'WORKSHOP

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120 LE,120
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PASSENGERCARS
F{evised
Edition l9B0version
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 The child'proof lotch of the reor door.scon be
" n g " ! J U y t i p P i n g d o w n i t s l e v e r 'T h e d o o r s
; ; ; ; " o p e n " d ' f r o i r o u t s i d eo f t e r d i s e n g o g i n g
pulling the Press'
i u n f o c t i n ' g 1t h e l o t c h b y
button.

F i g . 1 . 3 1 1I n s i d eD o o r M e c h o n i s m s
1- Hondle
2- Lock Press-button
3- Drop window cronk
4- Door pull F i g . 1 . 3 1 2C h i l d ' P r o o fL o t c h
5- A s h t r o y ( d e p e n d i n go n r e o r d o o r o u t f i t )

I N S T R U M E N TP A N E L t
a
(

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9 1 0 12
1978 only'
F i s . 1. 3 / 3 S K O D A 1 O 5 S l n s t r u m e n tP a n e lu p t o O c t o b e r

1 - W o r n i n g l i g h t o f l e f t - h o n dd i r e c t i o n 6- C h o r g i n gw o r n i n g l i g h t , r e d
indicotors,green 7- Oil pressureworning light, reo
2 - Speedometer 8- Distonce recorder
3 - W o r n i n g l i g h t o f r i g h t ' h o n dd i r e c t i o n I - Fuel reserveworning light, omber
indicotors,green 10 - Broke sYstemworning light, red
4 - H i g h - b e o mw o r n i n g l i g h t , b l u e 1 1- Fuel gouge
5 - T h 6 r m o m e t e r( o f e n g i n e c o o l i n g l i q u i d ) 1 2- U n o c c u P i e dg, r e e n
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UfIf T'UO}ICVIINOHII/VI 13NVd IN3U\INUISNI
11.ll 8!
 W o r r r i n gl i g h t s :
5 - left-honddirection indicotors,green 12 - unoccupied,green- fog lomp worning light
6 - oil pressure,red included in speciol
7 - right-hond direction indicotors,green extros
8 - broke system,red 13 - unoccupied,green- low-beomworning light
9 - chorging, red i n c l u d e di n s p e c i o l
10 - fuel reserve,omber extros
1 1- h i g h b e o m ,b l u e 1 4 - u n o c c u p i e d r, e d

The thermometer indicotes the temperoture s w i t c h s w i t c h e so n t h e h e o d l o m p s t, o i l l i g h t s ,

of the coolont with the ignition switched on.
The optimum operoting temperoture ronge is
from 75 to 105oC. In SfOon 105 S, this ronge
is identified by the green zone of the scole.
The fuel gouge indicotes the level of the fuel
with the ignition switched on. The scole is
provided with divisions 0 - r/2- 1, i. e., empty,
holf full, ond full tonk.
The driver is worned by the red worning light
w h e n t h e n eo r e l e s s t h o n 5 l i t r e s o f f u e l i n t h e
fuel tonk.
The tochometer indicotes the speed (revol-
utions) of the engine. The speed should never
rise to the red zone. When chonging the geors,
on increoseof speed within the ronge of the
yellow zone is permissible.
The porking lights come on when the switch
is thrown to the first right-hond position. The
o n d t h e l i c e n c ep l o t e l i g h t .
The heodlights,i. e. driving (high beom) ond
dipped (low beom), ore switched on by throw-
ing the switch to the second right-hond pos-
ition. The switch switches on oll porking lights
ond the heodlights in occordoncewith the pos-
ition of the switch stem-type lever: centre
position- dipped lights, towords the instrument
p o n e l- d r i v i n g l i g h t s .W h e n t h e d r i v i n g l i g h t s
ore on, the blue worning light glows.
The ouxiliory heodlomps come on ofter pull.
ing the switch knob, but only while moin heod-
lomps ore on.
The heodlomp flasher storts floshing when
p u l l i n g the switch lever toword the steering
wheel ring.
The horn is sounded by depressingthe lever
toword the steering wheel shoft.

Fig. 1.3/6 Switches - port I Fig.1.317Switches- port ll ond oshtroy

-
1 Porking light switch ond feederof heodlomp 1- Switchbox ond steering lock
dipswitch 2- Switch of windscreenwipers ond wosher
2 - Horn switch, direction indicotor switch, 3- Heoter switch
ond dipswitch 4- Switch for on odditionol device- not
3 - Switch of ouxiliory (extro) heodlomps stondord fitted
4 - Door switch 5- D i s o b i l i t yw o r r n i n gl i g h t s w i t c h - n o t o n
SKoDA 105 s
6- Heoter control
7- Ashtroy

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Boot lid up to 1978 - To open it, press down (in
t h e r e l e a s eo n t h e r i g h t - h a n ds i d e u n d e r t h ef a c i a egr
o a n e lT . h e nl i f t t h e l i d o n t h e r i g h t - h a n sd i d e a n d WO
s e c u r ei t i n i t s r a i s e dp o s i t i o nw i t h t h e a i d o f t h e r,no
articulatedstrut. After loweringthe lid, lock it by pul
go.
' u l l i n gt h e r e l e a s ea s f a r a s i t w i l l
p
T
S i n i e 1 9 7 8 o p e n l i d b y p u l l i n g h a n d l ea n d rem
l o w e ra s d e s c r i b e da b o v e .T o l o c k p r e s sl i d a b o v e
fore
catches.
B
Pus
the
lug
forn
, 4 n cus

F i g . 1 . 3 1 1 1C o n t r o l s b e t w e e n F r o n t S e o t s

1 - Geor lever
2 - Hond broke lever
3 - Choke

Fig. 1.3/13 lloot Lid Releose

Engine bonnet - To open it, pull the lever in

the operture of the left-hond reor door. To close Fig.
the bonnet, press it down with the hond into OT
oosition.
't488
For ony work in the engine comportment see Set
F i g . 1 . 3 1 1 2S w i t c h i n g P o s i t i o n so f S w i t c h b o x the notice in porogroph 1, Chopter 2'1.
Cor
c/w Steering Lock by thr
only r
0 - A l l f u n c t i o n so f f , e n g i n e s t o p p i n g is pro
| - lgnition on - ignition systemond oll ports The
o l e l e c t r i c o l e q u i p m e n t o r e s u p p l i e dw i t h ofter
current lifting
ll Engine storting - before repeoting the
- stort-
"0" pos-
bock,
ing procedu,re, return the key to the by its
i t i o n o n d o n l y t h e n s t o r t t h e e n g i n eo g o i n positi
S T O P- P o s i t i o n f o r w i t h d r o w i n g t h e i g n i t i o n Ash
k e y o n d e n g o g i n gt h e s t e e r i n g l o c k ( o f t e r tion o
h o v i n gw i t h d r o w nt h e i g n i t i o n k e y ,t u r n t h e open i
steering wheel till the lotch of the lock its cos
c l i c k s h o m e) . hold i
l f t h e k e y c o n n o t b e t u r n e dw h e n u n l o c k i n g inworc
t h e s t e e r i n gr,e l i e v et h e s t r e s so f t h e s t e e r i n g first it
g e o r b y t u i n i n g t h e s t e e r i n gw h e e l s l i g h t l y - F i g . 1 3 l M R e o r B o n n e t R e l e o s eL e v e r oshtro

1.4 C
LUGGAGE AND ENGINE COMPARTMENTS SEATS,ADJUSTMENTAND CONVERSION

To moke the seot slide, unlock it by lifting Jqck

T h e m o i n l u g g o g ec o m p o r t m e n t( b o o t ) i s i n
t h e l e v e r o n d t i l t t h e b o c k r e s tb y r o t o t i n g t h e iock is
the forebody,the interior (inbuilt) luggoge held in
comportmenb t e h i n dt h e r e o r s e o t b o c k r e s t s . rosette.

14
 9t
e d o S 6 u 1 r * o 1; o 6 u r 1 o o 1 -g1V ' L ' 6 t J u! plaq
a q l l l J ' d o . t } sD l o s u D e u A q u o ; 1 1 s o d
puD luauruodtuocau16uaeql u! peMols s; lco! eql 6
puDq eql - lcD! puoq eql q1;rndn 6u;pop 6utrlt
9Nt/V\Or CNV dn 9Nt)CVr UVC V'L N
'll esolc puo Ao:1qso
Je
eql sserdap '.roop eql olu! 1:od .rarvro;s]t lsJtt
'1coq lo.rlqsDeql 6ur11nduaq6 'prDmu!
Uosu!
1.rod.rer*o;s11 6ulnotl lq 6u;soc eql ul ploq
s l r t u o J l1 r e 6 o 6 u a s gp u o ' r o o p e q l u r 6 u r s o cs 1 l
lo lno lrod :eddn sl! d!] 'uMop qsnd ,11uedo
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s! tu;o;1o;d 6u1poo; V 'lueuyodruoc e6o66n;
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1o e6pe dot eqt putqeqsrs^el aql lfo 6u;qsnd
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'slsoJlcDqeql urttopdll puo uo;11sod
lsoularol
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aq lou lsnu lseJpDeqeql 'iq6!ldn sl! uo IrDUI
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l o u o 1 1 du o t p o p n l o u lr o l e p o u S I g Z L o p o l g u 1 ) uMo
lsaJpDaqaql ,o rq6!eq pa.rrnba:eql lsnlpDof
 Lifting the cor with o Power iock - When
r-rsingo service Power iock, let the cor rest on
the points shown in Fi1.1.412.
To tow the cor, hook the towing rope on to
the brocket under the cor nose.Threod the pin
through the loop of the rope ond the brocket
l u g s o n d s e c u r et h e p i n w i t h o c o t t e r p i n ( b o t h
t h L p i n o n d t h e c o t t e r p i n o r e i n c l u d e di n t h e
cor occessories).
1 . 5 S P A R EW H E E L A N D F U E L T A N K
Spore wheel - After having opened the lug-
goge boot lid, pull the hondle of the spore
wheel corrier releoserod. The corrier is re-
l e o s e do n d s w i n g s d o w n ( s p e c i o le q u i p m e n to f
the cor includeso sofety lotch behind the
bumper which hos to be pushecloside to
r e l e o s et h e c o r r i e )r .
F i g .1 . 5 / 1 H o n d l e o t S p c r e W h e e l L o c k Relecse
R o d ( f r o n r o b o v e) c r n r lS a f e t y L o t c h L . e v e r
F i . 1 . 5 t 2 F u e l T c r t r kF i l l e r N e c k
16
A f t e r h o v i n gc l o s e dt h e c o r r i e r( b y l i f t i n g i t ) ,
push the releoselever under the bumperto the
right os for os it will go.
F u e lt o n k - T h e f i l l e r n e c kw i t h c o p i s i n t h e
r e o r o n t h e r i g h t - h o n ds i d e o f t h e c o r - l t c o n
be locked ond unlocked by meons of the re'
spective key.
1 . 6 S T A R T I N GT H E E N G I N EA N D C H E C K I N G
ITS CORRECTRUNNING
1. Moke sure thot the geor lever is in its
n e u t r o l p o s i t i o n ,s w i t c h o n t h e i g n i t i o n ( p o s -
ition I on the switch box) ond wotch the
c o m i n g o n o f t h e o i l p r e s s u r eo n d c h o r g i n g
worning lights, i. e. check the function of the
olternotor- see the informotion in porogroph4.
P r e p o r e t h e e n g i n e for storting occording
to its temperoture:
- S t o r t i n g f r o m c o l d i n winter - do not touch
the occelerotorpedol ond use the full choke
- S t o r t i n gf r o m c o l d i n summer - do not touch
the occelerotorpedol ond use only holf of the
choke
- Storting o wormed-upengine - depress the
occelerotorpedol slowly to tlre toe-boord,do
not touch the choke
2 . D e p r e s st h e c l u t c h p e d o l ( o d v i s o b l e i n
summer, necessory in winter) ond stort the
e n g i n eb y t u r n i n gt h e i g n i t i o n k e y t o p o s i t i o nl l .
Let go of the key os soon os the engine fires
o n d r e l e o s et h e o c c e l e r o t opr e d o l{ i f i t h o s b e e n
clepressed).
It the engine ,refusesto fire, return the key
" 0 " o n d r e P e o tt h e s t o r t i n g
to the position Pro-
cedure.lf the engine is wormed up, depressthe
occelerotorpedol to obout one third of its totol
trovel.
lf the cold engine stolls even ofter the
second ond third storting ottemPt, enrich the
s t o r t i n g m i x t u r e b y q u i c k l y d e p r e s s i n gt h e o c -
c e l e r o t o rp e d o l o n c e o r t w i c e t o h o l f o f i t s
t r o v e l d u r i n gt h e n e x t s t o r t i n g o t t e m P t .
Never let tlre storter motor run for more thon
obout 5 seconds.Woit some 5 seconds before
r e p e o t i n gt h e s t o r t i n g .
Fuel is injected by every quick depressionof
the occelerotorpedol ond enriches the mixture
so thot it is difficult to ignite. lf the engine
is flooded, stort it with o fully depressedoc-
c e l e r o t o rp e d o l .
3 . I n c r e o s et h e e n g i n e s p e e d c o r e f u l l yw h i l e
r e l e o s i n gt h e c l u t c h p e d o l . l f t h e e n g i n e s h o w s
signs of stolling, depress ogoin the clutch
pedol.
 LL
% 9 + u ro ' l l slle/v\uao/vuaq-
%9 + ur 9'9 Icerl (aurlaJluac)laaq/v\eprsur-
%9 + r.rrz'0 ! lcerl (au!l oJluac)laoq^ aprslno -
srelaurerpelcjlc 6uruJnl qolnl
url ooo't/srll8'0 urnurxeu 'uorldurnsuocIo sur6u3 sMo
qdur gL el!q
L'6/r'62 o'6/n'LE
L'9/Z'Zn 9'9/9'en 9'9/8'Zn qd|x gg
9'8/Z'te L'8/9'Ze 6'8 /L 'Le ueqrn I
(srlnseg1se1 letct14g -cD P
;1)
lapour086t l l)l/gdt,l uorldurnsuoclanl crspg eug
oJnu
ces/l cas6l cosgz reab qlt ol qbnorqtts 1
lo uo
rqlul oot - o:uorlereleccv
url ott urr 08? rur o99 ' x o r d d e ' a b u e r6 u t g l e n e r l erole
%6e %ne %Lt luarperOalqeulllc urnullxeul uDql
rqlurl 09 t rqlurl o? t rqlul oe t paeds >;ee;
sl! lo
-cD a
r 90t
sr ozr 1 ozL s 90t aql q
epols EPOIS epols se;uedord Eupuung e9l t
lolol
61 08L alxereou eql s
6>1089 alxeluou -o:d
'6urler Ae>;
lq6rennalcrqsn-ssor6eqt 6urpeacxelnoLllrmsolxe aql lo euo A;uo1o DurpeolalqessrulJod
speol o|xe elqesslurrod
uooq
61 09/ 61 09L 61 9EL 61 9 Z L alxe Jeau seJll
6>q0t9 61 9?9 61 ot9 61 0e9 alxe luou 'il uo
(6urpeos eql l
le 'M'n 'o 1o)s6u;pr peot etxv u! el
6>g98Zl 6>tgtzt 6 > tg t z t 6>tggz t ]r" :".r:, lqbtennolclqo^-ssoJg
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OOt'l
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urrr 082 L/oleL 6u;6
tiltx oLz t/oot t reeUnuoi1 - lueurdrnbe eql
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suo!sueul!o
vlvo lvcrNH33L L'l eNr
'Joc eql q1;r.tAorvro1|nd 'fuossaceu uoql .re6uol eloq3 eql esn Je^eN
uoc noA 'rap:o ur s1 6u;qlA.rena '1no o6 sfq6ll 'eAlrp snolne.ldo Aq papc!rqnl puo ulroM -eJ e
;g
bululom 6ur6loqc puD ernssa.rd 11oaql lDql eJns uDc I
lllls s! eu;6ue eqr l! pallltuo eq uoc po;.raddn-
alou 'peads eul6ua aql 6u;soaicu! ueq6 -t -6u1ulor*puo 6u11oc!Jqnl s!rl1 'relu!rvru! elnu!ur aql u
' 6 u ; 1 g o 1 s s u 6 1 se r o u o u s M o q se u r 6 u e
;o auo lnoqD puD .lauuns u! op lll,1^alnulu o lloq
eql uoqM Allnt U asolo puD parll sDq eu16ueeql 'au16ueploc o qUM 'dn
l! urroM puD eloclrqnl eql o
'(ll 6
Jallo uoos Allonpo.r6elor{3 eq1 6u1so1cpolg o1 l;;a;rq puo r{le1o.lapouaug6ue aql ecDU
L' t-9', L
 ENGINE
Model
- for Skodo 105 S ond 105 L Skodo 742.10 Engine No/l
- for Skodo 12o L Skodo 742.12 Engine No/2
- for Skodo 120 LS Skodo 742.12x Engine No/9
Type four-stroke,spork-ignltion,
corburettor engine with overheod volves
Number of cylinders 4
Cylinder orrongement in line
Cooling pump-circulotedontifreeze,
thermostotic temperoture control
Swept volume
- Skodo 105 S ond 105 L 1,046 c. c.
- Skodo 12OL ond 120 LS 1 , 1 7 4c . c .
Bore
- Skodo 105 S ond 105 L 68 mm
- Skodo 120 L ond 120 LS 72 mm
Stroke 72 mm
Compressionrotio
- Skodo 105 S, 105 L ond 120 L 8.5:1
- Skodo 120 LS 9.5:1
Engine power output to CSN ond DIN
- Skodo 105 S ond 105 L 33.9 kW (46 h. p.) ot 4,800 r. P. m.
- Skodo 12O L 38.3 kW (52 h. p.) ot 5,(X)0r. p. m.
- Skodo 120 LS 42.7 kW (58 h. p.) ot 5,2(X)r. p. m.

ii Moximum torque
- Skodo 105 S ond 105 L
- Skodo 120 L
- Skodo 120 LS
7 4 . 5 N m o t 3 , 0 0 0r . p . m .
8 5 . 2 N m o t 3 , 0 0 0r . p . m .
9 0 . 2 N m o t 3 , 2 5 0r . p . m .

Fuel - recommendedoctone number

- Skodo 105 S, 105 L ond 12O L 90 minimum
- Skodo 120 Ls 95 minimum
Corburettortype duol, twostoge, downdrought
nrodel JIKOV 32 EDSR
i
Fuel lift pump type d i o p h r o g mp u m p , m o d e l J I K O V M F

CLUTCH
Type dry, single-plote,with direct disengogement
Control hydroulic

GEARBOX
Type with helicol spur geas
Speeds 4 forword ond 1 reverse, synchrolock on the
1st-, 2nd-, 3rd-, ond 4th-speed geors
Geor rotios - 1st-speed geor 3.8
2nd-speed geor 2.12
3rd-speed geor 1.41
4th-speed geor 0.96
reverse geor 3.27

18
 6r
' 'oelo 6u14oJq a^llJerls -
zwc 9L luoll
'leleulo!P
*,t""n luorl ls!P e{orq -
g:3 J D a J ' D a J D6 u 1 u 1 1e o q s - e l r t l q a ^ ! ] c e l l o -
r.uruOtz lDeJ 'laleuDlp unJP alDlq -
' J D e i ' l c o l u o c 6 u g u 1 1 - e o q.sr o l n 6 u o -
"OZL ' J D a J' S S e u l c ! q l u n u ! x D t l l -
turu I
ruru9'0 T 0t roer 'q1plrvr- aq1 U
:6u;u1geoqs-ololg
sloeqM JoaJ uo
' 'elorq puDH
6u11co'adA1-e1qoc'6u!1co-lce:!P'lDc!uDqceul
(Sf OZf Dpo)S) cllounaud-o.rpiq olres'ltuos ro
c rl n o r p A q 6 u ! l c o - l c a r ! p ' l ! n c r ! c - u ! M l olDrq lool
lueu
Joel salDJq-eoqs
' adi1
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Sf)VUS
1'6 1,rerdeq3 oas - selnssald a:A_
et x 99! t! x 99! salAl
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slff H/n
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p e . r g n b a sl u r n l l a e t l M 6 u 1 . r a a 1'so r a q u n N
"9V loEZloOZ l e e q M s p l s r D l / o p ! s r D a u' o a 1 6 u o 1 c o 1 6 u ; 1 c e q 3
"ltl,OE'6Z t e
reaqM !srol/aR
.ep 1to
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'
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6u1.rea1s 'lDc!Jqouu^s '1cal1P edIl
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L ' g r s l d D q C a s s A l l a u o e 6 ( 6 u 1 : a a t se
JDq uolsJol puD
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sJeqrosqD
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slaer.lM
pepuedsnsAltuepuedapu!puD seuoqqslmqt!M adll
f.IXV INOUJ
g'9 JoldDqC ees u !-eol leaqM JDaU
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(o11o.rulolunouu) yy'y
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. . : . . .
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sleaqm pepuedsns
' adll
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3'IXV dV3U
 1.8 Tt(
B r o k ef l u i d : BC
- clossificotion SAE J 1703C
- brond filled-in in the foctrY - SYNTOL HD 190
1. Ap
vonized
out o sL
FUELTANK 2.tt

Locotion suspendedunder floor boord of cor reor holf

F u e lc l e o n i n g( f i l t r o t i o n ) s t r o i n e ri n f u e l t o n k , f u e l f i l t e r , o n d s t r o i n e r
in corburettor
Generol

CHASSIS LUBRICATION

s e l f - l u b r i c o t i n bg e o r ni g s , r e p o c k i n gw i t h g r e o s e Threo
TyPe
b y g r e o s en i p p l e s ;w h e e l beoringspocked with
greose
ELECTRICALEQUIPMENT

