remove f our copscrews to
seporote the cylinder with the yoke
from the
flonged cylinder.
2. Pull off the retoining
ring of the dust boot
ond lift owoy the dust boot.
Connect o com-
pressed oir supply (or
the broke moster cylinder)
ond use it to force the piston
out of the
Fig. 9.5/1 -
Front Broke Wheel Cylinder c/w
Broke Pods
volve in the
spring plote,
Fig. 9.312 -
Secondory Piston Cup Mounting
Fixture for dio. 12 mm
Moster Cylinder
(1 -
guide bush, 2 -
clomping ring)
Fig. 9.3/3 -
Secondory Piston Cup Mounting
Fixture for dio. 22
mm Moster Cylinder
(1- guide
bush, 2 -
clomping ring)
9.4 REAR BRAKE WHEEL
CYLINDER
'l-he wheel cylinder requires procticolly
no
servicing. Whenever removing
the broke drums,
exomine the rubber dust boots.They hove
to be
perfectly tight, flexible,
ond undomoged. When
replocing them, exomine the inner surfoce of
the wheel cylinder ond the surfoce
of the piston.
Fig. 9.4/1 -
Sectionol View of Wheel
Cylinder
138

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

I 5.7*
1
5.8
sell-lubricoting type
but the greose is intended
to rid the beorings of ony moisture which moy
get to them post
the seols in certoin circum-
stonces. Apply the greose
gun
till the lubricont
seeps post
the upper rubber cuP.
Front Wheel Toe-in
For meosuring
ond odiusting the toe-in, see
Chopter 6.1.
Fliminqtion of
King Pin PloY
Remove the coter pin
of the king pin
nut ond
rotote the nut to the next cotter pin
hole pos-
ition. lf the ploy
is not elinrinoted ond no
friction sets in with the nut in this position,
continue rototing it
until this condition is
ochieved -
see Chopter 6.5, porogroph 21. Lock
the nut in the f irrol position
with the cotter pin
Fig. 15.712 -
King Pin Hold-down
cnd Adjusting Ntit
Note: irr the list
of servicing (mointenonce)
iobs,
I,he porogroph on "Checking
Front ond Reor
Wlreel Brokes" includes
o) inspection of the broke-shoe lining ond its
replocement, if necessory
b) in the cose of the front broke, the cleoning
ond inspection of the protective (dust) cups
of pistons octing on the broke pods (shoes),
in the cose of the reor broke, the inspection
of the wheel cylinder dust cups (boots),
ond
in both coses the replocement of domoged
ports.
i5.8 BRAKE SYSTEM
Broke Fluid Tonlk -
filling
The brake f luid tonk is instolled in the boot
{inoin luggcrge comportment)
cnd closed with Fig.
15.8/1 -
Broke Fluid Tonk
o screw cop. lt serves
olso the r:lutclr lryrlrotrlic
control systenr. Keep the brqke fluid level withirr tlre ronge
of the moximum filling, i.
e., not lower
thon
10 mm below the "MAX"
mork or so high thot
it just
covers the pcrtition
woll of the tonk
which con be seen on looking inside the tonk.
Observe obsolute cleonliness when filling
in
the broke fluid through the screen in the tonk
filler neck. Refer to
Chopter 15.2 for recon'r.
mended broke fluid bronds. For broke fluid hondlinq precoutions, see
Chopter 9.9.
Brqke Fluid Chonge
The broke f luid obsorbs otmospheric humidity
ond the chcnge of its properties
is opt to offect
broking ond even bring obout corrosion of some
ports of the broke system.
The time period,
in which these chonges
con
toke ploce,
connot be defined with ony pre-
cision. Therefore forestoll troubles ond chonge
the broke fluid in the broke ond clutch system
every few yeors (preferobley
two to three
yeors ) .
Suck out the old f
luid from
the tonk, fill in
fresh fluid, ond remove the bleeding screws
one
ofter onother to let the old fluid be forced out
by the fresh
one from oll bronches of the broke
line to the clutch -
see the broke ond clutch
bleeding procedure.
Broke Bleeding Air con get
into the hydroulic system
of the
brokes either due to lock
of the broke fluid in
the tonk (low
level) or when removing
or dis-
montling some ports
of the hydroulic line. lf
there is o smoll omount of oir in the hydroulic
system, the pedol broke feels "spongy"
ond the
broke efficiency decreoses. Ingress of o lorge
228

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