Eorthing n e g c t i v ep o l e
Roted voltoge 12 volts
Servicevoltoge 14 volts
lgnition bottery (coil) type
StorogebotterY . type AKUMA 6N 37 - 12 volts, 37 ompere-hours
Alternator 14V 35 amps 1976-79 1 O 5 / 1 2 OL
PAL Magneteton 14V 42 amps 1979 on 1 O 5 / 1 2 OL
14V 42 amps 1976-79 120 LS
14V 55 amps 1979 on 120 LS
Voltoge regulotor type PAL Mogneton, 14 volts
Distributor t y p e P A L M o g n e t o nw i t h c e n t r i f u g o lt i m i n g ENGINE
d e v i c e o n d v o c u u mu n i t
type PAL Mogneton, 12 volts Connect
l g n i t i o nc o i l
Storter motor t y p e P A L M o g n e t o n ,1 2 v o l t s
0 . 6 6k i l o w o t t s ( 0 . 9 h . p . ) Nut of c
Nut of c
S p o r k i n gp l u g s - s e e C h o P t e r1 3 7 Nut of v
Nut of fr
Nut of c
BODYWORK Nut of s
o l l - m e t o l c, l o s e d ,f o u r ' d o o r c, h o s s i s l e s sb o d y Nut of c
Type
5 occuponts Cylinder
S e o t i n gc o p o c i t y Bolt of c
Luggogecomportments,coPocitY 0.40 mi (0.28 rn: moin luggogecomPortmentfor
q l o o d o f o b o u t 0 k g , 0 . 1 2m r i n t e r i o r l u g g o g e Flywhee
comportmentfor o lood of obout 10 kg) Bolt of cr
hot-woter heoter with fon, fed with woter from Oil sump
Heoter Oil sump
t h e e n g i n ec o o l i n gs Y s t e m
Droin plu
F I L L I N GC A P A C I T I E S Bolt of ft
Bolt of o
4 l i t r e sm o x i m u m- 2 . 5 l i t r e s m i n i m u m Socket ol
E n g i n e- S k o d o 1 0 5S , 1 0 5L o n d 1 2 0L Oil press
o f e n g i n eo i l
4 . 6 l i t r e sm o x i m u m- 3 l i t r e sm i n i m u m Sporking
Skodo 120LS
o f e n g i n eo i l
G e o r b o xo n d f i n o l d r i v e c o s e 2 . 5l i t i e so f g e o ro i l ( 2 l i t r e sw h e n c h o n g i n go i l )
S t e e r i n gb o x 0 . 1 6 l i t r e s o f g e c r ro i l ( o b o u t 0 . 2 5 l i t r e s w h e n
t o p p i n gu p ) CLUTCH
B r o k es y s t e mo n d c l u t c h O . 4 At i t r e s o f b r o k e f l u i d ( f i l l i n g f o r t r o p i c o l
r e g i o n s ,e t c . s e e C h o P t e r1 6 . 2 ) Connecti
C o o l i n gs y s t e m
Fuel tonk 12.5 litres of ontif'reeze
38 litres Bolt foste

20
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GEARBOX. FINAL DRIVE

Tightening
Connection Dimensions torque Nmt)

Nuts of cosingclompingbolts . M 8 22-25

Nut of primoryshoft M 22x1.5 35-45
Plnlonnut . M 24x1.5 40-50
Nut of pinion beoring coP M 8 14-17
Nut of releose sleeve bol M 6 6 - 8
Nut of front cover bolt M 8 19-25
Nut of speedometershoft clip bolt M 6 7 - 9
Nut of speedometerdrive beoring bolt M 6 7 - 9
Nut of reverse-georpin bolt M 8 17 -20
Bolt of reverse-geor pin M 8 7 - 9
Bolt of shifter forks M 6 14-17
Bolt of cop of lock-bollsprings M 6 7 - 9
Silentblock bolt M 10 30-40
Bolt of differentiol cose M 8 20-30
Bolt of crown geor M 10x1 70-80
Droin ond inspection hole plugs M 22x1.5 30-35
Switch or bolt of reversing lomps . M 14x1 7-9

REAR AXLE
Tightening
Connection Dimensions torque Nmr)

Rood wheels nuts . M 12x1.5 60-70

Nut of oxle-shoft boll ioin; boit M 8 20-25
Nut of oxle shoft . M 18x1.5 17O*)
Bolt of broke bocking plote M 8 a
Bolt of wheel cylinder M 10 40-50

FRONT AXIE
Tightening
Connection Dimension torque Nml)

Nut fostening lower wishbone fulcrum brocket to bodywork M 12x1.5 6s-70

Nut of lower wishbone fulcrum brocket
(next to rubber bush - inner) , M 12x1.5 45-60
Ditto - outer lock nut . M 12x1.5 70-90
Nut of upper wishbone fulcrum brocket
(next to rubber bush - inner) M 12x1.5 45-60
Ditto - outer lock nut . M 12x1.5 70-90
Nut of upper wishbone pin (connectionwith steering
knuckle pivot) M 12x1.5 70*)
Nut of lower wishbone pin (connectionwith steering
knuckle socket) M 12x1.5 7 0* l
Nut of wheel hub beoring . see Chopter 6.5, points 24 ond 25
Nut of steering knuckle pivot . see Chopter6.5, point 21
Nut of lower wishbone brocket bolt . M10 40-50
Nut of bolt fostening shock obsorberto its onchor brocket M 12x1.5 50-55
Nut fostening shock obsorber to bodywork M10 12-14
Wheel nuts M 12x1.5 60-70
Bolt fostening front oxle to bodywork . M10 40-45
Bolt of onti-roll bor brocket M 7 12-16

*) Furthertighteningos requiredfor olignlngholesfor the cotterpin.

22
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 metre), ond the relotion of 1 kpm :9.806 Nm is' o f w h i c h m o k e s i t e s p e c i o l l ys u i t o b l e f o r t h i s
o p p l i c o b l e .W h e n o p p l i e d t o t i g h t e n i n g t o r q u e s p u r p o s e .U s e g r e o s e s o n d h y d r o u l i c f l u i d b r o n d s
of bolts ond nuts, use the relotion 10 Nm : specified in the Toble of RecommendedLubri-
: 1 kpm. conts.
tW' (wott) e) Use new cotter pins ond metol lock
d) The unit of power (output)
"h.p." (horsepower) woshers if you ore not convinced of the perfect
r e p l o c e st h e f o r m e r ond
t h e r e l o t i o n o f t h . p . : 7 3 5 . 4 9 9W i s o p p l i c o b l e . condition of the old ones which could breok
F o r p r o c t i c o l p u r p o s e s ,o m u l t i p l e o f k W ( k i l o - o n d l e o v e t h e j o i n t s u n s e c u r e d .M o r e o v e r , t h e r e
wott : 1,000 wotts) is used, i. e., t h. p. : is o risk of the broken ports domoging other
:0.736 kW. functionol ports.
"Po" f) Cleon new ontifriction beorings (boll, rol-
e) The unit of pressure (poscol) or, in
p r o c t i c e , M P o ( m e g o p o s c o l: 1 , 0 0 0 , 0 0 0p o s c o l s ) ler, ond topered roller beorings) of preserving
o r k P o ( k i l o p o s c o l : 1 , 0 0 0p o s c o l s ) r e p l o c e s t h e g r e o s e u s i n g k e r o s e n e .P r e s e r v i n g g r e o s e i s n o t
"bor" "kglcmz", suitoble for lubricotion ond it mixes bodly with
former ond ond the following
r e l a t i o n i s o p p l i c o b l e : 1 M P o : 1 0 b o r s: 1 O . 2 Iu b r i c o n t s .
kg/cm2 (kp/cm2). For current meosuringof tyre g) Some of the joints hove to be tightened
p r e s s u r ee t c . , u s e t h e r e l o t i o n : 1 0 0 k P o : 1 b o r : with o moximum occurocy to the specified tor-
: 1 k g l c m 2 ( k p / c m , ): 1 o t m . ques listed in the previous chopter.
'Ihe
h) p e r m i s s i b l er o t o t i o n u n b o l o n c e i s s p e -
cified for some of the rototing ports, usuolly in
1.10 GENERAL INSTRUCTIONS gcm (gromcentimetres). A well boloqced port
con be stopped in ony position if it is instolled
With the exception of o few speciol pro- so thot no rototion resistonce octs on it. With
cedures or ossembly techniques mentioned in the exception of dynomic boloncing, the ports
the respective section of this monuol, every ore usuolly tested on on ouxiliory shoft ploced
removol ond refitting (disossembly ond re- on the edges. The unbolonced port moves from
ossembly) should be governed by the following the deflected position with its heoviest (i. e.
g e n e r o lp r i n c i p l e s : unbolonced) port downword. The volue of un-
o ) U s e s u i t o b l e t o o l s o n d e s p e c i o l l yt u b u l o r bolonce con be determined when fostening
box sponners which couse the leost domoge o weight correspondingto the permissible un-
to nuts ond bolt heods. bolonce to the opposite side of the unbolonced
b) During disossembly note corefully how port. lf the port does not move when deflected
t h e p o r t s h o v e b e e n o s s e m b l e d .T h i s k n o w l e d g e or if it moves with this weight downword; the
is involuoble for correct reossembly. u n b o l o n c ei s w i t h i n t h e r e c o m m e n d e d l i m i t s .
c) Cleon ports in trichloroethylene or tech- The weight of the testing weight sholl be de-
nicol petrol. They do not contoin substonces termined by dividing the volue of the permis-
(esoeciolly leod) which horm the skin os motor sible unbolonce by the distonce of the weight
petrol does. Current bronds of seoling com- from the rototion centre of the port.
pounds con be removed with denoturoted ol- i) Even slightly domogedseols ond pockings
cohol or scroped off. For o speciol seoling must be reploced with new ones
compound see the note ot the end of this
chopter. Note:
A v o i d c o n t o m i n o t i o n o f s e l f - l u b r i c o t i n gm e t o l
beorings with ony degreosing ogent os this In the foctory, the speciol seoling compound
"Velvonton
would unfovouroblyoffect their self-lubricoting of the C" brond is used for seoling
properties. the engine reor cover on the cylinder block, the
Cleon ports of the broke ond clutch hydroulic m o t i n g s u r f o c e so f t h e g e o r b o x h o u s i n g h o l v e s ,
system with olcohor. ond the guide of the clutch releose beoring.
d) Lubricote oll ports moving on or in eoch This seoling compound is mode on the bose
other before their ossembly. Operoting lubri- o f o p o l y u r e t h o n e p l o s t i c o n d i t c o r r e s p o n d st o
" H y k e m o r " , " R e i n e p l o s t " ," C u r i l
c o n t s d o n o t s p r e o d e o s i l y o n d r y s u r f o c e s ,t h e K" ond similor
ports ore not properly lubricoted, ond friction compounds. lt con be removed from the ports
oreos ore opt to get domoged. Coot the os- by scroping ond woshing with ocetone, butyl-
sembled ports with the lubricont which is used ocetone or chlorinoted solvents, for exomple
t o l u b r i c o t e t h e m i n o p e r o t i o n .W h e n l u b r i c o t e d c h l o r o f o r m ( t r i c h l o r o m e t h o n e )o n d c o r b o n t e t r o -
with oil, dip the ports in motor oil, the fluidity chloride.

24
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l!o eq} u!DJPpuD
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oql a^oueJ puo '6u11r*oceq1 ,tor"roU!l
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2.2-2.3

10. F
t h r e o d s .F i l l t h e e t r g i n ew i t h o i l o n d t h e c o o l i n g 6 . I n s c r t t h e b e o r i n g s h e l l h o l f i r - r t ot h e c o v e r
specio
systenr with on ontifreeze,ond bleed them. o f t h e b e o r i n g N o . - l o s d e s c r i b e d i n p o r o g r o p h4 ,
end on
ond fit the cover with the recess for the guide
Drive
ring turned outword. Proceeding from the front
s u c h ro
2 . 3 R E A S S E M B L I N GT H E E N G I N E of lhe block, slip on the next guide ring with
be turn
the oil groovespointing owoy from the block so
cover. I
The reossembly procedure depends on the thot itJ lip engogesogoin into the slot in the
ever, tf
extent to which the engine hos been dis- c o v e r . C o o t t h e r i n g w- i1t 'h1 1o2i l o n d s l i p o n t h e
thrust colloron the the cy
r n o n t l e d .F o r b e t t e r u n d e r s t o n d i t r g o, r e o s s e m b l y thrustring. Fit the MP
speciol
o f o c o n r p l e t e l yd i s n r o n t l e d e n g i n e i s d e s c r i b e d cronkshofi ond tighten the beoring slightly
note in
in the following porogrophs. u s i n g t h e b e l t P r r l l e Yb o l t .
1 1 .T i
7. Instoll the next two beorirrg covers corl'l'
lnspection of Cylinder Block p l e t e w i t h b e o r i n gs h e l l so n d l i g h t l y t i g h t e n l . h e
the tigh
in the
1. Clomp the thoroughly cleoned cylinder cover nuts. Press the cork seol into the reo'r
covers.
block into the MP 9-101stond with the engine cover moking sure thot it f its the groove snugly
hoving
c o r r i e r t y p e M P 1 - 1 0 1o n d c h e c k i t f o r c o m p l e t e - ond slightly bverlops the lower seoting surfoce'
does no
ness - see Chopter 2.6. Fit the block with its Before titting the cork seols,compressthem for
o while in o vice to distort them. Insert the
must ro
l u g s o n t h e e n g i n e c o r r i e rp i n s o n d u s e t h e s i d e Then lo
bolt for ltolding it down. distorted seols in the grooves or gops between
wosher
the cover qnd the cylinder block where they
ond nut
will expond onci provide for perfect seoling.
lnsert tob woshers under the nuts of the To Refi
beoring covers ond while tightening the rruts
12. R
check their correct position so os to enoble
greose i
o s u b s e q u e n tc o r r e c t l o c k i n g o f t h e n u t s .
it with i
o flywh
engine,
with rec
under tt
Chopter
bending
shoft og
powl ins
DK 1188 For flyw

F i g . 2 3 1 1 - C y l i n d e r B l o c k F o s t e n e do n t h e
A s s e n r b l y S t o n d b y l V l e o n so f t h e M P 1 - 1 0 - l
Corrier

2. Rernove the pressure relief volve, moke

sure thot the boll contoct {oces ore cleon, ond F i g . 2 . 3 1 2- M e o s u r i n g C r o n k s h o f t P l o y
r e f i t t h e c l e o n e d v o l v e . F o r rf i t t i n g o n e w v o l v e
see Chopter 2.6. 1 - Thrust collor, type MP 1 112
3. Removethe cronkshoft beoring covers ond 2 - Diol indicotor in o speciolly mode yoke
tlre i;ylinder block reor cover.
To Refit the Cronkshoft 8. Rotote the cronkshoft severol times ond
4. Force the beoring shell lrolves with the using o mollet top the covers ond both shoft
fingersinto the cronkshoft beoring boresso thot ends to ensure o correct bedding of the covers
the shell lip snops home into the slot (cut-out) ond cronkshoft guide rings. Fig.2.3l3
in the block ond so thot the shells do not pro' 9. Tighten the belt pulley nut to clomp the Using thr
trude over the beoring surfoces for the beoring thrust ring, ond rotote ond force off the cronk-
covers, ond lubricote them with engine oil. Be shoft to check its ploy. The cronkshoft must be
r;ure to fit shells motching the cronkshoft free to rotote but without ony noticeoble ploy.
Screw
i " : u r n o l s- s e e C h o p t e r 2 . 7 . lf there is o noticeoble ploy, recheck its volue
holes, for
5. Slip the oiled guidering on the cronkshcft ond odiust it by replocing the guide ring with
con be u
"vith oil groovespointing toword the cronkshoft o new one. The moximum ploy should not ex-
'.vebond {it the cronkshoft with the pressed-on further o1
ceed 0.10 mm, the recommendedminimum ploy
the hond
boll beoring (see Chopter 2.7) into the shell. being 0.04 mm.

30
 tt
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aql u1o6o 6ursn 'lceqcal uaq] puD a6uol; a1
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'8
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Aq uollrsod uI uaq] lcol puo '(g'; raldoq3
aas) s1loq eql uetq6lt 'spDaq ]loq eqt Jepun
s J e q s D Mq o l u e s u l ' a u r 6 u e e q l o ] p r o D a r q l l m
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aql LuoJ]pe^oruer ueeq soq qclqM leeqM^ll D
6 u l l l l l a - r u o q g ' 6 u r . r .rr o a 6 u o - p a s s a . r ds l ! t l l l M l !
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gllnn 6u1.roeq uDqs)uoi3 eql 4code5 'zL elqDua
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.6u;
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. r q l l ( ) a l o l d o 1 e q l e ^ o q D l c a l o r d o ] a ^ o L ls r a u r l sJonoc6uuoaq alll lo sa6pa aql ia^o sreqsoM Aeql er
a q L ' l D n o r u a : s n o r n a r dr t a l l l l o a c u a n b a sa q l u ! e q l l o s q D +e q l 6 u t p u e q A q s l n u a q ] l r o l u a q l uoeMlo
, t o Z L ' Z r a l d o q 3 q l r M e o u D p J o c c ou r p a a o o r d 'acuolsrsor t u J o j ! u n o q llM A1aall alDloJ ]snul eql ue
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lsDluos ' s b u l . r o a qa q l
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q u n q l I q s r a u r ; : a p u r ; I c 6 u r 1 : a s u ra r o l a g ' € ! re]lD atr]!l rlcDe lloqs)uorc aql alolou'sle^oc A16nu
o r r r r l6 u r u r o u l e r a q l L l l r M J e u u o t ! a u j o s g q l u l JoeJ ell
spog 6ullcauuoC aq1uel
p u D s u o l s ! d ' s r e u ! - l r a p u 1 1 A 3l ! l e 1 o I p a e c o r d ' ( g ' ; r a l d o g C e s s a n b . r o l6 u l u e l q D l la q t
-r"UocsJ
. r o 1) . r a n o c a r l u a c a q l j o s l n u a q ] u . a g q 6 1 1' 1 1
'01'L raldDq3 ur alou
a l p u D H A r o l ; 1 x n y- V l t , Z 6 l J A l l q6 t 1
a L l t u ! p a u o r l u e u r p u n o d L u o c6 u 1 ; o a s ; o ; c a d s
e q l q l l M a o o l r n s 6 u 1 1 o r - ul c o l q l e p u t l A c a q l eql uo J
909 vO 'Ja^a aql uo
] D o c o l s 1 p a r : a ; a . r d e g o ] a r n p a c o . r de q l
- r v r o H' J e ^ o c e q 1 6 u l g o e s J o + 1 a 1 s o Bo e s n ' J e ^ o 3 aql u!
a q 1 6 u r 1 1 r ; a lu o q M a u r 6 u e e q ] p r o M o l p e u J n l 3 q os lcolq
q l r r var 6 p a 6 u l q o e s s l ! q c l q M u ! u o r } l s o d D q o n s Vllm 6
u ! r e ^ o c e q l o l u ! e u o q 6 u r . r6 u r l o a s e q l e A l J ( l luorl e
' 6 u 1 1a q 1 aprn6a
Puo PUe 'y qdor
] l o q s e q l p a ; r o 6 u 1 n o q r e u D 6 u 1 . r; o a s l o l c e d s
'01 J a A O 3A
a q ] q ] ! M J e n o c l o e r p e l q u r s s s D e le q l l ! j

Fig.2.3/6- Position of Cylinder Liners, Pistons
ond Connecting Rods in Engine
-
1 Proiectlon of cylinder liners obove the top
foce of the cylinder block (0.125- 0.155mm)
2 - Connecting rod splosh hole
'3 -
Arrow on the piston heod pointlng toword
the comshoft
4 - Comshoft
14. Hoving fitted the piston rings ond con-
nectlng rods on the pistons,turn the piston ring
gops so thot they ore stoggered through 120o.
Coot the entire surfoce of the piston with the
fitted rings with oll ond insert the pistons
ossembledwith the connecting rods into the
liners in the sequence of the corresponding
numbersof cylindersond connectingrods.Moke
sure thot the orrow in the piston heod points
toword the morking of the cylinder liners, l.e.
toward the comshoft, ofter the ossembly with
the cylinder block. This is importont in thot it
does owoy with odditionol turning of the pis-
tons in the liner ond o posslble displocement
of the piston ring gops.
Smeor the top surfoce of the cylinder block
with point or o seoling compound before instol-
ling the liners with the pistons ond connectlng
rods into the cylinders in the order of their
numbering.
It is odvisoble to prepore o sheet sleeve or
o pilot ring occording to Fig. 2.317 to com-
press the piston rings when fitting the piston
Into the cylinder liners. Force the piston into
the sleeve or pilot ring so thot the piston heod
is flush with its edge or protrudes sllghtly
over it, locote the piston on the liner, ond then
force down the piston through the sleeve or
pilot ring into the liner.
15. Ploce suitoble ouxiliory devices over two
holes for cylinder heod bolts, for exomple
lorge-diometerwoshers, ond screw them down

Fig.2.317- Pilot Ring for Piston Rings

Dimensions of pilot ring to motch cylinder
liner diometer:
dio. 68 D:68 H 7 Fig. 2.3/8- Fitting Piston into Cylinder Liner
dio. 68.25 D :68.25 H 7 U s i n gt h e P i l o t R l n g
dio. 68.50 D :68.50 H 7 1 - pilot ring
dia.72 D:72 H7 2 - c y l i n d e rl i n e r

32
 te
a q l l o ( 1 o u 1 u r e 1 )M e r c s e L l l l ! l u n r o t n q ! r l s ! p € q l aq l l ! M U o q s I u D r c e L l l s n r l l ' + n u a q l u a 1 q 6 r 1p u o
'lrvrod '(sllu.red
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rouqlrlsl6 puD .loloC roeg 6u;ugl UJ oI eql lDrll os puD p:onndn la1 iel1nd ]leq eqt
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'euioq paqsnd aLll uo {1ear; e}D}or lsnrrr e1old lsnJql eql
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lloq puD u D r c a q l o l u ! A e > ;a q t
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ugoqc6u1tu!loql 1o uogllsod eql lceqcau '[Z s : a p u l 1 A co q l q l l M l c o l q a q l . r e n o 6 u 1 n n g. 7 1
' 9 1 . ' 7: a 1 d o q 3 '0lg6L0-L0L'o5 6ulraprg'sraqsDM qllrir uolllsod
ees 6uluogsual s1g puD u!Dqc 6u!ur!l aq],o u! Luaql 1co; 'anb.rolpe!]lcads eql Aq peuagqDrl
uogllsod lcarroo eql JoJ
' J e q s D Me q 1 6 u g p u a q A g e q ] o u u D c s l n u a q } j l ' u D q s ) u D J ce q l u o p u e
llorlsruoc aql uo s.roe6 aql lo ]loq-e!l eql lcol 6 l q e q r ; o ( I o 1 d ) e c u D r D e l cl D r x D a q l I 1 ; o n s 1 n UMOP tr
' u ! D q c a q l p e u o ! s u e 1 I 1 1 c a . r . r o6 curnoq .re1;y > l c a q c ' u o l l D l o J a a J l J o + r . I I s l u D q s e t !) u D J 3 s l t l u s alduox
'uDqs4uDtJ e q l > l c e q co 1 s a L u r l l D r e ^ e s u o q s ) u D j c e q l e l D l o J oMl Je
aql uo .roe6 6ugugi eqt drls 'euoq {1e1e1dluoc puD lellDru D qll/v\ eutorl sre^oc eql dol'g'L
; e l d o q g r a d s o a n b r o l D q ] ! r l , rs l n u o q ] u e 1 q 6 r 1 JO e^e
UDqsuIDceqt 6urqsnd eJoJeB'sroe6 6ururl 'uDqsluDJs eLl]
p u D u l o q c e q l ] o u o r l l s o d e q 1 6 u 1 6 u o q c] n o q l r M u l l r n r r s j a ^ o c p u D s 6 ur q s n q uorll pu
eug6ua eq] olut )coq UDqsrrDc srll qsnd uaql pue 61q eq1 ql!^t e+sldruoo spor 6u rgceuuoc 111q6;
' g 1 - ' 7 1r -e l d o q 3 . r e d s o s r o a 6 6 u g t u 1 1e q l u o s ) r D u r a q ] e l q L U a s s Dp u o ' ( g t t ' z ' 6 1 3 a a s ) u D q s u r D c poeq u
aql ueaMleq sallupd ulDrlc eqtr las puD ]unoC a q l o l l c a d s e : q l ! M u o ! ] l s o d ] c a : : o c . r o 1s u o l s r d olu! uo
'pJDMlno peurn]
l.t,orrr qcund sl! rlt!rl,r u!DLlc eql looqc 'l!o r1llm suldluolc eql roorus 'g! uolsgd
'suollolado -uroc ol
a q ] o l u l . r o a D 6 u r t u l ] l J D q s ) U D J Oo r . l l 1 ! ] p u D ] x s u e l l ] 6 u g . r r r p1 n o p a q s n d 6 u r e q
l o a D l l o q s r . u o c o r { } u o u ! D r . l 36 u ! u r } o q l } n d 1su1o6opeJncss puD uMop pleq snql eq lllM JO 9AAe
'pua s u o l s l d r { } r M s r a u ! l . l e p u 1 1 A 3' s l l o q 1 ; o q s 6 u r s n
l l D r l s I u D J ce q l l o l u o i ] u l
l
s 1 r o o 6 6 u ! r u ! l s l r D q l o s U D r 1 s r l r oec q l 1 n o 1 1 n d rleql lo
'roe6 6ulru!t 'uo!ll s r a q s D 4 1p1u D s l l o B 6 u g s 6 6uglce
;ruo UoqsluDrc eq] enoueJ
- s o d 1 o 1 u o z l J o qe L l ] o 1 u 1 e u 1 6 u a 3 q l u J n l ' 0 2 u o ! l l s o d u r s r e u r - l : e p u r 1 A 3 6 u r > 1 c o -1 6 l t ' Z ' 6 l J -lolsu!
- p . r o r v r drno e 6 6 u 1 t u 1 ]e q l q i l M
lcolq r
,.a*a's
peuJnl au16ua eqt deal'6ulrnsoau 6u1,rrr6
' a s o d : n d s ! q l J o l o l q D l l D ^ De i o
)clql IUAUieC
r u r u g L ' g s J a q s D M 6 u p s n l p v ' L u u rL ' 0 l o a n l p ^ -s1deq
u r n u l ! x o r uo s o q 6 u o q J e A o a t { } l D q } o s A l q o : e l e r d t! pql
s J e q s o Ma n l l c e d s e l e q l 6 u l s n u o ; 1 1 s o ds 1 gl s n l p o qllM Al
'lvrol 'e't 'sj
loqmeulos sl UorlsluDJo eql uo :oa6 eql
' l u a r u u 6 t l D r o , s l u o l l . r o o 6 6 u 1 t u g ]a q ] > l c e q c s1u1od
11
s e 6 n o 6 J e l e e l p u o e l n r o 6 u 1 s 1 ' '1l l D q s I U o r c e q l e{ow's
uo pJDMlno paurnl )rotu qcund eql q1!M rDo6 6u;puo
6u!u!t aq1 d11spuo au16ue eql olul slournol ol.ll olu
puo sruDc pel!o qll/v\ ljDqsruDc aql u€sul suolsld
'uDqsluDls eqr ql!,
eql lo pua luor, aql uor, pe^ouer aq uDc JDlloc ; ozl q
lsnJLl]eql MoN'uo!lcel!P lDtxD eq] u! ue^a 6u1ruo
6 u g n o u r t u o J l p a l u e n a : d p u o u o 1 1 1 s o du ! p a l c o l
-uoc pu
p r i m o r y f e e d t o t h e d i s t r i b u t o rc o i n c i d e sw i t h greot thot it connot be corrected by rototing Con
t h e c o n n e c t i n g l i n e o f t h e d i s t r i b u t o rc e n t r e the distributor, remove the timing geor cover, using
line ond the first cylinder heod bolt os per rotote the distributor slightly ond repeot the torch.
F i g . 2 . 3 l 1 0 .S e c u r et h e d i s t r i b u t o ri n t h i s p o s - entire procedure of refitting the timing geor the br
i t i o n b y l i g h t l y t i g h t e n n i n gt h e t i e - b o l t o n d cover. slowly
r e m o v et h e t i m i n g g e o r c o v e r f r o m t h e c y l i n d e r 26. Smeor the protruding end of the cronk- indico
b l o c k .T h e u s e d t y p e o f d i s t r i b u t o ri s d e s c r i b e d shoft ond the outer shoft end (stem) of the belt A corr
in Chopter 13.5. p u l l e y w i t h o i l , f i t t h e b e l t p u l l e y ,t h e n e s p e c t i v e is not
wosher, ond tighten the bolt. Bolt the PumP timing
suction stroinertothe cronkshoft centre beoring 28.L
ond use o spring wosher under the bolt heod. beorin
27. Bolt down the timing geor cover using Then f
s p r i n g w o s h e r s o n d c h e e s e - h e o db o l t s ( e x c l u s - while
ively) cnd finolly fosten the timing geor cover oil sun
in such o position thot the contoct breoker the thr
p o i n t s o p e n b e f o r e t h e c r r o n k s h o f tw i t h t h e c o n - the tyl
necting rod ond piston hos ottoined the top see Cl.
deod centre (TDC) position (see the lgnition s h r in k s
Timing Toble in Chopter 15.3). of the
F o r c h e c k i n g t h e i g n i t i o n o d v o n c e ,o n e l e c t r i c woter
power supply is requiredwith o bulb connected move i
in o circuit with the distributor. this circuit
ively.
being interrupted by the oction of the contoct To Fit
breoker. Toppet
An odopted conventionol torch with o metol
iocket con be used with odvontoge for this
25. r
purpose. remove
Remove the flywheel powl ond set the re- positio
F i g . 2 . 3 l 1 0- P o s i t i o n o f D i s t r i b u t o ro n E n g i n e quired ignition odvonce by turning the cronk- sure thr
s h o f t w i t h o s c r e w ' d r i v e ri n s e r t e d i n t o t h e g e o r cylinde
-l -
screw of primory power feed ring ond propped ogoinst the cylinder block cylinde
2 - cylinder heod bolt f l o n g e . R o t o t e t h e s h o ft o n t i c l o c k w i s e o b i t n u t s .F <
3 - index line rnorking the position of the more thon necessoryond bock it off so os to first bo
distributor ornrwhen cvlinder No. 1 f ires o d i u s t t h e b o c k l o s ho f t h e t i m i n g g e o r s o n d t h e woteir p
distributor drive geors. oir clec
24. Coot with oil the moting surfocesof the
finol ti1
timing geor cover ond the cylinder block, locote
2.16.
the cover gosket on the block, oil the timing Ploin
choin ond the comshott worm geor. Removethe
heod bo
f lywheel powl ond rotote the cronkshoft through which t
360o so os to bring tlre pistons of the cylinders wosher
No. 1 ond 4 to their TDC position ogoin. This
no wos
p o s i t i o n c o r r e s p o n d so p p r o x i m o t e l y t o t h e v o l v e
heod bo
geor position when the cylinder No. 1 f ires (the cy I i nder
tips of the coms of cylinder No. 1 ore turned
the outs
downword, owoy from the engine). Lock the
hove to
cronkshoft in position by refitting ond tight-
of the rc
ening the flywheel powl. Tighte
25. Turn the distributor orm in the direction broce or
oK6ls
of the screw (1) in occordoncewith Fig. 2.3110,
30. Sc
hold it down with the finger in this position, thermom
F i 9 . 2 . 3 1 1 1 -L o m p f o r C h e c k i n g t h e O p e n i n g into the
o n d r e fi t t h e t i m i n g g e o r c o v e r o n t h e c y l i n d e r of Contoct Breoker Points
block. By sliding the worm geor of the distribu- cosingo
- 1- ofter ho
tor drive into the comshoft worm geor, the orm t o r c h c o m p l e t ew i t h d r y c e l l o n d b u l b
is turned to coincide with the timing mork for 2 - leod with olligotorclomp Use spri
cylinder No. 1 on the distributor housing. lf 3 - botterv cell
thermos
t h e r e i s n o c o i n c i d e n c eo f t h e o r m o n d t i m i n g 4 - torch coo
cooted g
m o r k , o dj u s t t h e p o s i t i o n o f t h e o r m b y s l i g h t l y 5 - contoct spring
with the
with the
rototing the distributor. 6 - i n s u l o t i n gp l o t e
lf the misolignment of the distributor ornr 7 - e l e c t r i c o l - c o n t o c tc o n n e c t i o n o f t h e l e o d
The th
o n d t h e t i m i n q m o r k o f t h e c v l i n d e rN o ' 1 i s s o s h o u l db
with the drv cell

34
 9t
'adgd
p u o l l o q p o d D u r l o l n s u! a q ] l o p o e q e q l r a p u n e n l l c a d s e . r e q 1 q l ! r l r rp a l q L u a s s o a q p l n o q s
r e q s D M u 1 o ; do u a s u l ' s l n u a L l l u a l q 6 r l p u D l l D M 6ursoc loJluoc arnloledual ctlDlsoulleql eqj posl e
loolq repu;1{c eq1 u! s}loq pn}s eq} uo dund 'slloq oq] qt!M
aql puD 1 e 1 s o 6 d u n d 1 a n 1 e q t ' p o d 6u;1o1ns s r e q s D m 6 u 1 . r d so s n ' p r o M u M o p l e ) c o s € q l q l l M
-ut eql '1e1so6pod 6urlolnsur aql -gt 6 u g s o c e q l u o r e n o c e q ] l l l p u o ' l e > 1 s o 6p a l D o c
llDlsul
ronerngrDC puD 'IelllJ tlo 'dund lenJ lll ol asoa:6 sql elDcol '6u1soc aql olu! lDlsorrraq]
e g l l n d ' s l n u e q ] J e p u n s r o q s D M 6 u 1 . r d sa s 1
'97 'asoer6 Ll]rr* ql
qdotBolod eas 1a1so6 i.rp ool D lol ]e)sDB s1g paroaus 6urnoq .ra1;o
' u o l y o l s l p lroc loJluoc ernlo.raduel crlDlsourleq] ell 1o 6ursoc
l u a u o u l a d s 1 gl u a n e . r d
o1 A11q6r1s lcellep reloo aqr ll!] lsnl i1enl1 eql uMop lloq puD pDeq rapur;{c eq} o}ul
6urued
- l s u e s p u o A ; 1 n ; e l D cs l n u e q 1 u a l q D r l . s r e q s D M 6 u g . r6 u r ; o a s 6 u q u 1 o l l a d d os 1 r q l ! M l e l e L u o u J e q l
-alel e q l -0t
eql puD Jeloo aql ueaMleq padruolc aro s6ur-r lo lueLuele {lotul.rd eq} Mercs s 1 9r 0
l o o s a L l l ] D q l o s s l n u e q l r e p u n s J a q s D Mp o t l s l p J e q s o M 6 u r - r d so l a n o e c o r q
puo s6ulr lDas uasul 'Ja^oc eLll uMop lloq lalcDrq JolDurellD sql lo ]loq aql ua1q611 i-
'7g qdo$orod
puo (glor*6ur61nq eql lo e6pa aql o1) .ranoc aes 'Uoqs ulrD-reloor eq] lo
u o r l D l l D l s u to q l J o U D l ; u o p a u e g q 6 l l e q o l e ^ D r . l g
por-qsnd aql ol uo 1a1so6 eql ]ueuaC -tt /.\/LJ
'g;_'7 : a l d o q C slloq oql'sl.roddns UDqs UJD-ro)oorep!slno eql
aes - lnu oq] qyM uo!l! a,
-sod u1 urd eql ,lJ
1col
'enlD^ s]!
lceqc o1 a6no6 J o s l l o q J o l p a s n e t D s l e L l s D Mo u e r o q . r a p u r l i c
il.
wu ZL D q]!rlt saul6ua u6 'a6uo;1 ruotloq poaq ' /
I C t l
r a l e a l D a s n p u o ' u 1 d l l D q t u J D - r e l c o re q l , o
pro sql q]rM acuorDolc e^lD^ aq1 lsnlpy -gg sql jo slnu eqt Jo] peilnba: erD sleqsDM ou \? ,/
'57 qdo.r6o.rod a l ! q M ' ( 1 a 1 c o : q s ! q ] A q p e c o l d a . r6 u r a q s J e q s o M
q ] ! M a c u D p r o c c ou t s l l o q p D o r l L a p u l ; A ce q l u e l e q r ) r a > 1 c o r gr e u D e l o l D a q l u l r n o p p l o q q c l q M
-q6;1 e . r o q r e p u l g i { cu w l D q}!M seul6ua ug
slloq onnl orll lo uolldacxa eql ql!M stloq poerl @
's1:oddns uJoZ -JalcoJ aatql 6ugu1or.ue.t r a p u r l l c d o ] a q l r e p u n 6 u o 1 e q s r a q s D Mu ! o l d
a L l l i o s l l o q e q l r a p u n s J e q s D Mu 1 o ; d p u o , p o a q .91'Z
:apu1;Ac alll lo au!l elluac lourpnl6uol aq1 raldoq3 eas 'cla slloq eq] ;o 6urualqDll lDull
q l r M l a l l D r D dp u o l a p u r l i c l s l l e q ] ] D ' e . ! ' ( a . r o q JoJ 'sllog dol onnl Jepun le>loorq lauDalc lD
: a p u t ; A c u w Z L q l l M e u ! 6 u e u o l . r o d d n sp u o c a s ) eql llDlsul 'lloq prlql eq] ol reploq edld ialoM a q ] P U Ds
l . r o d d n sl s r l e q l ' o l l o q e q l r e p u n u l ! q s o l n d aql puD e6uo;1 ruolloq pDaq aql uo ]loq lsrll ol sD os
q;";i:Xi,"il,#?H.:ll e q l o l l e l c D r q o c D J qJ o l D u J e l l o e q ] u e l s o J ' s l n u ]rq D es
6uurecuoc
srrDlap
;"n5 p u o s l l o q e q 1 u a 1 q 6 r 1A l t q O t t p u o , p o a q . r a p u r l l c lcolq re
aql Jepun 1e1so6eql uesul 'sruJDJelcol puo p e l q u o s s D e q l l l o t s u t ' 1 . r o dl o a . r 1 c o l q . r a p u 1 1 I c :oa6 aql
q
slloddns l!M Uoqs urD-Jeloor aql llDlsul -zt e q l u ! A o r r t g r oo q l l o n r l s q o ] o u s e o p l ! l D q l e r n s -Iuorc e
'sacolJns e l o t u ' l e l s o 6 p o e q . r a p u q ; I ce q l e l D c o - l ' u o g l s o d -ar eql l
d o 1 l o c l L e q d sl r a q l u o l t o d 1 . r po s l o p u o
pDeq ropu!lAcaql ut soloq anrlcadselJ!eql olu! u! sreu!l :epur1{c eq} 6u11cot Dtl aqt e^ourer
s p o ; q s n d U o s u l ' u e q l o l u ! l t o d r . r pp u o s l e d d o l puo u1o6o lcoq Icolq .rapu11Aa c Lll ul1 -62 s!ql .!ol
e l l l U e s u ! ' l ! o r l l ! M ) c o l q J e p u ! 1 I ce q 1 u r s l a d d o l sladdol lDlaurD
a^lDA alll ,o secDlJns eprn6 eql JDotuS -!C e ^ t o n p u D ' s e u ! ! e d 1 6 ' s p o e ; 1 r a p u 1 1 A 3r l J o I
'lolluos lsDlUOC
alDiq ro+ esoLl ulnnsD^ eq]
lo uo!]ceuuoo eLll ,ro; 6urlcod q]!M lelcos aql
'A r
1an
] r n c J ! cs
oslD l!l 'luaudlnba Joc aql o1 6urploccv 'Jolla"l - s s e c x a s l l a M s ] r e r o l s q J a l o / v \a L l l u r o J l l r e ^ o u J Pelceuu
-nqroo aql Jol 6urdrd elDlut aq] -aJ p u D e z r s s ] ! 'or,u!l D rol JeloM c l J l c e l su
]o puo 6urdrd lseLlc u o r l s
'saloq
pelceuuoc Jequnl eql roJ plo]!uDru lsnDqxa loq u! ll lnd esDc D qcns ul lloq eql lo
aql sllog pnls 6urssrtu Auo luatuelddng uo111u
J o 6 u r c o d s a q l 6 r " r ! c n p alro ] l n s e r a L l l r . l l l M s I u l J q s
'plo'luour eql ' 1 1 - ' 7 : e 1 d o q 3a a s do1 eq1
,o gloq do1 lsl, aql l! Arp ool sr lDes lroc eql ll -uoc aql
l o L u ! q se q ] o 1 e d r d u o r l c n s 6 u r 1 . r o 1 s - p l oacq l l o 1 a 1 s o 6 6 u r q c l o u r . rs l t p u o d r . u n s 1 r o 1 o a d A l a q t
J e p l o t l a q l p u D e d l d ; o . r 1 u o cu : n n 3 p n a q 1 ; o d r l c rol 'lcolq repurlAc aql ,o saloq pepoerqt eql relDarq I
e q l u a l s o j ' s e q s u D J qe p l s l n o e L l ] l o s l n u a q l o l u ! l r o d u p ' > 1 c o 1 .qr a p u r l l c M e u o o 1 d u n s ; 1 o ranoc ro
-snlcxe)
J e p u n s J e q s D Mu r o l d p u o p l o j t u D u l l s n o q x a a q l aqt 6u$loQ aro1eg 'sieqsDM6ulrds 6ursn ellqrur
duns e q l u M o p l l o q p u D 1 a 1 s o 6a q l 1 l u e q l 6ugsnre
lo qJuDJqarlusc erll lo slnu eql Jepun sJoqsDM 1 r o 'Poeq
6 u 1 . r d se c D l d ' l l o q - e ! ] u o t u r u o cl a q l l o s u o a u A q 'lDes eql
; o s 1 . r o d6 u l p n . l 1 o . r ]dl o l n 3 p u o 6 u l r o a q
l
s p l o , ! u D t uq l o q ' o s a 6 u o l ; e q 1 . r a q l a 6 o 1 6 u 1 d r u o l c llDtjsluDrc rDar eql lo loes lroc aql "to"o.lrllr,,
6ulroeqe
u a q M s r u r q sa s n ' s p l o l t u o u q l o q , o s l n u e q ] u a l dund aq
- q 6 1 1p u o p o e q r s p u l l i t c e q l u o s l a l s o 6 p l o l ! u o L u uotl1u6t lceJJoc eLl] Jol lDrluasse rtllornlou i1 enllcads
elDlu! eql uaq] puo lsnoLlxs eql lsrll elDcol do6 lurod re)Derq aql to luaulsnlpo loarroc V ]|aq eql l
-luDJc e
' a s D ca q l e p ! s u r 6 u u d s 'rolnqlrrlslp aql lpu!
l o u o l l g s o d l c e r r o c e q l s e'lID1or u rols
eq] LlltM pue eql puo do1 uo eloq lue^ s1 qltM 1 n o s a o 6 1 q 6 1 1e q l e i e q M 1 ur o d a q 1
'6urnno16 .roa6 6u
(g';; -ra1doq3eas) lorluor arnlo:adr.ual c!]Dls ,to lr lcoq uaq] puo slrDls qlnq eql
-oureql eql 'lelcos eql u! eq1 load
llDlsul 1 16 u r u a l q D r l l!lun eslMlcolc Jolnqtrlstp aLl] alDlou'qcrol 'Je^oc -|)
elolaq 1u1od rlllM pDeJql sy pelDoc 6utnoq e q l u o t l c l l M s p u o d u o ; c . r o 1 o 6 1 1 1eoq 1 6 u g s n
6ullolo.r
ieUD l! lljal 'pe^oulsJ ueaq soq adrd eLl] Jl l o u ! r . u r e ]J o l n q l J l s r p e q l 0 1 q o J o l a q ] ] c e u u o c
ilil
ll
I Z,l
spring woshers under the pump fostening nuts.
36. lnstoll the oil filter - see Oil Filter in
Chopter 15.3.
37. Bolt the brocket ond the reloy lever of the
occelerotorlinkoge to the intoke monifold, Use
spring woshersto lock the bolts in position.
38. Locote the corburettor gosket, sheet
guord, onother gosket, the insuloting wosher,
ond o third gosket (oltogetherthree goskets of
the some type) on the intoke monifold inlet
socket, instoll the corburettor, ond tighten it
down with nuts.
On 105 ond 120 l- engines, the sheet guord
must be fitted to the intoke monifold inlet
socket with o throttling spider, while 120 LS
engines must hove the possoge unobstructed.
39. Smeor the boll pins of the linkoge ond
corburettorlever with greosecontoining molyb-
denum disulphide ond mount on them the oc-
celerotor link (tie-rod). Hold the link in pliers
ond slip securingclips over the heods.
Hook o spring on the shonk of the reloy link-
oge boll pin ond on the rib of the forehousing
on the corburettor.
40. Screw down the vocuum control pipe on
the corburettor (using double-sided seoling
rings) ond slip on the rubber hose connecting
the pipe with the distributor vocuum control
unit. Securethe pipe by bending the clip under
the nut of the intoke ond exhoust monifold.
To Refit Alternotor
41. Attoch the olternotor brocket to the side
of the cylinder block while putting ploin
woshers under the nuts. Mount the olternotor
holder together with the engine mounting lug
on the bolt of the timing geor cover ond the
front lug of the cylinder block. Use self-locking
nuts for the bolts f ostening the olternotor
holder.Lock the lower bolt of the lug by meons
of o spring wosher ond nut. Using onother bolt,
bolt together the lug ond the brocket. lnsert
the tie-bolt from the side of the lug, slip on
o ploin wosher ond tighten the nut. Fit the
short-circuit strip on the bolt ond lock it in
o position porollel with the olternotor brocket
by screwing down the respective nut with
o ploin wosher.
42. Put the olternotor into the holder, ttrreod
in the bolt, ond screw down the nut with o ploin
w o s h e rw i t h o u t t i g h t e n i n g .W i t h o u t t i g h t e n i n g
the self-locking nut, bolt the strut into the
brocket on the cylinder heod. Swing the olter-
notor toword the engine, fit the V-belt ond,
w h i l e t e n s i o n i n gi t , c o n n e c tt h e o l t e r n o t o rw i t h
the strut using o bolt, spring wosher ond nut.
At the some time, tighten the nut of the bolt
holding down the olternotor in the holder ond
the nut of the bolt connecting the strut with
the holder. For the belt slock odiustment see
Chopter 15.3.
36
43. Fosten the second engine mounting lug
using nuts with spring woshers.
To Fit Cylinder Heod, Air Cleoner,
ond Sporking Plugs
44. Fit the cylinder heod with cemented.on
gosket on the cylinder block ofter hoving slip-
ped o seoling ring ond o wosher on eoch bolt,
the some os in the cose of the push-rodcover.
In oddition, fit the fuel pipe holder on the reor
b o l t o n d h o l d i t d o w n b y s l i g h t l y t i g h t e n i n gt h e
nut.
45. Fit the oir cleoner in position ond fosten
it to the corburettorwith o bolt using o seoling
ring ond wosher. Put o spring wosher under the
nut on the brocket ond screw down the nut on
the bolt of the cover without ony wosher.
46. Threod the fuel hose through its holder
on the cylinder heod ond use clips to fosten it
to the corburettor ond pump. Adiust the most
suitoble position of the hose by rototing the
holder ond then tighten the nut.
47. Attoch hoses connecting the oir cleoner
with the corburettorond the oil filler neck.
When preporingthe cc for driving in winter,
instoll the winter oir-intoke tube (hose) - for
detoiled instructions see Chopter 15.3 "Air
Cleoner- Winter Operotion".
48. Screw in the sporking plugs with seoling
iings ond fit the ignition cobles. For the re-
commendedtypes of sporkingplugs see Chopter
13.7.
The outlet on the distributorcop morkedwith
o notch is intended for the coble to cylinder
No. 1. The remoining outlets ore.to be counted
clockwise ond in direct order from 1 to 4 ond
the cobles will be connected to sporking plugs
in the order of numbers cost on the cylinder
heod beside the recessesfor sporking plugs.
Plug Screws ond Lubricotion System
Accessories
49. Plug the oil sump with the conicol screw
p l u g w i t h i t s s e o l i n gr i n g . I n t h e c o s e o f o n
e n g i n e w i t h o u t t h e o i l c o o l e r ,p l u g t h e o i l w o y
on the timing geor cover with o screw plug
w i t h o s e o l i n gr i n g , o n d t h e o i l w o y o t t h e r e o r
end of the cylinder block with o pressure
switch. lf the socket for screwing down the
pressureswitch is missing,instoll o new socket
together with its respectiveseoling ring.
lf on oil cooler is provided,hosesond o press-
ure switch should be connected to the oilwoys
occordingto Chopter 11.9.
Put the oil dipstick with the f itted rubberring
in its ploce. For the type of the dipstick see
Chopter 2.17.
50. Using spring woshers with the bolts,
screw down the flywheel guorclofter removing
 LI,
' g L ' z J o r d o q c e a s - a c D l r l ] s d o ] p D a L lr s l ) : [ i url g u o u r 6u lnou:a
- u ! l A o a ( 1 u o s l l o q o q l e n o u r o ru e q l p u D e 6 u o l l 'slloq e
f l P o u l 6 u e a q I q l l M 6 u r p a a c o . r de r o-r,epqa csuuor lool ql
L u o l l o q a q l j o s l l o q j o s l n u a L l l u a s o o l l s' D rll 6 u r r " r o 1 1 oe1q l _ l l D L u o 1 A . r o s s e c a us l l !
'loLl la^aN A1;ocruoulp6ugaqeur6ua eqt lo Mar^ ul .Z ees lcrls
l l l l s ' l p D e q . r a p u r l I co q l a ^ o u e r 'g'7 leldoq3 aes -
A l q r u e s s Ds l t r o 1 s D 6u1.reqq
p u D l s e r u D So r l ] 6 u r s n a u r 6 u e e q ] e l l u D u r s r C. l
r a l l n d s O L ' Ld y \ sAorrtllo
'uotluello - s s a : do p
6 u 1 s 1 -s1r o u r l r a p u r l 1 3 6 u t 1 c o . r 1 x-3 L I V ' Z ' 6 l J lolcads
a^Jesep qo!qM seJnlDe' crlrceds auos 1o I;uo '6u
'erolereql 'lllrvr 0 7 1 7 'sqol
1
loeds a u rlnor A;1son ]eIcos M
'e;nr D sD 'erD laql so suorloledo
6urlluotus;p eql uMo
l l o l l D l e p u t a q r r c s a po 1 u o t l u s l u l r n o ] o u s l l l alnssald
J o e Ja q l ]
f Nl9Nf :lHI 9l\llllNvhlstC n'Z 6n1d mar
Aolr;;o e
uD lo o
'acDltns
]3DlLlo3 aql uoJl MAJCS IO
'rolDulello
1 ur o d 1 ; o a d o : c g aq] Jepun uorloeu
- u o c p e l l o q i e J o a q s s o l c p u o 6 u l l u n o u ue u r 6 u a
a q l l o J a q s D M 6 u r . r d sa q l i e p u n d u l s l g n c l r c -
- u o q s o q l u e l s D l ' e u t l e u l D So L l l ] v ' l n o - ] n ce q l .
r . l l r Mp u a J a q l o s l ! J o l s r a q s o M 6 u r . r d sp u o u r o ; d 'sDnl
q l r M s l n u p u D ' p u a a u o s l t l o J s l a L l s D M6 u l r d s lepul;r{c
qllM s]loq 6ulsn 1r uelsol puD rerDoq ssorc s 6 n l d6 u
aql alDcol 'lcolqlualrs puooes o 1o suoeu Iq puD t o]
Alturrl g1dLuo;cpuo au16ua eql uojl uollca"itp palunoc
aql u! 6n1 aq1 olur Icolqiual!s o Uesul .tg iapu;;A
'sduolc aql puD Jeouelts qlrM pal
' p e ^ o t u a l A p D o r l ou a a q lsnoqxeeql lo suollcouuoc pelloq aql ue1q6;1
'a6uo;1 :a1doq9
s o q l e a q r v r A la' q r l l 6 r ! . r e q l o u or o ; m o d l a a q m A l y
' ] r o q s l u o r c a q l 6 u 1 : n c e sr o 3 xoqloa6 aql Jo aprs oq] uo ]nu D puD 'JaqsDM -eJ eql r
L L L - Ld t A a q l a s n
'tilsruDqcetrt 6 u u d s D ' J D l l o oD ' l l o q D p u D ' e p r s a 6 u o ; ; e u l 6 u a 6 u ; 1 o eq
s
luDJ3 eJllua aql ,o 6ur;luousrp eq]
A 1 q o 1 1 n a us 1 l r o t u a 6 u 1 r a q l o r l o 6 u t d d r l ss r q l
t a q ] u o r e q s o M 6 u g . r d sD q l l M l l o q D ' p l o l l u D r u
' s u o 1 1 o : e d o6 u r l l u o r u s ! p e q l lsnDqxa eql lo opls aq] uo slnu 6ur1co1-;;es J!V,, C'9
]o auos 6uunp pua
] l D t l s l u o J l e q 1 l s u g o 6 o6 u t q s n d u e q M l l D q s l u D r c 6utsn recuelrs lsnDqxe eql uelso, puD ltl puD ro; - (es
'plo]!uDLu ';e1u1rvr
e q l l l o 6 u 1 d d r l s ( 6 u r . r o a q l J D t l s l u D . t cl s r , r l a q ] lsnDqxe eql uo 1e1so6D aoDld .09 u
.slnu uMop 'lceu
1 o ) 6 u g . re p l n 6 r e u u l e q l 1 o . r a 6 u o p o s r a r a q ] s D
p J o M ) c D q 6 u g n o u rl s u t o 6 o U D L l s l u D . rac q ] e r n o a s p a M e r J S I ; a s o o 1 q l r r n ( s a 1 o q 1 o c r 1 d r l l ea q l J o l JeuDelcJ
s A o r * ; o ' 6 u 1 1 1 u o r u s 1spq ] ; o a s o d . r n de q t ] o u s l s J e q s D Mu 1 o ; d o n n l ' u o l l c e u u o c p e l l o q q c o e . r o y )
a u 1 6 u e e q ] l o 1 . t o d o6 u r 1 o 1 a l a l d u o c D l l ' t racuells lsnoqxe aql o1 uo sdluolc oMl uelso, eql 6u!l
'sJaqsoM
6 u r . r d sp u o u r o l d p u o s l l o q 6 u r s p ' 7 g lsoru srll
'sa!lquassD ]! uelsDl
lDnpr^rPul
eql qllM 6u11oop s.raldoqc ul peurDluoc sl ( l ! u n r e n n o ds q l l o u o ! l D l l D l s u ! e r 6 u ; r n p ) reploq sl
reJ,DeSssoJc puD Jesuel!s lsnDr{x:l llleu ol 'ieq
6 u 1 1 r o t ue L l l 6 u ! u J o J U o cu o r l D t u l o l u r p a p D l s C
'JepJo 'peLlclDul uo lnu a
lcsJjoc Jtorll u! puD '6'g-1-
uasq e^Dq ,{eqr qclqm o} s}-rodaq} ol }cadsaj l a l d o q C e e s - ]ods aq] uo ralooc aql Jepu
qllM suolllsod lcel:oc Jraq] u! slrod panortte.t l!o eq] lceuuos .to
'esoq D LlllM rrarl]
lceuuos 6 u ; 1 o eos
eqi l!lal o1 noA alqDUa 1;rm 6urlrour srtll - r e l u r J o l c o l q r a p u r l A c a q t 1 o A o m ; 1 oe q l p u o uelsD, pu
lenoc roeb 6u!u!l oql lo suorlceuuoc asoq eql
' (rap:o antlcadsar.rreq1 6n;d 'aur6ue eql uo pallll s! relooc po uD ll aq1 6uru
u1 lorvro uaql tnd o1 :o) sladdol engon eq1 (6
'qolrMs emssard aql
;o ecold JDoJeql
'JaAOC
l ( . r e p . r oe n l l c a d s e : r ! a q l u ! eql u! a6no6 arnssard llo uo MeJcs puo 'I.ro PO
-ssacou ' l l o r . l l l Ma u l 6 'lloq qcD
l o n n o r u e q l l n d o l : o ) s 6 u 1 . r o a ql l D q s ) u D r c ,l lolnq!rls!p eq] aloc!rqnl
-ua aql 'palodlcrtuD s! '!g - d 1 1 s6 u ;
p u o p u e - 6 1 qp o . r 6 u l l c a u u o c e q l l o s l l e q s o q ] ( l 111; tset a)Drq D 1
uo-polus
i s a n l o no q l ( p lsel e{Dr8 eroleS ro rDc u!
l s . r a p u r l { ce q } ( J e u ; 6 u 3 6 u ; 1 ; o g s u ; e ge r o l e g u o ; l o r e d g ; o u 1 3
:g'7 laldoq3 eas - UDqs)uorc
puD 'I;qtues
l a s q M A t l a,lr lo suo!l!sod ;onlnu eql (q
l;'g raldoqC aes - laaql.vt -so aur6ua at{t 6ultelduroc uor}orado 1ou1e ; qt
- r { 1 1p u o q c } n l o a q } } o s u o 1 l 1 s o dl o n } n u a q } ( o s ! s l q l ' l e e q r r r r A 1alq l u r o r f s e l P u o q f u o 1 1 1 x naoq 1 6n; 6ur1
t z-E'z
 5. Use the MP 1'105 puller for removing
cylinder liners from the block. Turn the centre
bolts of the iig to expond the iig iows in the
cylinder liner (ot the top flonge of the liner)
ond pull out the liner by turning the vwench.
6. Before removing the comshoft, lift owoy
the volve toppets. lf o removol of the cylinder
heod is not considered,releosethe boll pins of
the rocker orms, lift cwoy the push rods,remove
the si'de cover of the push rods, ond withdrow
the volve toppets.
( D e u t s c h eI n g e n i e u rN o r m e n ) , i . e . w i t h o l l o c '
cessoiresreducing the gross engine horsepower
(woter pump, olternotor, oir cleoner, exhoust
silencer). The effective horsepower con vory
with respect to the diogrom volues within
o toleronce limit of minus 100/s.
Every engine ofter o top overhoul or reploce'
ment of individuol ports of the cronk mech'
onism hos to be run'in exoctly like o new
engine. Do not forget to drow your customer's
ottention to this foct!
'",ffi
15

2.5 BRAKE TEST AND ENGINE

NM
LUBRICATION SYSTEM DIAGRAM

Broke Tcst

In view of the very specific chorocter of

the test, especiolly with regord to the speciol
testing eguipment,wedo not intend to describe
the test procedure,restricting ourselvesto men'
tioning only the moin volues which the test is
supposedto verify.
Volues indicoted in the diogroms ore oppli'
coble to o new engine or on engine ofter o top
overhoul, which hos been correctly run'in by
running for o period of obout 50 hours (2,500 km 300

trovelled). lf the engine is tested under other t000 som t/n{a

conditions, the meosuredvolues must opprooch
the diogrom volues conformoblywith the mech- Fig.2.5l2 - Power Output ond Fuel Consumption
onicol condition of the engine. Diogrom- Skodo 120 L engine
ln diogroms, peok performonce volues ore 1- 3 see Fig.2.5l1
indicoted os meosuredin complionce with the
CSw (CzechoslovokStote Standords) ond DIN csilr
i kwuril'
50

,CsNr
kwrotN'
1{J
I

ilii I

20

r5

t0
5000 t/mrn

Fig.2.511-Power Output ond Fuel Consttmption 5000 l/rnrn

Diogrom- Skodo 150 S engine

Fig.2.513- Power Output ond Fuel Cons
1 - power output, 2 - torque, 3 - specific fuel
Diogrom- Skodo 120 LS engine
consumPtion
k/SAE: h.p. (SAE) 1 / m i n: r . P . m . 1- 3 see Fig.2.5l1

38
 6e
leeqM^lJ Puo
ou!6u3 ,o suolsueurlc6ullunotN- Vlg'Z'6lJ e
uo!ldutn
0s
/ Nto\r(l
TiSJ'
. a !
w uo!lduns
i4,r{t
a3t! xo
gt
ru,*
S,JeUlOlSnC
Mau o e)l
-qceut luol
-acoldet Jo
utr{}!/li{ se
l.ron uoc .
lsnoqxe 'lq
rarvrOdesl
-cD llo rll!,r
 F o r t h e i n s t o l o t i o n o f t h e e n g i n eo n t h e t e s t o b o u t 8 0 t o 9 0 o C ,o n d o i l t e m p e r o t u r eo f 1 2 O " C 2.6 cYL
b e n c h ,w e i n d i c o t e t h e d i m e n s i o n so f t h e e n ' m o x i m u m- s e e C h o p t e r2 . 5 , p o r o g r o p h5 1 .
g i n e f l o n g e o n d f l y w h e e l .D u r i n g b r o k i n g ,t h e The cyl
Engine Lubricotion
engine qnd the engine oil must be properly mochine
cooled to preclude exceeding the oPtimum T h e i n n e r l u b r i c o t i n go i l d i s t r i b u t i o ns y s t e m the cron
s e r v i c e c o n d i t i o n s , i . e . w o t e r t e m p e r o t u r eo f i s s h o w ni n F i g . 2 . 5 / 5 . ports, forr
ore mode
B locks fo
72 mm di
Ii n e r s .
Oilwoys, I
o) Befo
9 o new cyl
ossemble
blow thror
b) Coot
pound or p
the oilwoy
c) Likev
into the e
pound or p
of the cyli
one (of lo
limits ind
8 Ports) to e
d) Tighte
ot cylinder
underit.
e) Foste
the cop of
Fosten the
with o bolt
I
?
?
I
;
t
7

2 4 5 t 6 DK .r5+9
Fig.2.61
F i g . 2 . 5 1 -5 E n g i n eL u b r i c o t i o nD i o g n o m ond
-
1 choin gre
Skodo 120 LS engine hos, in oddition, on oil cooler incorporoted between the punrp delivery
plug,3 - inie
b r o n c i ro n t h e t i m i n g g e o r c o v e r o n d t h e m o i n o i l w o y ( s e e F i 9 . 1 1 . 9 )
relief volve,
4
t - s r l c t i o n s t r o i n e r , 2 - p u m p , 3 - p r e s s u r e r e l i e f v o l v e , 4 - m o i n o i l w o y f, i5l t- eo ri l, 6 - b y - p o s s with cop, 6 -
o i l h o l e , 7 - o i l p r e s s u r es w i t c h , 8 - p u l s o t i n g c h o m b e r ,9 - r o c k e r o r m s , 1 0 - c o n n e c t i n g r o d inlet from o
s p l o s hh o l e , 1 1- c h o i n s p l o s hs c r e w p t u g ,I
 LV
e q l u l a u o q l l D q e q l d D l ' e n 1 o ne q l 6 u l l q u e s s D p D e q r a p u r l , t co 1 A o r t l l o - 3 ' 6 n 1 d
ls.rll ueq6
'MeJcs e^lD^ puD ';oas '6uuds 'llDq M o l c s 1 a 1 c o ! J o I D M- L ' J e l o o c l t o L u o J l l e l u ! po.r
:ropJo 6urr*o;1o; eql ul e^lD^ eq] elquressv .ro e6no6 arnsse:d Jot uollceuuoc - g 'dDc tlllm sSDd
u o 1 1 ; 1 . r o dr a l l ! + l ! o p u o M o r c s - g ' e ^ l o ^ l a l l e r
o^lDn le!lou srnssajd '6n1d
a r n s s e l d- p ' d u n d u o r l l o u u D q c l e l u l - g Itarr
'DaJD 'dnc asoelD ulDqc-
lcDluoc eql Jo luoJ, - Aom11o ulDtu - 7 L
6u1co1lods deap o ;o itllssaceu eql puo dlqc
Mercs 6n16 1e1cof relo6 puo
ue^sun puD Ic!rl1 D lo lD^ourer eql u! llnsor o1 ' s e l r o s s e c c v r l o q l ' s A o r * 1 1 6-
Llg'Z'6lJ
1do s1 epnsse;d ueneun puo q6;q A;;.rossacauun
u V ' , , p u D L ll q 6 ! 1 , , D q l l M q c u n d e q l e l p u D H
'lrotu qcund o Iq
'uo11rsod
Ilqo:e;ard slql ul dnc asoa:6 aql )col
'lcolq eql ul s:epur;Ac eql
lo eutl erluac aql
t u o ; I o g t l n o q o i q p a l c a g ; e p ' e ' ! ' d r . u n dJ a I D M
eLll q}!M 3u!l u! s! eloLl uo!lDc!rqnl oql lDq}
os uloqc eq] ]o dnc asoa:6 aq1 uelq6ll (g
u D q s L u D Cp u D
tloLlsluorC lo sacuDtslCarluaC -tlg'Z'6lJ
vo
' r a q s o M 6 u t . t d sp u D
lloq o qllM
u o g 1 1 1 . r oadq l p u D ' M e l o s D q l l M d D c e q l u e l s D l
'6u1:oaq
U D q s r u D c e q ] o l A o n n l l oe q l l o d D c e q l
r o l o r e t l ! + l ! o o L l ] ; o u o 1 1 ; 1 r o da q l u a l s D l ( e
'l! rapun
6 u 1 r l o e s o 1 n d 6 u g n o q r e ] + D t ' o 5 : a p u g ; d c1 o
1 e 1 c o ! r e l D M o q ] l o 6 n ; d a n a r c sa q l u e 1 q 6 ; 1 ( p
'l3olq aql u! ploq urrtl sl! arnsue o1 (s1lo6
arodg,o a n 6 o 1 o 1 o 3e q l u ! p a l D c l p u ! s l l r u l l
ecuorelol oq] ulLlllM ralarrDlp la6lo; 1o) auo
Ja)orql D esn 'slloq phls poaq ioputlAc aq1 1o
e u o e c o ; d a l o 1 f u o s s o c e u s r l ! 1 1' 1 u t o d . t o p u n o d
- t u o c 6 u 1 1 o o so r l l l M r o l J e l u ! a u 1 6 u a e q t o l u !
6u1pn.r1ord
suoq pnls aql ]Doo"ri5"#l,o(3u*
rassorc 901-Ldt l 6 u 1 s p s r o u ! 1. r e p u 1 1 It3o ; olu! uMop ueql 6u1r*ercsaroleq 1u1od.ropunod
ssaceu Io sacDlrns6 u r 1 o 6 16 u r s s a r 6- Z l g ' Z ' 6 l J -ruoc 6u11oas D qllM s6n1dr*e.rcsaql ]DoC (q
'.r1opassa:druooqllM q6no:ql molQ
puo por unB o qllM ueql uoelc '(pe;qruesso
A1e1a;drue oq c euD
c o l s ! l l 1 ) l r o l q . r e p u 1 ; IM
a:o;eg (o
; o s l o r u l r o o q l o l u r s 6 n 1 d6 u t 1 1 r 1
'c1e 's6n16'sllog 'sAorrrr;gg
' s r e ur l
reputl{c ro} saroq .r1eq1Iq ,{1uo-ra1ppww Zl
puD tutu 'Dlp s e r o q l e p u r l A cr o ] s l c o l g
' A 1 1 o u o r8191 pppaDl t]!ol p u o I l e l o . r o d a sa p o u a r o
'1runilquessD uD 's1.rod
lcolq oq] gllrrrr6ulurro;
6 u 1 u 1 o u a :a q r l l V ' r o n o c r D a r l l D q s l u D r c a q l uelsA
puD sJe^oc 6ugroaq q11melaldruoo peulqcou
6 u ; 1 s o ce 1 pi o 1 l o - 1 q 6 o
; ps g) o o l q . r a p u r l Aacq 1
'1
)cols ufoNtl^c 9'z c,oz
 2.6-2.7

seot in the cylinder block using o copper or domoged mechonicolly, use the MP 1-106 To Grind
o l u m i n i u mr o d . d r e s s e r ,o r t h e M P 1 - 1 5 7i i g w i t h u n i v e r s o l g u i c c
For gri
rings. shoft by t
between 1
'Ihe
ReconditioningRecessesfor Cylinder Liner Reconditioning of Comshqft Beorings reor
Flonges ond there
lf on oversize comshoft is to be f itted (ex- for detoils
B e f o r e o s s e m b l i n go u s e d c y l i n d e r b l o c k , cessive beoring cleoronces in on otherwise beoring.
i n s p e c t o n d c l e o r r t h o r o u g h l yt h e m o t i n g s u r - sound block), drive out the plug on the reor
For grir
f o c e s o f t h e r e c e s s e sf o r c y l i n d e r l i n e r f l o n g e s . side of the cvlinder block ond reom the beor- prepored
lf chemicologents (petrol,etc.) foil to hove i n g s t o d i m e n s i o n s s p e c i fi e d i n t h e f o l l o w i n g clomped t,
t h e r e q u i r e de f f e c t ,o r i f t h e s u r f o c e sh o v e b e e n Toble: pins must

Stondond comshoft
D i o m e t e ro f b e o r i n gi n c y l i n d e r b l o c k D i o m e t e ro f c o m s h o f ti o u r n o l s
mm mm

+0.02s l s g
38.5 l- 38s- -0.025
-0.041
+0.021
Oversize comshoft
l-;- -0.020

_ =l__i
tl
o

_-L1il
L_
T h e n u m e r i c a ls y m b o l s o f t h e b e o r i n g s ( l - l l l )
indicote the respective front, centre, ond reor
b e a r in g s .
Reconditioning
of Volve Toppet Guides
I
-t
t o i. l l

Close the newly mochined bore with o new l f t h e r e i s o n e x c e s s i v ec l e o r o n c e i n t h e

plug ond seol it with o dob of point. A poor
seoling would result in oil leoking from the
engine into the clutch.
guides (beorings)of the volve toppets, it is
p o s s i b l et o r e c o n d i t i o nt h e g u i d e s o n d t o r e -
ploce stondord toppets by toppets of o lorger
-T-
QZt0.l

When reboring the bore for the comshoft,
observe the centre distonces of the cronkshoft
o n d c o m s h o f t .O t h e r w i s e t h e t i m i n g c h o i n w i l l
be either too slock or too tout. For the correct
distonces see Fio. 2.6/3.
Azi' r
diometerT . h e c e n t r el i n e o f t h e b e o r i n g si s p e r -
p e n d i c u l o r( n o r m o l ) t o t h e s e o t i n g f o c e o f t h e
c y l i n d e r b l o c k . T h e r e l o t i v e d i m e n s i o n so f t h e
beoningond toppet ore specified in the Toble
below:

Diometer of Beoring Toppet Diometer

Volve Toppet in CylinderBlock, mm mm
Stondord 21 21 -0.020 @)
on;rsizt- +0.021 -0.007
21.2 21.2
Externol Col
2.7 CRANKSHAFT Cronkshoft Beoring (for clutch shoft) Nomir
AND ITS ACCESSORIES iourn
I t w i l l b e d r i v e n o r p r e s s e di n t o t h e s h o f t
T h e c r o n k s h o f th o s t h r e e r n o i nb e o r i n g so n d l u b r i c o t e dw i t h t h e r e c o m m e n d e dg r e o s ew i t h Stondord
f o u rc r o n k p i nb e o r i n g sl.t i s o f o r g i n gw i t h s o ft , its cover turned outword. After its pressing-in, 1st regrin
n o t h o r d e n e di o u r n o l s .W h e n w o r n , i t m u s t b e odd odditionol greose by forcing it into the 2nd regrin
r e g r o u n dt o d i m e n s i o n so s p e r T o b l e f o r f i t t i n g s h o f t b o r e b e h i n dt h e b e o r i n g . 3rd regrin
o v e r s i z eb i g - e n d o n d m o i n b e o r i n g s h e l l s o s Use the extroctor MP 1-109for the removol 4th
w e l l o s c n o v e r s i z eg u i d e r i n g . of the beoring.

42
 w
066'L zt, t9'o!p - !Pu!rDerqlt IDAOUI
s98'L 9/8'Lr 9Z't9'olp- prg
6u;pu1.rDe.r
t0'0- ovt'L 920'0+ 9L'LT 0 9 ' t 9 ' D ! p- pu7
6urpur.r6e.r oql ol
'u1-6u
919'L 929'Lt 9t'v9'otp - 6urpug.rOer
1s;-
proPuDls qllM,s
06r't S'LC 9 9 ' D ! P-
llDqs e
tu ut ruut ssoulc!rll ecuoJololI tuul JelsuDlp 1ou:no!
ecuojslof 6u1.rep;n9 q16ua'1 | ,,o,, q16uel lDuJnol uoqsluorc lDu!uroN
sseulclrll 6u1X ep;ng; puo (,,o,,) ql6uo'l lournof lo uolptaiJoc lDuralxf
sugdluo.rclD - B
uollouo;dxe puo elqol eql ess - ;ournol
lsrrl eql ;o uogldecxaeql qlltl,t sloulno! lo - V
sqeM uoqsluDJc lo secDlJns
apls ol leeqM 1o 6u;peel puD sn!pDrleeqM
6 u l p u u b - s l D u r n o fl u o r o 6 u t p u t : g - Z l t ' Z ' 6 l J
elqol
eql lo
eql io
-redsg
:a6.ro
-ar ol
iD/Tz9 r1d s! lr '
s e u 1 1A n o e q u ! u M D l p e l o s e o D l J n sp a u o t l l P u o c e l oq] u!
e q l - s fo u J n o f l u o l C 6 u l u o l y p u o c a y - y 1 7 ' 7 ' 6 t 7
t9 w zt 6 u r p u r i 6 e :q l f
620'0- 9Z'V9 920'0- 9Z'VV 0- 9t8'Lt p.rg
6u1pu;.r6a:
010'0- 600'0- 920'0+
09'ts 09'tt 9t'Lt, 6 u r p u l r 6 a p: u 7
9t'vs 9L'rV 929'Lt, 6urpur.r6a:1s1-
99 9V 9'Lt ez!s pJopuDls
ultll uJul ulut ultu..D,,
uruI ultll
acuDJelol 'o!c acuDJalol 'D!CI ecuoJalol q16uep slouJnor lo ez!s
P louJnof P q16ue1 louJnor
lDurnor
'q16ue1 u1d1uo.rc eq1 6u16.ro1ue lnoql!M re^eMoq agqlsslturad rleql puo LutugO'0+96eq lsnu suld
'seoDl puo aql qcnol ol pelllt-uJeds1
leeqM -luD.rceql lo rl!l aql 'puo tlDrls eqt ol paduolc
6ulrvt
6u;pu116eq1 '6ugrvroJp eql lo ,8, uotlcas oql aq ot e^Dq qclqm 'se1o1d- saJnlx!' peroderd -JDAq e
'PopuouutocoJ l;;onprngpu;esn suldluDrc or.ll 6u;pu1.16 .ro1
o1 6u;puodseJlocecuolsu! oql ul JDoJ AL
'6u1.roaq
s! ZtL'Z '6lJ .rad sD leeqm 6utpug.t6oql Jo es!MJe
6u;peal 'punol6 eq ol sDq ecDl er.lloslD qclqM eqt qllM 6u11oepqdorBo.tod eql aes sllDlap ro, -xa) p
'u1d4uo.ro lsrll eql uolgdacxeaql qll4l1 - po^ouer eq lsnu 6u1:oeqoq] aJolelaql puD
1o lo
'Zll'Z'6lJ o1 6ulp.roccosn!pDro qllr* 6u;roaq aql Jepun sr eoDlJnslocluoo rDaJaql
leeqM 'au!qcou 6u;pu1.rD sql lo serluec oLll ueemlsq
6 u r p u r . r DD o s n s l o u . r n o !e q l 6 u t p u 1 : 6 J o J
'unurlxotu spue UDqs eql lo secDlrnslDcluoceq1 lq 1loqs
,0to0 s! u1d>1uo.tc 1s.t11 -luoJc aq1 duolc 's;oulno! aq1 6u;pu;:6 .ro1
aql puo sgou.rno! orlt lo eu!l elluec eq1 qbnolql op1n6
6u;ssodeuopdaql ol lcedser qllM lueuu6;1os1tu lloqsluorc eql Pulr€)ol 901-L
2.7.-2.8

Guide Rings i s w o r n t o o n e x t e n t w h i c h m o k e s d o m o g eo f dynomi

t h e g u i d e r i n g l i k e l y ,r e p l o c ei t w i t h o n e w o n e ism sh
R e g r i n d i n go f t h e f o c e o f t h e f r o n t c r o n k s h o f t or regrind it. sembfe
w e b r e s u l t si n o n i n c r e o s e d( o x i o l ) p l o y o f t h e T h e m o x i m u mp e r m i s s i b l er e g r i n d i n gi s , h o w - Thus
shoft. e v e r ,t o o t h i c k n e s so f o n l y 3 . 7 5 m m . sitioqof
R e p l o c et h e r e f o r et h e o r i g i n o lg u i d er i n g w i t h shoft be
o n o v e r s i z eo n e . from o 1
O v e r s i z eg u i d e r i n g s o r e f i t t e d e x c l u s i v e l yt o Cronkshoft
Moin Beoring Shells When
the regrround loterol foce of the cronkshoftweb. rnork on
S t o n d o r ds i z e r i n g s s h o u l d b e o l w o y s f i t t e d t o F i t t h e c r o n k s h o f tm o i n b e o r i n g s ( s h e l l s ) zero line
t h e t h r u s tr i n g s i d e ( n e x t t o t h e t i m i n g g e o r ) . occording to the respective nominol diometer ond prol
Thrust Ring . he shells ore not
o f t h e c r o n k s h o f ti o u n n o l s T mork op
p r o v i d e dw i t h o d i o m e t e rs y m b o l s o t h o t t h e y cylinder
l f t h e t h r u s t r i n g u n d e rt h e c r o n k s h o f t i m i n g hove to be checked for the respective woll the rem
g e o r ( s p r o c k e t )o b u t t i n go g o i n s tt h e g u i d e r i n g t h i c k n e s sw i t h o m i c r o m e t e r . gcm sin
mosses(
concent
Motching Cronkshoft Main Beoringswith Journols cronksho
holes rot
T h i c k n e s so f b e o r i n g T o l e r o n c el i m i t wheel ir
N o m i n o l c r o n k s h o f t iournol diometer
s h e l lw o l l of woll thickness interfere
mm
mm mm For thi
on the r
d i o .5 5 stondord 1.497 sition, i.
cronksho
dio.54.75 1st regrinding 1.622 fore the
d i o .5 4 . 5 0 2nd regrinding 1.747 - 0.007 When
dio.54.25 3rd regrinding 1.872 one or wl
d i o .5 4 4th regrinding 1.997 follows:
1. Fit .
r e s i d u o lo
olly offec
l f o n e o f t h e s h e l l si s w o r n o r d o m o g e d ,o l l 2.8 FLYWHEELWITH GEAR RING 2. The
cronkshofm t o i n b e o r i n gs h e l l sm u s t b e r e p l o c e d bolonce r
hos o hig
w i t h o u tf o i l! Boloncing- Removol ond Refitting
correctio
once. lt
For the respective correlotion of the cronk- A n e w f l y w h e e l o s s e m b l yi s o s t o t i c o l l y b o -
pins ond connecting rod big-end beorings see l o n c e d u n i t , i t s m o x i m u m p e r m i s s i b l er e s i d u o l occording
' 1 0g c m . T h e f i n o l porogroph
Chopter 2.11. o u t - o f - b o l o n cweeight being
Chopter 1
b e n d i n gt
To Reploc
Reploce
worn or d,
ring, toke
the interf
sion). The
prime imp
ossembly
storter mo
The gec
removed b
port pod cr
MP 1-153.I
ing the ge
it off. The
monufoctu
When ur
F i g . 2 . 8 l 1 -M o r k i n gC o r r e c tP o s i t i o no f F l y w h e e l front foce
o n C r o n k s h o f t( p r i o r t o r e m o v i n gt h e f l y w h e e l ) ond drill o

44
 9?
'sl!ru!l aouDreloluorlcnpoJdeql ol 6upploc e c o d s q l o o l D M o l e q 6 u g . r. r o a 6 o q l ] , o l l t r p p u o
-cD 'C puD 'g 'y sessolc ecuoJolol ul pessDlc ( e c o l l n s p a u a p t o q ) 6 u g . r. r o o 6 e q l l o e c o t l u o J l
ero dno.r6releuDlp rlcDa lo s.reulg.repulg{3 eql llo pur:6 'poqletu reqlo eq] 6u1sn ueqg
'Pesn eq o1 a^Dq 'lsanber uo Jelnl3olnuoul
s u o l s l d e z ! s r e ^ op u o t a l q D l u o t l D O ! l ! s s D lrco p r o c a q l A q p a r l d d n s e q l l l t * 6 u r n n o . r pe q l ' , l o l l
-u1glceql qllr* ecuopJoccDu! JeteuDlp lDulurou 6 u 1 s s e . r de J o l o q i l e l o l p e u r u r 6 u r . r : o a 6 a q 1 6 u 1
lxau eql ol psroqer ro euo /vlauD qyrvr peco;del - 1 o e q l l l o c o l r o ; q c . r o 16 u r p ; e M o e s n ' S S L - L
d17!
eq lsnu Jeull aql 'utu L'0 speacxa JoaM eql ]l D u l r v r o r pe q l o l 6 u l p : o c c o e p o u r e q u o c p o d l r o d
'lapoureugDueeql uo 6urpuedap'ww - d n s o ' ; ; o 6 u g s s e . r d. r o 3 ' u o l l c n r l s e p l q p a n o u a " r
ZL lo gg sl
a r o q r a p u r l l c 1 o u 1 r , u co lus D qo q l ' I c o l q L a p u l ; A c r o l l o p e s s a . r d r e q l l e s q u o c 6 u 1 . r. r o a 6 e q 1
aql olu! pauosur 6ureq uor lsDc la.r6 lorceds1o ' u o 1 u 1 dJ o l o u r J e U D l s
s r a u r lr a p u l ; A ce q l ' a l o . r o d a o
s l o s l e p u q l l ca q 1 e q l l o a n b l o l 6 u 1 n r . r pa q l s l ! L u s u o . r 1{ g q u a s s o
6u;.r roa6 - leaqrrrAgleql ecurs ecuol.rodurr atul.rd
'(uors
(uarurr)ufoNrrlc 6'z lo s! 1l (e6o>1uuqs)acuerepalug aq1
-o:qo Aq) laaqr*i11 eql
lo l!' scueralialur eql
l l l . r o s s a c e u u n q s ! u ! u J t p o l l o u a l o c a > 1 o 1' 6 u r . r
: o e 6 e q l 6 u r M D J p r { } l l vur e q M ' p a 6 o u o p J o u J o M
Agpoq e:o qlaal eql ;1 6ur.r.roa6 eq1 acoldey
6u;X roag eqt ecoldeX o1
' s r e q s o r n ,q. D l a L l l 6 u l p u e q
A q u o 1 1 1 s o du ! u a q t l c o l p u o ( g ' ; r a l d o q 3
:ad so) slloq leaqMtrl' eqr ua1q6r1 '(sqdo.rOorod lou!' eq
s n o g n e r da e s ) s l r o L u e , r r l c a d s a . re q ] o l 6 u g p . r o c c o lDnp!se
-oq i11o
] ! l l D l s u ! o 1 l ( l o s s e c a u a J o J e J e q ]s ! l l ' e c u D
-lDq rus!uDqceu luDJc eJ!lue eql
Jo uo!lselloc
o q ] o ] a n p l q 6 ; a r * e c u o l D q - j o - 1 n or a q 6 1 q o s o t ;
1aeqml1l plo eql 1nq laeqrrrlll eql lo acuoloq
aq] ]callD louuoc euolD 6u1.r roa6 aq1 'Z
'trts!uDqceur
)uDro eql lo aouDloq aqt tcal1o 111o
- ! l u o l s q n s J o uu D c ] q 6 I a r * a c u D o q - ] o - l n o
I lDnptsaJ
s l l ' u o 1 1 ; s o di u o u g l e e q r v r A lM .l
l ou eql lll
:sMollol
s o p e e c o r d ' 6 u r . rr o e 6 s 1 g6 u 1 c o l d a l u a r l m J o e u o
Mou D qllt* laeqrurr{lp } l o u o 6 u 1 c o 1 d e ru a q M
'pa^ouer sDrvr
leeqMAll aq1 e:o;
-oq sporu s)Jom eql puo Aellnd llaq llDqsluDrc
eql ,o 6uluas eql ol 6ugp:occo 'a'! 'uo!]rs
- o d l c a r r o c 1 o u ; 6 1 . r os l l u l l l o q s l u D J c a q l u o
'qrp!M gaaqmi{1e ; q} }!}aJ o} erns €q uosoer s!q} ro1
' e u 1 6 u ae q l
s 1 r 6 u o ; o l o m p l u r L u u tl 0 ' 0 + l o a c o l J n s u o ! l 3 r r l l o a J u D l D qe q l q l l M a o u a r e l r e l u l
ur llnsal plnoM uogllsod rsLllouD olu! laeqM
aql lo lno-unr a1q;ss;ruled eqt ernsDelA 'e3Dl -AU eqr 6ugulnl 'ecuarelurncr!c sil punor saloq
s ! q l u o l ! ' o l e r n t x ; ; 6 u g d r u o l cA r o p ; 1 x n u oD e)oru pelllrp lo rurol eql u! Ae1lnd lleq Uor.lsluDJO
'reneMoq 'elqDs!^pD s!
o1 ll
'aco; 6urloes s!ql
eq] io uolldacxa sql qllM l! u! pelDJluecuoc
o 1 6 u r p . r o c c o1 q u 6 r ; o ' l l a q d 1 d . r a d s l ! u o l a e q r v r i l y uoaq sDq rus!uDqser! uDr{sluojc aql lo sassDul
e q 1 6 u g d t u o l ou e L l g ' l l o q s l u D r c e q l u o l e e q r * { 1 1 pacuDlDqun aql lo uorlJeJJoc aq1 aculs tuc6
eql lo aco; 6u11oesaql qlllrr lallorod sl acDl
-rns srLll1o auold aql loql erDc elol qolnlc eq] 0 L u D q l r a 1 o a . r 6e q l l l M l e a q n n A l ; p e ^ o u r a r e q l llD/vl e^l
'loolq rapull,{c laql 1o
r o | e c D l J n su o l l c r r l a q l 6 u 1 u o ! l ! p u o c a ru e q M l o a c u D l D q - r o - l n or r n u ! x o r r l e q l
eql lo a6uo11 €ql ul lloq eql altsoddo >1.totu ]ou oJD
qclnlc aql Jol esolrns uollclrJ uolllPuoceu oI r o r . l l o u DJ o l o p o q l l M l a a q r v r A l le q l e p l n o : d p u o JOlsirD!
:enoc loa6 6utull aql uo elDoseql lo aurl oJez ( s 1 1 e)
'uMop 'Alossec a q t e l l s o d d o A a l 1 n dl l a q I t D L l s l u o r 3 a q l u o l r o l . t l
looc llquesso aql lal puD
-ou ';aaq,u 6 r - r r r u 1e1q l l o s ' u o r 1 1 s o de q l 6 u 1 1 r o r uu e q 6
' t , { t t q 6 t t l a a q r * 4 1 1a q l a u o q d o 1 'lD^orrsJ
-ill aqr l ! ul llDlsul puo alogd ]Dlf o uo 1t acogd l a a q r v r A l ;s n o l n a l d D u o l l
'C.O0Z ol
081 ;o arnlorcduel D o] ecournl o uI l l e l I J D r Uo u s r e r e q l j r l D ^ o r u e j s l l o j o l a q l J D q s
' 6 u 1 : . r o a 6M a u D u o 6 u 1 1 u ; : q s u a q M
l! tDeq -luDJc eql ol lcadser ql!M leoqMrtll aqr lo uo!US
'pelourer l1;soa eq uoc -od lcalloc sql l:oru o1 Alosseceu sl l! snqf -rvroq's1
p u D s l D a r q 6 u 1 . r. r o a 6 e q l ' l a e q M l l l e q r e 6 o u u o p ' a u 1 6 u ap a l q u e s
ol lou repro u! 1gq 6ulqs;utl D rlllM 6u111grp -so Alelaldruoc o u1 petcelle eq plnoqs usl gUO MeU
q s l u l l ' r e l e t x D t p t u t u C L o l Z L t o ; 1 t . r po 6 u t s n - u D q o a u l u o J c e J r l u o e L l l l o 6 u g c u o l o qc l u o u l p
;o eOou
 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
c y l i n d e rl i n e r o n d g o u g e s .

Mochining (Reboring) Cylinders

DK 626
Fig.2.911-Morking of Cylinder ToleronceCloss
Grode the rebored cylinder liners in the some
monner while odding the number of the re-
spective rebore before the designotion of the
F o r m o c h i n i n g( r e b o r i n g ) t, h e c y l i n d e rs h o u l d
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

Groding of Cylinder Liners According to Diometers ond Toleronce Closses

Nominol diometer Toleronceond I Diometer Diometer
mm rebore closs I I
mm toleronce
Dio. 68 (stondord) A 68.00
B 68.01
c 68.02
68.25 (1st rebore) 1A 68.25
1B 68.26 + 0.009
1C 68.27
68.50 (2nd rebore) 2A 68.50
28 68.51
2C 68.52
A 72.OO
Dio.72 B 72.O1 + 0.009
c 72.O2

Fig.2.912- Outside Dimensionsof Cylinder

Liner
Cylinder bore 68 mm
Cyf inder bore 72 mm
dio. D :75f7
dio. D:76t7 Fig.2.9/3- Mochining the Cylinder
1- cylinder liner, 2 - centering heod, 3- clomp.
ing plote, 4 - clomping bolts, 5 - cutting tool

46
 LV
. s a 6 n o 6e q l 1oo16u
puo uolsgdaql qloq rol luolsuoc eq lsnu qc!qM C,0Z ,o a.rrrloradrua]
o ] D r a i a u l D r pa q l l c e q c -dtuolc-
ra
16'LL c
96'LL I
96'LL V
tv'89 cz
9t'89 az
(aroqar pu7 rol)
9t'89
zz'89
tz'89
vz
CL
8L

09'89
ff
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'locupuglIc l D c ! u o op u o
t u t u g z ' g g ' o 1 p ' 6 r . r r > l t o r ]l -nro q l l m s u o l s r d L u u g g l o ' u o l l D u r q u o c D s r I . r ; > 1uso l s g d
a q l ' 4 1 ; o c r . r l e u r o'e( som c S I 0 Z L D p o l S 1 o s e u r 6
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9 i t seNtu Norsld
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erDreurl t a p u l l A c e q t s u o l s u e r r t ! ap!stn6
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lo Ilquass
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eql paull 6ugnoqraUDacD, tsnrql luor, eql puo pecolde
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ro 00'gl lo ralauolp o .ro1) uur eO'O lnoqo -o!plou
plnoqs ieull lopullAc aql
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lo ecuDrDslcD o^Dr{
a ) o ] o l o r o q a q l ' s e l p u r d se ^ r r p a q l u o l ; l c e : ! p uorlDc!
T o b l e o f Motching Gudgeon P i n s t o P i s t o n so n d S m o l l ' e n dB u s h e s The cle
shouldbe
C o n n e c t i n gr o d cleoronce
G u d g e o np i n Pin bore s m o l l - e n db o r e
Nominol diometer the rings
diometer in piston (br-rsd hiometer)
mm nl n]
mIn mm
2.11 COn
20 20 - 0.003 zu
- 0.004
- o.o1o 2a 1333? The con
20.0s 20.0s-- 0.003 ,o05,33?3 ,oos1333? o brorrzeb
b e o r i n gs h
in the big
Before r
for compli<
GUDGEON PIN g > o i n t i r i gd o w t r w o r d . l f t l - r e r ei s o n y d o u b t o s t o weight, ol
the coriect selection of the rings, check them ond motch
Tlre gr-rdgeon p i n i s c r s l i g h t i n t e r f e r e n c ef i t i n for proper seoling in the cyli.nder.before os- shoft.
t h e p i s t o n - l t s c l e o r o n c ei n t h e c o n n e c t i n g r o d rurbty. ltrserttlre ring into the cylinder ond For its <
s m o l l - e n db u s h i s : ; p e c i f i e d i n t h e C h o p t e r l e v e l i t b y p L r s h i n gh o m e t h e p i s t o n h e o d ' I n ter 2.12.
" C o n n e c t i n g R o c "l . the cose of o used cylinder, insert the ring
The steel gudgeon pin is lrollow ond hos obout 20 ntin below the top edge of the cylinder
To Check
c r r o n r i n o lc li o m e t e r o f 2 0 n t n r , r e p l o c e m e n t p i t t s lirrer, i. e. o plcce rvhere the cylinder. liner is Connect
l . r o v i r r go; n o m i n o l d i o n r e t e r o f 2 0 . 0 5 m n r . W h e n olreodv worn, while checking for the right weight gro
f i t t i n g o n o v e r s i z eg u d g e o n p i n w i t h 2 0 . 0 5 m m clecronce in the piston groove ond for the foctory, ligl
n o m i n c l d i o m e t e r ,t h e b o r e t o k i n g t h e p i n m u s t correct gcrpin the cYlinder bore. yellow po
b e r e o m e d t o d i m e r r s i o n ss p e c i fi e d i r r t h e r e - F o r r i " n g st h o t h o v e n o t b e e n r u n - i n , t h e f o l ' Shouldthe
spective l-oble. lowirrg circumferentiolgop or contoct cleoronce during stor
with rlgord to the cvlinder liner is permissible: been fitted
PISTON RINGS n o n e f o i t h e c h r o m i r - r m - p l o t ecdo m p r e s s i o n r i n g , determined
two in c totol ronge of on ongle of 35 degr' for remove o c
To ensure their correct function, they must the bevellecl compression ring ond the oil smoll ond t
b e f i t t e d i n t h e c o r r e c t p o s i t i o n ,t h e y m u s t h o v e control ring. Lcrger contcct cleoronces olong the smoll r
no or onlv c minimum cleoronce clong their t h e c i r c u m T e r e n c ed e n o t e e i t h e r o n i n c o r r e c t in the engi
r : i r c u m f e r e n c eo, s m q l l c l e o r o n c e i n t h e g o p s ' selection of the ring, for exomple the ring does (+2 gr.).
o n d t l r e y m L r s tr r o v e f r e e l y i n t h e p i s t o n g r o o v e s . not correspond to the cylinder bore, or on When re
e x c e s s i v ew e o r o f t h e c y l i n d e r l i n e r . odjust its w
Check the ring gop cleorcnce using feeler connecting
105 r20 g o L r g e s -F o r n e w c o m p r e s s i o l l n g s , t h i s g o p
'.;iA
'!.t l .leo"ronc" should be 0.25 to 0.40 ntm, for new
\Lt { .,
o i l c o r r t r o l r i n g s 0 . 2 0 t o 0 . 3 5 n r n r .T h e n l o x i n r t l t t t
x),:= o e r n r i s s i b l ec l e o r o n c eo f w o r n r i n g s i s 1 m m '
s!-9

DK63

\ D K1 4 3 6

F i g . 2 . 1 O l 3. - S e q e r e n c eo n d [ J l e t h o d o t F i t l i n g l
PistonRings ( Mork Positioning).
Fronr top to bottom: chromium-plotedcompres-
s i o r . rr i n q , b e v e l i e d c o m p r e s s i o n r i n g , s p r i n g
l o c r d e de x p o n d i n g o i l c o n t r o l r i n g

Fit the {irst ring in cny orbitrory position

( i t s c y l i n d r i c o l c h r o m i u m - p l o t e dp e r i p h e r o lp o r t
is chomfered on either side, focilitoting identi- Fig
ficotion), the second, bevelled ring with the 'l -
'TOP" or onother mork on top, ond boloncin
lettering
f : i g . 2 . 1 A 1 -4 C h e c k i n q P i . ; t o n R i n g G o p 2 - numerico
llre oil lontrol ring with its outer shorp edge

48
 6n
a l o A 6 u l d r u o l c- g ' u t d u o e 6 p n 61 o 1 1-d7 s : e p u g g Aoc1 6 u g p . r o c ceop o c l D c ! J e u n-uZ doe
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t s s o q 6 u l c u o l D -q L
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'sr.usud 6 u t l . r o d d n u
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3 u 1 q 6 ! a 7-1 ZnILL'Z'6tJ uD JO '
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'pua 61q puo 6uo1o s
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(pa1o.re111qo) pe6ouop eq 6ul1roruaql plnoqS 'lo+ aql
' 1 u 1 o de n l q q l ! , v r r e ! ^ D o L le q l ' 1 u 1 o d m o l l a l {
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eql rol
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rq6!e/![ pou DultcauuoC lcotlC ol :apuglA
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ul "pDe
- d o q C a e s u o l s 1 da q ] q ] ! M A l q u r a s s os ] ! J o J puo Je
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ruLu tL uoql JeMol eq Jo^au lsnu ssoq pua l l D t u sa q l l o l u a l t r u 6 t l o ol sD lql
llDurs eql
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' p o : 6 u r l c e u u o ca q l 6 u ! i 1 ' e r e r o l s €
o l l o u e r D c e l o l ' d 1 q c e q 1 D u g n o r u e ru a q M 1l lceqc
' p u e 6 1 q e q l s D A o r v re u o s e q l u ! . p u a 6 1 qa q t u t
1 16 u g q 6 t o r u t
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r u o r l p u e 6 t q a q r 1 o 1 q 6 1 e r r re q l 6 u 1 l c o . r l q n sA q p a l l D M - u ! qp] u o p u e l l D u s e q l u ! q s n q e z u o J qD
paulDlqo eq uDc pua llotus aql lo tqBlerrraq1 gllrrr 6ur6rol leals D s! por 6ullceuuoc aq1
'pecold ueaq e^Dq susud puo utd uoaOpn6
s
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oou eNlrcSNNoc ll'z
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I
A;lorcedso uo peuoddns s1 qclqM 1o pue 61q
t-
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u o ! l D r l s n l l !e q I ' u o l l s o d l o l u o z g : o qA ; l c ; r 1 so tDql erns lsDel lD elDtu
'txLu
u ! p u e 6 1 q p u o l l D L u se q l l o a u ! l e i l u a c a q l sgql 6u11ceqcacu!S t0'0 lsoel tD aq Plnoqs
u ; 1 1 l r o d d n s ' p o r 6 u l l c e u u o c o 6 u 1 q 6 1 a r nr o' 3 s e n o o : 6 u o 1 s 1 de q l u l s 6 u l l ; o e o u o J D e l ca q f
 {

spond with the number of the respective gVtin- 2. 1

Smoll End ond Big End Alignment OCCo
derwithwhich theconnectingrod is ossembled.
A misolignment of the centre line of the When replocing o connecting rod, provide the
Selec
smoll-endbush ond big-end beoring or the bore new connecting rod with its very some identi- cyl i nd
for the big-end beoring shells must never ex- ficction numbel. Stomp the figures os much tolpro
'lO0
ceed 0.03 mm per mm of the connecting
toword the for end of the boss os possible to
the (
r o d l e n g t h .F o r c h e c k i n g o n d o l i g n m e n tu s e t h e ovoid fouling the loterol guide foce. motch
M P 1 - 1 0 2o r 1 - 1 5 9f i x t u r e . Son
Insert the odiusting pin into the fixture ond 2.12 CYLINDERS, CONNECTING RODS
pin or
set both its diol indicotors to zero. Clomp the gudge
AND PISTONS
connecting rod without shells into the fixture, in wh
threod the pilot pin in it, ond swing down the o )' O n l y o c y l i n d e r ( l i n e r ) o n d p i s t o n o f e q u o t suitob
connecting rod. The recdings of the diol indi- diometer ond the some toleronce closs con bush.
c o t o r s w i l l s h o w o n y m i s o l i g n m e n to f t h e s m o l l be ossembled qs s unit. Mor
o n d b i g e n d . T h e m o x i m u m m i s o l i g n m e n tm u s t b) Theengine cs qn ossemblyunit con befitted respo
not exceed 0.03 mm os olreody mentioned. cnly with cylinder liners ond pistons of the with v
C h e c k f o r m i s o l i g n m e n ti n t w o p l o n e s b y t i l t i n g some diometer, the pistons being of the meric
the diol indicotors. some weight grnLtp. Rod'.
T w o p i l o t p i n s o r e s u p p l i e d ,o n e w i t h o d i - T h e i n c l i v i d u o lc y l i n d e r ' c n d - p i s t o n q s s e m b l i e s 3.L
o m e t e r o f 2 0 r n n r .t h e o t h e r w i t h o d i o m e t e r o f con be, however, of dif ferent toleronce the gr
20.05mm, to motch the gudgeon Pins. closses. On the othe'r hond, connecting rods 80"c i
of only the sqme weight group con be used- Sme
To Motch Connecting Rod with Gudgeon Pin
These ore the cc;tditions for the correct op- home
ond Cronkshoft
erotion of pistons in the cylinders ond for the some
With regord to the reciprocoting movement correct boloncing of the cronk mechonism. threod
of the piston, the gudgeon pin must hove the F o r d e t o i l s c o n c e r n i n gd i m e n s i o n s ( d i o m e t e r s ) , Pin, o
smollest possible cleoroncein the connecting toleronce closses (cylinder liners, pistons) ond circlip
rod small end (ony lorger cleorcnceresults in weight groups (connecting rods ond pistons)' on thr
pin knocking). Therefore select from severol r e f e i t o f h e c h c p t e r s d e o l i n gw i t h t h e i n d i v i d u o l pressiI
g u d g e o np i n s o n e w h i c h w i l l b e o c l o s e r u n n i n g pc|rts" Fit
fit in the smoll-end bush. lf no suclr pin is hole ir
ovoiloble, reom tlre bush but never exceed the To Assembie Cylinder Liner with Piston the orr
qnd Connectirrg Rod
moximumtoleroncelimits. 4 . F
An oversizebuslr lros to be reomed to o nom- 1. Toke cylinder liners ond pistons with or exp
inol diometer of 20.05 mm. For the respective m o t c h i n g d i n r e n s i o n s i, . e . c y l i n d e r l i n e r s o f t h e detoils
dimensions refer to the Toble supplied with s o m e b o i e ( t h e y n e e d n o t b e n e c e s s o r i l yo f t h e the ri
gudgeon pins. The big"end beorings i:;hells) scrmetoleronce closs), pistons of the some groove
inouta be selected occording to the nominol c l i o m e t e r< , n r lt c i e r o n c e c l o s s t o m o t c h t h o s e o f
diometer of the cronkpin.The shells lrove no t h e c v l i n c l r : i i t r e r so n d o f t h e s o n r ew e i g h t , o n c l 5- P
d i o m e t e r n t o r k i n g o n c l h o v e t o b e i d e n t i f! e d c o n n e c t i t r c tr o r l s , < r l l o f r t n e o f t l l e t w t l w e i g l r t the crc
by meosuringtheir woll thickness with o mi' clroLrPS. ond co
crometer.
lti'' 2.13 I
Motching Big-end Beoring shellswith Cronkpins
In o
M o t c h i n g C r o n k p i n o " | , , n " i i f l " , , rl o , u , o n t e ri s ti c
nominol diometer 1 thick"ness mm comso
mm mm
comsh
c leoro
45 (stondord) 1.490
the cor
4 4 . 7 5( 1 s t r e g r i n d i n g ) 1.615
4 4 . 5 0( 2 n d r e g r i n d i n g ) 1.740 0.007 '
Volve
4 4 . 2 5( 3 r d r e g r i n d i n g ) 1.865
44 {:lttrregrinding) 1 990 with

lntoker
DK 1161
N u m e r i c o l l d e r r t i fi c o t i o n o f C o n n e c t i n g R o d s
open be
For better identificotion, {igures con be
stomped on the bosses of the connecting rod Fi,c 2.1211- P r e s s ' ift t i r r g o f G u d g e o n P i n i n t o closeo
b i g e n d ( s e e F i g 2 1 1 1 ). T h e f i g u r e s c o r r e - Piston Usinq MP 1-i04 Drift

50
 t9
:r,uorODt6 purnno;
-lol eql qllrvt acuoploccD ur 6ulpaacold epLllvr ,0t.Et ,0t"9t ccl8 rello esolc c\lut ut
p a l s n l p o e q u o J . r a p u g ; l cr e t l l o u D l o s a ^ l D ^ q l o q 'OtoiL ,0eoDL 361 arolaq uedo
l o e o u o J o e l c a q l ' s a 1 o u r a 1 ; o . r a p u l ; A ce u o , o r9r!x
s r r l J oJ a l c o J a A l D ^ e q l ] o l u e u r e ^ o u Je q l u a q n n s't ozt DPoIs 1ozt
'90t Dpols se^lDn elDlul
!
'pasolc eAlD^
aql qllr* e3uorDalc eq1 lsnlpy 'ulJD re)oor eql :r.ur.u
gt'0 ol les e3uoroelc e^lo^ eql qUM
puD e^lD^ eql lo spuDl eql uearv\laq Peuosu!
e 6 n o 6 J e l e a l D e s n a c u o J D e l ce ^ l o A a q l 6 u 1 1 c a q c 6u1tu;1 en1o1
ro3'Arosseceu sD sJe)cor e^lo^ oql lo u!d ' . r o a 6a n ; o n a L t l
llDq eql alDlor
' e 3 u D r D e l ce ^ l o ^ a q l
lsnlpo o1 Jo uorlolado loellog aql
Jol ecuDuodut ar-uud Jo sJo]ool aro ocuoJDelc
eAIDA lceJJoc puo lloqsluolc eLl] ol lJoqsuoc
e q l l o 6 u r q d n o ce q l ' o r l D JJ e l o o l a ^ l D ^ p u o s u r D c
Luru0z'0 S 1 O Z LD P O I S eql lo u:eltod puD uotlrsod so qcns 'sorlsrJel
- J D J D q cu 6 r s a p e n r l c a d s a r e q l o l u o l l r p p o u l
ruru0z'0 urLuEL'0 -l ozl puo 901DpoIS
e^lD^ lsnoqx:l e^lo^ elolul uv39 fnlv^ tL'z
: e l q o l 6 u q r n r ' o 1 1eoq1l o l 6 u l p . r o c c o '(,,rpoU
au16ua ploc D uo ecuDroelc e^lD^ aq1 1snlpy 6 u 1 1 c e u u o 3. r
, ,e 1 d o q 3
a e s ) r a n o cp uo
pua 61q po.r6uglcauuocaql olur llDr.ls>luoro eql 1r;6ge
ecuDloalc onlDn ec!AJes ql!r',tpeLlclouJse^loq ;1eqs6ur.roaqsseJd's puo '1q
^
'seAooJD jo eso
otxDS a
uols1d aql u! luaua^our eaJl ro] s6u1r eql
' , , s 6 u 1 gu o l s ! d , , r a l d o q 3 a L l ] e a s s l l o l e p e q 11 oi
u l D r l C p u D s r o e e 6 u r t u 1 1- L l t L ' Z ' 6 1 ) lceqC eLll lo s
. r o 1 ' s . r a 6 u 1 ls q l q l l m s 6 u l r a q 1 6 u r p u o d x a r o
sre11d 6 u 1 s n s 6 u g . ru o l s r d a q l 't 9]!M s
; o l c a d s l l j
'Slt'Z'6lJ eas - poeq uolsrd sql uo /v\or,rD eql u
l o s p l s a l g s o d d oe q l s e c o ' p u a 6 r q s l r u t a l o q
qsolds aqt lDrll os por 6ullcauuoc eql l!l
'u1duoe6pn6 aql auoq 6ursserd
i o l l i l J p l o g c e d s a q l a s n ' d r 1 c - r 1rce q l o e q l u o 'l (Dsnupo!1^
d 1 1 sl g l o u g 3 ' a 1 o q u o l s 1 d e l l s o d d o a q ] u l d r l c r r c puo (s
aql sD JD] sD u1d uoe6pn6 "qr qsnd puo 'urd ' (slele
u o e 6 p n 6 a q l u o q s n q p u a - l l D r . u sp e l ! o a L l l p o e r q l 'uJsluD
'a6pe aloq uolsgd eql puoAeq uu g'L ol eqt rol
L suJos
s s e p n : 1 o . r d1 l o r l l o s u o l s g d p e l D e q e q ] o t u ! e u o q -do lce.
1l dDl puo llo qltru utd uoa6pn6 eLl] roeus 'pasn a
'JalDM
l o q J o a c D u r n ] 6 u 1 1 o a qp u ! C o 0 8 spor 6u
lnoqo o1 uolsrd aql loeLl puo u;d uoa6pn6 eql ocuDJa
u o d 1 ; c r 1 ca q l e c o l d ' s l e g l d ; o r c e d s 6 u r s 6 ' g
se!lqru
'.pou
6u11ceuuo3,, .ra1doq3eql ol JeleJepoc lDc!Jer.ll aq1 ;o
-nu aql roJ 'pelquesDeq 1ilrt Aaqt qsrqM qllM eql lo s
-il",f srapul;lc lo si€qunu ropro aql o1 Dugpuodsar pell!l eq
u eq},";(J L::ti"1"'
or{ruo rrD Tfr:;
i J,i? -roc sJequlnuqllM spol 6urlcauuoceql >lrou\
.roe6 goqsluD.rc eql uo lrDlu aql rano a;]ugd 'qsnq uDc ss
aq1) .roe6lloqsuoc aql uo lrDrx eql puo UDqs e q l u r o e r' p u o q l o l o u s ! u r d u o a 6 p n 6a ; q o i l n s
-),luorc aql uo 1:ou (qcund) 6urrurleqt uaeMloq lonbe ;o
' r e q l o u o ' 1 1 ;6 u l u u n rD a q p l n o q s q c r q r l u
1 l! tt
e r o ( s 1 u 1 1s) e g t u l du r D q cz L l D r { }o s ( s l e l c o t d s ) 'qsnq eql1 olur pauasu! eq louuoc u1d uoe6pn6
sroa6 6u1ru!leql uo pelllt uroqc o 1o suoeu lq e q l ] o q l o s q s D l cq s n q p u s - l l o u sa q l p u o u 1 d S
UoqsluDrc aqr qllr,t paldnoc sr llDqsruDceql uoa6pn6 oql io sl!uI!l eouD.rololsaur!leuoS
-uraq]ro; surd uoa6pn66urqclour
lcelos puD (,,pou 6u11cauuo3,,:a1doq3 eql ol alq!s
ees) spo.r6ullcauuoc eql u6!lo :ssolc acuoJalol qcntu s
flt"l ,0Cr0L ccf JeuD ssolc -!luop! o
a n l l c a d s e .ar q l q l ! M 6 u 1 d a a 1u r r e u ! l r a p u ; ; l c
,0eo9? ,0Lo0? 369 a:o;aq uado qcDo ro' po.r6ullcauuoc o puo uo1sldD lceles eql eP!
'g'7 .reldoqC eLll 'polquro
{0/ZtlSO! se eures 1o g; qdoroo.rodo1 oulp.rocco 'Z - u 1 1 l ce
ST OZI LL61requaldes reUV)sa^len lsneqxl lcolq ropu;;Ic eq1 olul sreu!l aqt llolsul
Et z-zl'z
 link from the choin front side ond fit the clip
from the reorwith its openend pointing in the
d i r e c t i o no p p o s i t et o t h e c h o i n m o v e m e n t .
Before storting work on the volve geor, re-
move the oil sump (engine bottom cover to
w h i c h t h e t i m i n g g e o r c o v e r i s b o l t e d ,t h e s u c -
t i o n s t r o i n e rb e i n g o t t o c h e dt o t h e c r o n k s h o f t
c e n t r e b e o r i n gc o v e r ) o n d l o c k t h e c r o n k s h o f t
i n p o s i t i o n i n t h e o x i o l d i r e c t i o nb y d e p r e s s i n g
t h e c l u t c h p e d o l ,i f r e m o v o lo f t h e e n t i r e e n g i n e
i s n o t i n t e n d e df o r o n o t h e rp u r p o s e F . or speciol
p o i n t s o f t h e r e m o v o lr e f e r t o C h o p t e r2 . 4 .

2.14 WATER PUMP

F i 1 . 2 . 1 3 1-2 V o l v e C l e o r o n c eA d j u s t m e n t
Alternoting
c y l i n d e rN o . 1
c y l i n d e rN o . 3
c y l i n d e rN o . 4
c y l i n d e rN o . 2
A d j u s t c l e o r o n c eo n
c y l i n d e rN o . 4
c y l i n d e rN o . 2
cylinderNo.1
c y l i n d e rN o . 3
Disossembly
1. Unlockthe wosherof the belt pulley nut,
r e m o v et h e n u t o n d p u l l o f f t h e b e l t p u l l e yu s i n g
t h e M P 1 - 1 2 0p u l l e r( o f i x t u r r ef o r S k o d o M B 1 0 0 0
c o r s ) o r o u n i v e r s o pl u l l e r ,f o r t h e b o l t s o f w h i c h Fig.2
i t i s n e c e s s o r yt o c u t t h r e o d s M 8 i n t h e b e l t
p u l l e yh o l e s .
B y p u l l i n g o f f t h e b e l t p u l l e y ,o c c e s sw i l l b e
g o i n e d t o t h e n u t s f o s t e n i n gt h e p u m p t o t h e
e n g i n e .T h e s o m e p r o c e d u r eh o l d s g o o d w h e n
d i s m o n t l i n gt h e p u m p o f t e r i t h o s b e e n r e m o v e d

@@@@ DK 1240
F i g . 2 . 1 3 1-3V o l v eA r r o n g e m e nitn C y l i n d e rHr e o d
B l o c k d i s k s- e x h o u s tv o l v e s
W h i t e d i s k s- i n t o k e v o l v e s
TimingChoin ond TimingGeors
M o d i f i e dc h a i n a n d g e a r sf i t t e d s i n c e O c t o b e r
1 9 7 9 r e c o g n i s e bd y s q u a r e dg e a r t e e t ha n d c h a i n
with split rollers.
T h e t i m i n g c h o i n h o s n o s l o c k o d i u s t e r( t e n -
sioner).A slock choin does not substontiolly
offect the volve geor occurocybut its operotion
i s n o i s y .T h e r e f o r ei t s c o r r e c t l e n g t h s h o u l d b e
e n s u r e de i t h e r
o ) b y s e l e c t i n go s u i t o b l ec h o i n f r o m o n u m b e r
o f c h o i n s o v o i l o b l e- t r y i t o n t h e t i m i n g
geors, o1r
b) by replocing the stondord comshoft geor
with on oversize geor (with greoter toler-
onces).The comshoft geors ore groded in
k e e p i n g w i t h t h e i r p r o g r e s s i v es i z e ( t o l -
e r o n c e s )i n t o c l o s s e sA , B o n d C . W i t h t h e
exception of closs A, the closs morking
l e t t e r so r e s t o m p e dn e x t t o t h e p u n c h m o r k .
For trying, the choin con be disconnected
t o o v o i d r e m o v i n go n d r e f i t t i n g o f t h e t i m i n g
g e o r s .T o r e c o u p l et h e c h o i n ,i n s e r tt h e c o u p l i n g
fromthe engine.
2 . W i t h d r o w t h e k e y f r o m t h e s h o f t o n d ,u s i n g
the drift MP 1-121,drive or press out the shoft.
Then lift owoy the housing plote from the
seoting foce of the pump.
3 . R e m o v et h e c i r c l i p l o c k i n g t h e o u t e r b o l l
beoring in position. Proceeding from the reor
s i d e o f t h e p u m p h o u s i n g ,d r i v e o u t t h e b o l l
b e o r i n g sw i t h t h e i r s p o c e rt u b e , o n d r e m o v et h e
r u b b e rs e o l i n gr r i n gf r o m t h e h o u s i n g .
Reossembly
1 . S m e o rt h e r u b b e rs e o l i n gr i n g w i t h g r e o s e
o n d i n s e r t i t i n t o t h e p u m p h o u s i n g .U s e t h e
M P 1 - 1 2 3d r i f t t o d r i v e h o m e t h e i n n e r b o l l
beoring (without sheet guord) pocked with
g r e o s e .W h e n o p p l y i n g t h e d r i f t , f i t i t s g u i d e
ring into the bore for the oute,rboll beoring.
2. Fit the gosket on the pump seoting foce
o n d p l o c et h e p u m p p l o t e w i t h i t s c e m e n t e d - o n
gosket (focing outwordsfrom the pump) over it.
F o s t e nt h e p l o t e t o t h e p u m p p r o v i s i o n o l l yw i t h Fig.2.1t
one bolt to prevent the gosket from being dom-
o g e d d u r i n g t h e f o l l o w i n g o s s e m b l yi o b s .
Insert the rubber seol, wosher,ond conicol 4. Fit t
spring into the speciol (bokelite) seolingring shoft ond
of the pocking glond. Instoll the spring with s t o l l i n gt h
its nose into the hole in the bokelitepocking. in positior
S l i p t h e o s s e m b l e dp o c k i n g g l o n d o n t h e s h o f t it with gre
with the spring toword the shoft geor,ond drive sheet guo
t h e s h o f t h o m e i n t o t h e p u m p b e o r i n g ,w h i l e 5. Top t
s u p p o r t i n gt h e b e o r i n gw i t h t h e M P 1 - 1 2 3d r i f t . lieve the r

52
 t9
' s 6 u l r o e qp a l l o l s u r1 s n !a q t
'rluPtzl
U ! J C I Z L - Ld t A l o s s e r l sa q l o ^ s l l ellqrvr'
-ilvL'Z'6lJ
6 u g s p s D u t . r o e gs u t o H 6 u 1 n t . r 6 - e l o ] u o l l c a J l pl D l x Ds l r u t u o q s e q 1 d o 1 ' g
'ap!slno (eco.r 3A!JPPu
11oq)p.ron6leaqs aq
sl.! q]lrvraluoq 6u1.rrooq eql a,^116'asDar6qtlm l! uDqs
'6u11c
pe4cod 6u1noq.ra1;odr1c.r1c sqt ql!tr,'uo;1;sod u1
q11m6u
6 u l r o e qe q l I c o l ' 6 u r : o a ql l D qr e t n oa q l 6 u ! l l o l s
-u! ro] CZL-L 6 u 1 16 u
d 4 l l r p a q l u r o 6 o e s n p u DU o q s
aq] uo eqnl .recodsEuuoaq llDq sqr rll 't loc!uo
's
-uop 6u
1}!J(lLZL.LdIA
6 u 1 s 6U o q S d L u n d1 n 6 6 u r n 1 . 1- 6Z l v L ' Z ' 6 t J q t r MA l l
'1r reno(
uo-Pel
eco; 6u
'6u1
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qllM P
llDq Ja
aql as
asoarb
eql s^o
iloq eq
IIIJQ ZZL-L dIN JosJ eq
6 u 1 s n s 6 u l m a g d u n 4 1 n 6 r6 u t n r : 6 - t I V L ' Z ' 6 l J llDq rel
eql uI
'lloqs a
6ugsn'
peAotx
uaqM p
eql ol
aq lllM
ltaq eq
q c ! q Ml
M e r n l D u o ! 1 c a g- d u n 6
0001Bl
6 u 1 s nA
'1nu Ia;
'i'
gogce
eugDu
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uDqsl
-cns eq
ol Je^
-a: 'too
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'Ae11nd aql ut
i o p l D e q l q l t M u o 1'1Alosnordru^te ll ! l c o l p u o dglceq
lleq eql aruoq do1 s]! u! Ia1 aq1 1;1
 6 . C o m p l e t et h e p u m p o s s e m b l yb y f i t t i n g t h e o r e o f d i f f e r e n t d i o m e t e r s ,t h e i n t o k e v o l v e s the cylin
Stoufferlubricotorfilled with the recommended b e i n g l o r g e r .O u t e r ( e x h o u s t ) p o r t s o r e s i n g l e , the oilwo
greose. o l l r e m o i n l n g o r e d o u b l e d , i . e . b i f u r c o t e do n d structed c
b r o n c h i n gt o t w o v o l v e s i n o d i o i n i n gc y l i n d e r s . Releos
The centre exhoust port bronches to the cyl. once odju
2.15 ROCKER SHAFT AND ROCKERS i n d e r sN o . 2 o n d 3 , t h e n e i g h b o u r i n gi n t o k e p o r t h e o d .l f n
to the cylinders No. 1 ond 2, ond No. 3 ond 4. the rocke
Assembly (on Skodo 105 engine) T h e c y l i n d e rh e o d c o n b e h o n d l e di n t h e c o r o s
o u n i t . O f t h e i n d i v i d u o li o b s , o n l y t h e r e p l o c e - 2. Swin
1. Instoll the lock ring, ploin wosher, ond ment of volve springs,cotters, ond cylinder down the
spring wosher on the ro6ker shoft with both h e o d b o l t s c o n b e c o r r i e do u t w i t h t h e e n g i n e porogroph
e n d s p l u g g e d .S m e o rt h e s h o f t w i t h o i l , f i t t h e i n . p o s i t i o ni n t h e c o r . F o r o l l t h e r e m o i n i n g opply the
rocker (with its orm with the thrust foce de- liminory o
i o b s ,t h e c y l i n d e rh e o d h o s t o b e r e m o v e df r o m
f l e c t e d t o w o r d t h e n e x t o s s e m b l e dp o r t s ) , t h e the cor. the sequ
shim, the rocker support, ond the other orm To remove the volve springs, screw out the (Fig. 2.16
deflected toword the support,i. e. the complete sporkingplugs ond, using o tommy bor with shoft supp
r o c k e ru n i t o f c y l i n d e r N o . 1 . o curved end (steel bor of obout 5 mm dio- 3. Adjus
2 . T h e n s l i p t h e s p r i n g , t h e r o c k e r ,t h e s u p - meter), broce the volve to prevent it from ter 2.13, re
port, the shim, ond the next rocker, i.e. the s l i d i n g d o w n i n t o t h e c o m b u s t i o nc h o m b e r . cleoner, re
c o m p l e t er o c k e r u n i t o f c y l i n d e r N o . 2 , o n t h e To RemoveCylinder Heod from Engine tighten oll
shoft.
3 . T h r e o do n t h e s p r i n g o n d , u s i n g t h e m i r r o r 1 . L e t t h e e n g i n e c o o l d o w n b e f o r er e m o v i n g Cylinder Hr
orrongement of the ossembled rocker units, t h e c y l i n d e r h e o d t o p r e c l u d ew o r p i n g o f i t s
i n s t o l l t h e r o c k e r u n i t s o f t h e r e m o i n i n gt w o beoring surfoce. Disosse
c y l i n d e r s .U s e o l o c k r i n g s u p p l e m e n t e dw i t h 2. Droin the coolontinto o cleon vessel(see heod on o r
o ploin ond o spring wosher to lock the os- C h o p t e r1 5 . 1 3 ) ,d e t o c h o l l p o r t s c o n n e c t i n gt h e o support i
s e m b l e dp o r t s i n p o s i t i o n . cylinder heod to the vehicle,ond remove oll it does not
T h e r o c k e rs u p p o r to f t h e c y l i n d e r N o . 4 m u s t p o r t s w h i c h o r e l i k e l y t o o b s t r u c tt h e r e m o v o l . o iob from t
be providedwith on oil hole to provide for the 3. Remove the oir cleoner, lift owoy the An exomple
s u p p l yo f o i l t o t h e r o c k e rs h o f t . c y l i n d e r h e o d c o v e r , o n d r e m o v et h e n u t s o n d
bolts holding down the cylinderheod (on en- 1. Remov
4 . C o m p r e s st h e s p r i n g sb y h o l d i n g d o w n t h e
gines of Skodo 120 L ond 120 LS cors, two the cosing
rocker orms ond lubricote oll loterol contoct
bolts olso hold down the end rocker shoft sup- control, end
s u r f o c e sw i t h o i l .
ports) reversingthe order of the numbers in- geor ofter
d i c o t e d i n F i g . 2 . 1 6 1 1B . y pulling the exhoust supports.
Assembly(on Skodo 120 L ond 120 LS engines)
m o n i f o l d ,d i s e n g o g et h e c y l i n d e r h e o d o n d l i f t
it owoy.
The rocker shoft is provided with two od-
d i t i o n o lr o c k e rs u p p o r t sf i t t e d f r o m t h e o u t s i d e To Refit Cylinder Heod on Engine
o f t h e r o c k e r u n i t s ( t h e s h o f t i s l o n g e r ) ,r e -
p l o c i n gw o s h e r so b u t t i n g o n t h e l o c k r i n g s . F o r . 1. Locote the cylinder heod gosket on o per-
f e c t l y c l e o n s u r f o c eo f t h e c y l i n d e rb l o c k ( c l e o n
t h e r e s t ,t h e o s s e m b l yi s i d e n t i c c lw i t h t h e p r o -
ceduredescribedin porogrophs1 to 4 obove.
NJote:Rocker orms on the Skodo 120 LS en-
g i n e o r e s h o r t e r ( 1 8 . 5m m ) t h o n t h o s e o n t h e
-120 -
Skodo L ond Skodo 105 engines, in order
(\-/3 r--{/\.4)
to obtoin o higherrotio.

Disossembly

R e m o v et h e l o c k r i n g f r o m t h e s h o f t e n d o n d
strike off the entire volve nockergeor from the
shoft.
?,3"'@-:lOt___v'
,/
/
\I
I

l
I
t l

I
I

2.16 CYLINDERHEAD, VALVES AND Fig.2Je

For holding c
SPRINGS bolt M 8 scr
rocker-shoft st
T h e c y l i n d e rh e o d i s o c o s t i n go f s p e c i o lg r e y F i 1 . 2 . 1 6 1 1T- i g h t e n i n gD i o g r o mo f C y l i n d e r
c o s t i r o n .T h e v o l v e s e o t s o n d g u i d e so r e c o s t Heod Bolts ond Nuts
o n d m o c h i n e dd i r e c t l vi n t l r e h e o d .T h e v o l v e s 1 - M P 1 - 1 1 3v
F o r t i g h t e n i n gt o r q u e ss e e C h o p t e r 1 . 8
2 - MP 1-114v
54
 99
'Zt qdDr6DrDd
rane; 6u1p!l e^lo^ VLL-Ldtl1-Z
't'Z .ra1doq3 ees - sulqs puD sJeLlsDM q]!M 8'L re
a 1 o ; d 6 u g l . r o d d n se n l o n S L L - Ld 4 - L
s11oq6u1sn sJe)cor qllm elelduoc Uorls Jelcor
eq] uMop lloq puo'1.roddns eql ul eloq aql pDoq aLll tuorl repur;{
otru! srrelue q16ue1lloq er!luo eLl] llll i11q611s tuLu gg er.uos6u1pn.r1odpuo lloddns UDqs-JalcoJ
'({lddns eql rol aloq eql u! uMop peMerss g l l iloq
l:oddns oql atolor lto rol oloq pelllrp D
qlgm {lqoralerd) }.roddns sq+ ut oloq aq} otul ILo;;;xno aql esn 'Je^al eql ur*op 6u;ploq roJ rr9 Io
r e q s D M L 1 l l r tltl o q e q l u e s u l ' l . r o d d n sU D q s - J e ) c o r s 6 u 1 . r d ga ^ l D n 6 u t t r t l e g - e l g L ' Z ' 6 l J
e q + o l 1 1 o 6 u ; p a e 1 A o r r r r l l oe q l ] o 1 u ; o d e q l u 1
pDeq repullio eqt uo 1a1so6 aqt ecold'g
'so^lDn eq1 uado o] suels a^iD^
e q l u o 6 u 1 1 ; . r 1 sr t q 6 u 1 1 c o 1 l c e J r o c . r o 1 s a 1 o 1 d
6 u 1 u g o 1 e r6 u 1 . r d sa q l l c s q c p u o e 1 o ; d y o d d n s
o r l l u l o r l p D e q r e p u ! 1 A ce q l e n o u r e i ' s 6 u r . r d s1 1 o
peull 6ugnog 'o^lDn aql uo peppeq Altcarroc
a^Dq selloq relloo eqt JeqleqM 6u;1ceqc ol!qM
{ 1 g n ; a r o c6 u g r d s e q t e s D a l e U ' a 1 o 1 d 6 u 1 u g o 1 a r
q c o e u ! s e ^ l D q J r a l l o ca ^ l D ^ o M l 1 n d p u o s 6 u l . r d s
a q ] s s e l d u o c ' r a n a 1e q 1 6 u 1 s 1 -'ll l o q o q l u o r e ^ o l
' , L L - Ld l ^ e L l l u M o p M e r c s p u D s a ^ l D ^ e q l r e ^ o
s e p l d 6 u 1 u 1 o 1 a rJ l a q ] q l l M s 6 u 1 . r d sd t t s ' l
'sburrdg an;en a;6urS uoagc)>1
Sl OZI LL6l o3urS. -:ed o uo
'alDld
l r o d d n s S L L - Ld 6 a q t u o s e A l D Ap o p l ] q l l r l t p D a q
rapugl{c eqt ecold '1sa1eDoloel oq} rsUV 't
'(sqdo.r6o.rod
'sl.roddns ]l!l PUDp
J e q u n l a q l e a s s . r l o d e :p u o ' 6 u 1 1 s e 1' u ; - 6 u ; p u 1 r D
lsnoqxe o
, r o ; ) e 6 o > 1 o a lr o l l o e q o p u D p D a q . r a p u 1 ; A ce q t Uot.1s-Jelcor eq} pelloqun 6ug,roq ra11oroe6 -u! sJequ
u ! u o q l l l l a r ' s l D o s u g - p u n o . r 6r l s r . l l q t l M s a ^ l o ^ J a l c o J e ^ l D Aa J r l u a a q l i o n r o 1 1 1 p 'loJluoo -dns goqs
1u D
e q l 6 u t q c l D 1 4' i 1 q 6 n o . r o q 1( s 1 r o de q l q l l M ) p D a q arnlorcdual c!lolsoLUraLllaql lo 6u1soc aqt o/!,\l 'sJDc
lapullAc aq1 puD so^lo^ eLll uoalc:6u!ltrtlor ' s p 1 o ; 1 u o reul D l u t p u D
l s n o q x ee q l e ^ o u e u ' l -ue uo) p
l c e r J o o J o l u r a q l l J D u r . r o . r a p . r og o u 1 6 ! J oJ l o q l u l PUDSlnu
e p l s D u a q ] 1 n d p u o u e l l l o A o u J a J' s a n l D ^ a l l ] u ! - ' l l g L ' Z' 6 l l u l u M o q s s r a l d u o x eu y eql ^DM
- p u n o l 6 6 u 1 n o qr e U V ' l D o s o q l q l ! M p o a q a ^ l D ^ 'rsquroqcuollsnquoc eq] 'lDAOIUo e
+o epls aqtruor; qo! o
eqt u!-pu!16 puo (punodtuoc) alsod 6u1pu;"16 6u1op uoqM slloq pnls aLll uo lseJ lou seopl! llD e^our
qtlm lDos o^lD^ aq] ]DoC 'sapln6 lca.uoc ,rgaq1 t D q l o s p o e q e q l e c o l d o 1 q c l q M u 1 p o d d n so eq1 6urlc
u! uaq] llDlsul ol arns aq 'se^lo^ pesn 6u9111;e"r o I D u o l e l q D s ! ^ p Ds ! l l ' q 3 u e ql r o M D u o p o s q ees) less
u a q M ' a p 1 n 6e ^ l D ^ a q l u ! e ^ l o ^ e q t l l D l s u l ' Z : a p u ; 1 A co q l e l q u e s s D o r p u D a l q u r a s s D s r C
' s : e d o . r c sp u D q J o ' l p r p
s 1 11 o 6 u
p u o q D u ; 6 u 1 d t u o 1 c. ! o l l u D q s D q ] ! M e d A l l s r p A;quressoslCpDeH repu;;,tg 6urnouer
a q l l o { 1 q o . r a 1 a . r'ds e q s n J q a . r g a n6 u 1 s n . r o ( : a . r n 1
- c D l n u D r ur o L l l l o s u o ! l c n r l s u l l u a u g l . r e da q l 6 u ! 'slulo! peua)cDls uelqDrl o
- n r a s q o ) s 1 u e 6 o l D c ! r u e q o q 1 1 ms l l s o d e p u o q r D c ;1o 'Jaqrr
puo 's1.rodpelcauuooslpllD tcauuoceJ'JouDelc
e l o u e u ' d o l u o s J a q r u D t l cu o r l s n q t u o c a q l q l l l n rD eql 'Jenoc pDeq repull{c aql l!}er 'tL'Z Jel LuoJ, +! lr
'6r3 ees)
Utg;Z Uoddns eql olu! poaq repur;[c -do,{C lad so eouDrDalca^lD^ aq} }snlpv .g -D!P tutlr I
pe:roder puD peuoe;c Al1ce;red eq] ocDld 'l q11r,rroq
'uog11sod ur lcol puo s1:oddnsUDqs
spto]luDl l puo pDoH repu;149 ;o rtlquressoay -raloor pauolcols eq1 ua1q61lau'(L/91'Z'6lJ) aql lno
.sapgn6r!aLl] ul uaql 6u!lll;e.r uollDJlsnll!eql u! pelDclpur acuanbaseql LuoJ' PaAO
uaqan dn uaql xlru ol lou sD os [!eq] )rrotr.tJo sl:osqo 6ulualq6!l lDurl sD llelvr sD fuou1ur; 6ulugoue
- r e p . r o1 o u 1 6 ! J oJ ! e q l u ! a p l s D s e ^ l D ^ e q l l n d -erd eql ro1 'enbrot 6utuetq6!]llnl aql llddo
a u l 6 u ee q
' e 1 o 1 d6 u 1 u 1 o 1 e6. ur 1 r d s u a q l ' I 1 1 q 6 ! lr u a q l u a 1 q 6 r 1p u o ( 6 2 q d o r D o r o d rapullAc
'g'7 raldoq3 eas) slnu puo slloq eqt uMop
eql uoJl so^lDrl Jslloc 3^lD^ Llloq MDrpql!nn -ecoldere
' 6 u ; . r d se ^ l D ^ o q l s s e r d u o c o l
l! esn puo'1.roddns MeJcs'spolqsndaq] olu! sre)oor aql 6u!ms 'z so Joc orll
UDqs-relcor aql uMop plaq Ilsnolne.rd q3!qM 'sl:oddns 't puD
't UDqs-ralcoraql t'o
lloq 3ql uo ra^al tLL-L dy\l aql uMop Marcs 1o 6u1ue1sol eql uesool os;o 'i.rosseoeu,l 'pDeq pod e>;o
'6u;.rds a q l 6 u l s o a l a i r a u o s r i e q u D L l 3u o ! l s n q oc u o
a q l u o J e l o o : s r l l l l D l s u rp u o ( l u e L u l s n l p a -1Acaqt o
-r.uoc o q l o l u ! u M o p 6 u l p g g st u o r + u a q l l u e n e r d -roolc a n l o n : o 1 ) s u r d 1 ; o qr a l 3 o l a q ] e s D e l e d 'srepul;[c
puo sellD^ eql l : o d d ns sJeq[lDLlo uo!]snquoc
'lcolq repu;1Icaql
lo llDMrDer eql uo pelcnlls puo pepc
eql otul 6u1pn.r1o.rd s u o ; 1 c a ! o . r ds l l ' t L L - L d l A -qo lou s! sJalcor eql ol ;to 6urpaa;[onn;goeql ' e 1 6 u ges
alogd Ouryoddns sql uo pDaq oql ecDld 'Z loql aJnselDu.rpuo (11ar*so pDeq repu!;lc aqr ss^lD^ el
 The rocker-shqft support hos o poper seol 3. To ensure o leokproof condition of the
preventing leokoge of the oil fed from the cyl- volves, grind them in with their seots in the
inder block to the rockers vio the support. lf cylinder heod.
o r e o d y - m o d e s e o l ( g o s k e t) i s n o t o v o i l o b l e ,
moke it yourself using poper 0.1 mm thick. Volve GuideS
A t h i c k e r s e o l i s u n p e r m i s s i b l eo s i t w o u l d The volve guides ore formed directly by the
couse c distortion of the rocker shoft. The hole cylinder heod motericl. lf reconditioning is
in the seol must coincide with the oil hole of n e c e s s q r y ,r e b o r e t h e g u i d e h o l e o n d p r e s s - f i t
the rocker. o bush.
Volve guide bushes ore not ovoiloble os
A p p l y t h e s e o l o n d r e fi t t h e e x h o u s t o n d i n -
s p o r r ep o r t s . T h e y c o n b e m o d e i n d i v i d u o l l y o c -
toke monifolds. For detoils see Chopter 2.3.
cording to the following drowing. The required
porogroph30.
moteriol is grey cost iron of 200 N/mmz (2O kpl
6. Reinstoll the thernrostotic temoeroture mm2) tensile strength, in Czechoslovokio cost
control cosing with its gosket ond do not forget iron to specificotionsof theCzechoslovokSton-
to put spring woshers under the nuts. dord CSN 422421.
Hoving press-fitted the bush, correct ony
N o t e : W h e n r e o s s e m b l i n gt h e c y l i n d e r h e q d shrinkoge of the inside diometer ond, to motch
of on engine removed from the cor, it is odvis- the new guides, rrecondition the volve seots
oble to proceedwith the iobs os per porogroph ond grind-in the volves.
5 ond 6 with the cylinder heod refitted on the
engine to focilitote the tosk. Valve guide tolerances
Fig.2.16
lf the cylinder heod gosket hos been reploced Guide 7.94 - HB + O.O22
mm
with o new one, invite the customerto bring in o.oo
the cor ofter trqvelling 500 to 1,000kilometres
l n l e tV a l v e 7 . 9 4- F 7 To Recon
for o retightening of the cylinder heod ond t 9 9?q .n-
odiusting of the volve cleoronce. + 0.013 These
volves fo
groph 3),
0.025 new volvt
Use o
conicol s
with its r
1. Che
necessory
volves. F
s h o n ko f ,
eter, ond
will resul
ing in oc
DK 1+J6 seot widtl
Check 1
F i 1 . 2 . 1 6 1-3 R e c o n d i t i o n i n gC y l i n d e rH e o d occordinq
f o r F i t t i n g V o l v e G u i d eB u s h Coot the"s
volve in tl
Seoling of Cylinder Heod troces of
centre of t
As o seporote unit or forming o unit with 2. Coot 1
the cylinder block, the cylinder heod must be volve with
seoled ogoinst leokogeof goses ond woter, i.e. of oil with
it must be gos- ond wotertight. volve into
1. When replocing some of the bolts pro- seot ond 1
truding into the woter iocket, seol them with severof tin
point. The woter iocket of the cylinder heod onother po
must be leckproof when tested with woter round the I
u n d e r c p r e s s u r eo f 0 . 5 M p o ( 5 k g / c m 2 ) . volve ond
2. lf it is necessory to restore the flotness grinding-in
o f t - h ec y l i n d e r h e o d m o t i n g s u r f o c e ,, e g i i n d t h e the volve c
s u r f c c e o n l y t o t h e l e o s t p o s s i b l e e x t e - n ts o o s x 1Tr9 grey. Use
n o t t o i n c r e o s e t h e e n g i n e c o m p r e s s i o nr o t i o . down the v
F i 1 . 2 . 1 6 1-4 V o l v e G u i d e B u s h

56
 L9
- 'u1-6u1pu;.rD 6u1.rnp e^lo^ aql uMop
Irrol uMop-ssard t
'eca1d pua - L
Jaqqnr- 7 '1-roddns 6u1p1oq.ro; dnc unncDl rsqqnr o esq 'Ie$ 6trrl ll
.r;y pessetdruo3 llnp urro,luno eq lsnu lDes oLll puD a^lo^ eql
qloq lo seco; 6u11oueql 'arnpaco.rd ur-Bugpu1r6
qlt/t^lssl e6o1oa1e^lon - UgL'z'6lJ eql lo sllnser sql Jo, l! lcadsul puo e^lD^
aql e^oural /!\oN 'acueJalunsrlc aAIDAeql punot
llD aJnpaco.rd s1q1loeder puD uo!l!sod .reqlouo
olu! punor a^lDAeql a^ou ueql 'sarrJllloJe^os
orl puo o1 11 6ugu.rnlAq u1 1g pu1.r6puD pes
s11lsugo6oe^lD^ erll sserd 'ep!n6 s11o1u1anlon
eql Uesu! puo ({reue po}ool} au!} q}tM lto lo
arnlxlru) punoduoc 6u1pu1.16 eu!] o qllM a^lD^
eql Io esDllns lDcluocoql ro lDes aql lDoc'z
'o^lDAaql
lo ocDlrnslDcluocaq] lo s4u3c
eql u! pecnpordel eq lsnur lDes aql lo socoJl
aql 'sIJDrulcoluoc ulDlqo o1 loes eql u! eAlD^
eql ls!lvr] puo lugod 6u1>;.rotu r.ll!Mloes aql tDoC
'poeq a^lD^ eql uo sIrDtx loDluoc o1 6ulp.rocco
lDes aql lo qrpl/v\ PUD relerilolp sql lcaqc
'sreilnc 6ug11gtu .raqlo6ugsnqlplM loes
eql ocnpar 'glgL'z'6ll qrtr,r acuopJoccou1 6ut
-peaco:d'MoN 'lDes eq1 6uguap!Mu! llnsor lllM
o Bulssalp slql 'lDas e^lo^ aql sse;p puo 'le1e
suoglo:adg;o acuenbes- rallnC 6ut11ty11 "ruolpenlo^ aLltro1 spuodsaxocqclqM lo luotls
6 u 1 s 1]'D
1 a S e ^ l o n 6 u r u o 1 1 1 p u o c-a9l 7 9 ; ' 7 ' 6 ; 1 'sellD^
aql 'Joqlo uD uo lellnc el6uo uD 1!l
aq] 6u;prn6 lceJJocD e:nsuo o1 'l:ossaceu
"fLr,e ' slo
e p g n Bs ^ l D ^ e q l r ! o d a r p u D '!
l! IOeqC
'e^lo^ anllcadse;sll qllm
u1-punor6oq louuDc lDos eql l! ocolJnslDcluoc
aql Du;uolllpuocel lol Jellnc 6u111tut D osn
'sepln6enlon 6u1uolltPuoca; JoUDJo 'sa^lD^Meu
6ulUt' ueqM 'ep!rvrool erD slDasaql ;1 '(g qdol6
-orod ees) 1se1aOolosl oql ssod ol llol sellon
eqr ll i.tosseceu etuoceq suo11o:adoesgql
so^lDn u!-Pu!19puD slDes e^lDn uolllPuocouol
uo!ltsod
rounC 6ut1tn - toes e^lDn 6uttltn - 9l9L'Z'6lJ
slDos a
qclDtuo
Iuo lce
-uDls lo/
]sDc DlI
Ft oa)
perlnbe
-co [g1
sD alq
11;-ss
s! 6u1
aql Iq I
,O6
'e6o1oe1rol eAlD^or.ll lcetlc puD 'polDJla eql
-ued enoq Aotu t! tlclqM u! sl.rod aql tuoll oslD at{i
punoduroc 6u1pug.16 eq1 elouel Alq6no:oq1
 2,15-2.'t8

3. The leokogetest should be corried out with h o n d l e )o n d t h e s h o r t o i l p u m P ,t o t h e c o s t o i l For eg

the cylinder heod fully ossembled by pouring s u m p t h e 3 3 0 m n - rl o n g d i p s t i c k o n d t h e l o n g e r s t r o i n e rv
o smoll quontity of petrol into the exhoust ond o i l p u m p - s e e C h o p t e r2 . 1 8 . brrocket r
intoke ports. The petrol must not leok post the 6 5 m m ) ,1
moting foce of the volve in the combustion (the len
chomber. Another method involves pouring 2 . 1 8 T I M I N G G E A R C O V E R. O I L P U M P proximot
o smoll omount of thin oil into the combustion The go
chomber ond introducing compressed oir into l n o d d i t i o nt o t i m i n g g e o r s ,t h e t i m i n g g e o r provides
t h e e x h o u s t o n d i n t o k e p o r t s u s i n g ,f o r e x o m p l e , c o v e r h o u s e s o l s o t h e o i l p u m p ( f o r mi n g i t s geors. lf
o rubber cone. No oir bubbles must oppeor h o u s i n g )o n d t h e d i s t r i b u t o rd r i v e . gosket is
oround the volve heods. thicker tl"
A g e n e r o ld e s c r i p t i o no f r e m o v i n gt h e t i m i n g
T h i s t e s t c o n b e s i m p l i fi e d b y o m i t t i n g t h e geor cover from the engine con be found in To pre
fitting of vclve springs while pressing the obnormo
C h o p t e r2 . 4 o n d f o r d e t o i l s ,r e g o r d i n gi t s f i t t i n g
volves into their seots by hond using o suitoble respectiv
o n t h e e n g i n e ,r e f e r t o C h o p t e r2 . 3 , p o r o g r o p h s
Jixture (fork) for holding down the volves. 22 to 25. limits sp
The enginewith the sheet oil sump hos the
Volves shorter oil pump with the suction stroiner
h o l d e r7 2 m m l o n g .T h e e n g i n ew i t h t h e c o s t o i l
The volves ore forgings of speciol high-tem-
s u m p h o s t h e p u m p3 0 m m l o n g e r .
peroture steel with o conicol seoling surfoce
o n d h o , r d e n e ds t e m e n d . T h e v o l v e h e o d s o r e
of unequol diometers (lorger with intoke volves A s s e m b l i n gO i l P u m p
o n d s m o l l e rw i t h e x h o u s tv o l v e s ) .
Current reconditioning of the conicol seoling C o o t t h e p u m pg e o r so n d t h e d r i v e g e o ' rs h o f t Betwee
w i t h o i l , o n d i n s t o l lt h e m i n t o t h e t i m i n g g e o r
surfoce is done by grinding-in with the respect- I d r iivveenn
ive seot. lf o mojor repoir is required, regrind cover. Insert the gosket ond close the pump
the seoling surfoce of the volve heod on w i t h t h e l i d w i t h s u c t i o np i p e o n d s t r o i n e r .U s e I Axiolc
o grinding mochine to on ongle of 91o +10', spring woshers to prevent the lid screws from I betwee
ond then grind it in with the seot. s l c r c k einn g . I and lid
When regrinding the conicol surfoce, it is
obsolutely essentiol to keep it in correct olign- Seol
ment with the volve stem.
Fi t t h e
Valve Springs rcs/po 1201S
t i gh t en i n
thot it pr
Outer Inner edge of tl
Free Length 45.85 43.6 45.20
Assembli
Wire 3.75 2.5 4.OO
Diameter 1. Thre
brocket, s
Mean Spring 26.75 18.5 26.5
urameter p o i n t i n gr
T odio.4
S p r i n g P r e s - L""En-I Length Length
sure
in the pr
3Omm 30mm 29mm
In s t a l e d 2 9 9 - 3 5 8N 108-127N460N bore (pin
length the pinne
When c
2.17 OIL SUMP sure thot
line with
A s h e e t o i l s u m p i s u s e d o n e n g i n e sw i t h is import
o 68 mm cylinder bore. Use o rubber gosket i g n i t i o nd
w h e n i n s t o l l i n gt h e o i l s u m po n t h e e n g i n e . To prev
E n g i n e sw i t h o c y l i n d e r b o r e o f 7 2 m m h o v e ing durin
o c o s t o n d r i b b e do i l s u m p .F o r i t s i n s t o l l o t i o n o pilot m<
u s e i t s r e s p e c t i v ec o r k g o s k e t . A s h e e t b o f f l e Then con
i s b o l t e d o v e r t h e b o t t o m o f t h e o i l s u m p .U s e u s i n go s
b o l t s w i t h s p r i n g w o s h e r st o b o l t i t d o w n . F i 1 . 2 . 1 8 1 1T- i m i n g G e o r C o v e rA s s e m b l y- 2. After
R e l o t i o nb e t w e e no i l s u m p ,o i l d i p s t i c k ,o n d S e c t i o n o lV i e w ensure tl'
oil pump: 0.1mm) I
( f o r b e t t e r i l l u s t r o t i o n ,t h e p i n n e d c o n n e c t i o n 3. Fit t
T o t h e s h e e to i l s u m po p p e r t o i n st h e d i s p s t i c k of the shoft ond geor is somewhot turned, its into the f
of o totol length of 305 mm (including its correct position being describedin the text) u n d e rt h e

58
 69
' J e u o e l sJ l o e q l r s p u n ' s p o e qM e r J Sa q ] J e p u n
(lxeg
e l o l l e q l q o n o r q l p e l u e ^ u | D D Ds r l e q u o q c t o o l j sJaqsDM6u1.rds 6u1sn:anoc loe6 6uru11eql olul sl! 'pou
e q l P U Ds e s o l c e ^ l o ^ 6 u l l u a ^ - J l D e q l , s e e J 6 s p g L 1a1so6sll r{l!M alelduoc }a)corq eq} ilJ 't uo!lcou
'UDqs eql puD .roa6aql ueeMteq (,utu
q6norql I a6Dls lo lslp elllorqt eqt lo 6uruado l'0
aLl] rV'e:eqdsotulo eq] olu! JequtDqc tool+ tnoqo) ocuoJDelc lDrxD urnuJ!u!ureql eJnsue
at{} uroJl sedocse Jlo puD enlon 6u11ua^-lD eq} o l l l o q s a ^ l r p o q ] u o d o 1 ' 6 u ; u u 1 dr e l l v ' Z - Alg
suedo a6olene; o '1 e6o1s lo lslp aluorql eql ' a r n l x l l e l q D l l n so 6 u r s n
; o 6 u r s o g cs q l J o U V
' J e u D e l cJ t D
eql lepun ro^oc Alquesso percdard snql eql sse.rduoc uaql
aql u! aloq enllcedse.r aql qOno.rq] lequDqc ' l o l c D J qa q l o l u ! p a l r e s u re q o l
l a j p u D r rl jo l ! d D
lool' sr.ll r.uol1sadocsa JtV 'pautDUD st la^al a l D r l r o l o l q o s r ^ p Ds ! l ! ' 6 ur 1 1 1 . r6pu r r n p 6 u 1
p a 1 ; g c e d sa q l u e q M e ^ l D A e t p e a u o q } s a s o l O -6uoqc uror] uolysod palsnlpo aq1 luanardo1
qclqm looll ot{} Aq 1q6req auDs eql }D paurol ' r o l n q ! r l s r pu o 1 1 ; u 6 ;
-ulouJ s! 'JequDqc oql jo requnt Auo ro1 luol.rodrursr
le^al sl! eJaH lDoll eql olul luarulsnlpo
'lols poeq
e^lD^ elpeeu eql puD JeulDrls len' aq1 q6norql ll u o r . l se q l l o s ! x D e q ] q ] ! M e u r l
sessod renoc eql qDno.rqt pallddns lenJ ug s1 rcaD aql ul saroq eq+ Io slxD eql lDql erns
a q : a q 1 e 6 o l l o q s p u o r o e 6 e q l 6 u l l l r r pu e q g
'uo!]ceuuocpauurdaql
Grc;Z p u o L 1 6 L ' Z' s O t J ) r e q u r o r l C l D o l J
e r ' n c e so l 1 q o u l l c p u D ( O Z x V ' o r p u r d ) a r o q
'se6o1s qloq eq] olul u1d o U a s u l
' s e l o r l p a l l l r p e r de q ] u l
lo sauoc Jezruroloaql ' l l t r p ' D ! pD
; o s 1 . r o dl s e m o r r D u e q l u o r l s 1 a ! r 1 o I q p a ; 1 d d n s U D q s p u D . r o e 6e q l r e q t a B o ll l l r p t
a.lnssard:epun Iq pelDnlco ur6otqdolp eql lq 6 u 1 s n' p u o ' l e ) c D r qe q l u o J l s p J D M t n o 6uglurod
palloJluoc JeqUnl puD pelcolun {lgocguor.loaur qlaal oql qlgrt .roe6uJoM aql uo drls 'le)corq
s ! l l u o 1 1 ; s o dq c t q M u t ' s a e l 6 a p g y q 6 n o r q r r o l n q r r l s ! pa q l o l u ! u D q s e q t p D e r q l ' L
pauedo soq I e6o1s lo a^lD^ aluorql oql rellD
lelcorg rolnq!rls!6 6u;lquessy
6 u 1 1 o . r e dsou D l s l t ' u n J a l p r A : o r p x n o ; o u r e l s i s ' o
puo 'ualsls ssod-Aqo '6urpoo; aul6ua .raq6rq 'aroq eq]
1o e6pa
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o s p u D r a ^ o c e q l a p l s u l p e u r n l u 1 16 u ; u e 1 q 6 1 1
'6;1)
{vrc;z lr e6o1g sl! rlllM eJoqesol luort aql lo loas eql llj
'pool lDes
eul6ue lln, Jol aJnlxrul eql lo 6urqcuua eLll sD
l l e M s D 6 u 1 p o o 1a u l 6 u e e q t j o u o d l o a . r 6 D p u D Pll puD
'uollDJelecco'6u11p1
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l u a J a l l l pI l u o a n o q A a q l ' s l e p o u rr D c l D n p t ^ t p u l : e l q o l 6 u l r v r o 1 1 oa;q ] u l p a l 1 1 c e d ss l ; t u 1 1
aql Jol pasn o:o sadAl .rollaJnqJDc e[!DS eq1 a q ] u l r , l l l l v r1 d a 1 e q l s n u r s a c u o : o a 1 c a n t l c a d s e . r sqdo.r6o
'sl!ur 6utrrtl st
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pepueuruoceJeql o1 elqolsnlpo s! lueluoc epr ol enp a:nsse.rd llo lo ssol D apnlcard o1 u! puno
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L'0 uoql Jals!rll
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's.roa6 s 1 16 u 1
l q l l g o c r l o u o l n Dp e l l o r l u o o s r 1 ; e 6 o 1 s' ; o p a d eulnue6 ou puD pacolda: aq ol soq 1r 1g
JoloJalecooeqr lq pellorluoc s! unr eu16ue aql I o eouDrDalc 1 o 1 x op a : 1 n b a Je q l l o ; s a p l , r o l d .roe66u
olsDqeql :o1 I e6o1g 'se6ols oMl Jo 6u11s1suoc s.roe6durnd eql ,o pll eql repun 1e1so6 aq1
adll lq6noJp-uMopeql lo s! rollernqroc eLlI '(A1a1ou1xo:d
- d o r u r . ug g ; 6 u g a q l a I O D . r q a q l , o q 1 6 u a 1 e q 1 ) dNn
'(tuttt gg
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euos s! Uod e:luec sll u! PolnsDeul lalsoiq
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6t'?-9t'z
 Technical Description
Carburettortype and model
Car Model 1976/1979 1979 onwards*
105 S and105 L JlKOV32EDSR- 443751290 100 JlKOV32EDSR- 443751 292400
120 L JrKOV32EDSR- 443751319 800 JlKOV32EDSR- 443751 292500
120 LS J|KOV32EDSR- 443751290000 J|KOVg2EnFF- 443751 292600
Types of carburettors and their functional elements according to the,polex cdnparison table or to
their bore (in millimetres) ; 1

' l2OLs:
Carmodel 1 0 5 S 1, O 5 L itZOr-
Carburettortype and model Se.Babove
E l e m e n t so f s t a g e I a n d l l o r i n c o m m o n Fge
1 2 t 2 1 2

A t o m i z e rc o n e d i a m e t e r 21 22 22 23 ' . 122
12/110* 23
Main petroljet 105 120 1 1 2 / 11 0 * 125 130/125*
Main airjet 170 160 170 160 170 160
P i l o tj e t 50 45 50 45 50 45
P i l o ta i r j e t 140 140 140
A u x i l i a r yp i l o t j e t Jo Jo 60
Econostatpetrol jet 60 60 70
Econostatmixture jet 95/85' 110 1'to
Econostatair jet 70 70 70
Choke petrol jet 90 100/90* 1Orygo*
C h o k ea i r j e t d i a m e t e r 4.5/5.5* 4.5/5.5' *erF 4.5/5.s*
Diaphragmcontrol air valve 130 80 160 or"fs? . 8 0
Pump by-pass orifice 40/45* 40/45* ,.w'1' 40/45*
Injector 50 50 50
N e e d l ev a l v e d i a m e t e r 1.5 1,5 1.5
S u c t i o nc o n n e c t i o nd i a m e t e r 1.2 1.2 1.2
A c c e l e r a t i o np u m p d i s c h a r g e 7 to 9 c.c. per 1O strokes(1976-79)6 to 8.$19f9 onwards)
Float weight 2O t 1 gram Fuellevel.FloatRemoved.'28mm t'1mm frEmbp face

Moin System (Fig. 2.1gl1l interferencewith the smooth flow ot o hlgtler

Both mixing chombers hove self-contoined
moin systems.Air is mixed with petrol in the
emulsion tube ond the finol odiustment of the
mixture tokes ploce while it is corried off by
the oir flow with the throttle disc open.
ldle Run ond By-poss System
(Fis.2.19l2l
These ore token core of by two circuits - by
the idle run system in stoge I ond the ouxiliory
oir system in stoge ll. Both systems ore con-
nected to the moin systems of both stoges in
the zone of the emulsion orifice by the re-
spectiveelementsterminoted by the odiustoble
idling screw ond fost-idling (ouxiltory oir)
screw.
- Stoge I incorporotes the petrol iet seporotor
for the preventionof self-ignition.The idling ori-
fice is interconnectedwith the mixing chomber
by two by-poss bolts enobling c smboth tron-
sition to the moin system, ond o hole is pro-
vided in the mixing chomber to obviote ony
u n d e r p r e s s u r(ev o c u u m ) . .
ln stoge ll, the by-poss hole enhonces
o smooth ond continuous intgrconnection of
both corburettor stoges.
Econostot or rich-mixture syste4 (Fig. 2.19/3)
This system enriches the mixture in stoge I
ot higher engine lood (output). lt operotes
outomoticollyoccording to the volue of under',
pressurein the otomizer ond in dependence onf
the flow of oir sucked-inby the engine.
AccelerqtionpumP (Fig. 2.19i5)
This is o mechonicol, diophrogm-typePumP
controlled by the throttle disc of stoge l. Fuel
sucked-in by the diophrogm from the floot
chomber posses through o non'return boll volve
to the iniector ond through the by'poss orifice
bock into the floot chomber. At o sudden open-
ing of the throttle disc, the moior part of the
fuel poses through the iniector, ot o slow
opening into the by-poss without the oction
of the iniector.

60
 llr-
&
t9
w tolld -vLL 't o6Dls lo re! lolld - LL 'te! rlD
ll puDI e6ols rouarnqroc - Isz puo - 0L 'Mercs uo!]ceJroc6u;lp1-1sol- Merss 6ulu
'rolorDdas
lS L (1;) le! rolld - 9e 'lt e6o1s1o1e! -n6eJ alnlxlLu-rlclu - 6 '/v\ejcs uollcejrcc.tty i
Luelslsunu alpl - Z16L'Z'6tJ
n,4"
- 'll e6Dls
ll puo I a6Dls rollarnqroS - ls z puD v lo eqnl uolslnut3- ve 'l
'Je^oc orll eql lepun uolslntrJ3
ls L lo euDld Jall^ol le^sl lo oqn] -t '1; e6o1slo 10! rlo
'uollceuuoc -VZ 'l e6ols
lenl to rqoloq : L + 0z lolu! lonJ lo la! rlD ulDW- Z '!l e6Dlslo
- I " e u l o J l s l o n J - I ' o A l D A e l p a e N- g ' l D o l J 'l e6Dls
lorlod utow - VL lo lo! lorlad uloytl
requoqC polJ puD ruels{S ulDt4 - LIBL'Z'6lJ
Choke - Cold-stortingDevice (Fig.2.1916) c r o n k c o s ed u r i n g i d l e r u n o n d i t r e m o v e sf o r
burning ony residuesof unburnt hydrocorbons
Bosicolly,the choke is o self-contoinedcor- which hove got into the cronkcose.
burettor consisting of o fuel reservoir,o petrol
jet, on oir iet, o vocuumcontroller,ond o throttle
volve. The mixture is formed in the throttle
volve zone where it is sucked out from under
the corburettorthrottle disc.
At increosingengine speed,the rising vocuum
movesthe plungerof the chokevocuumcontrol,
t h e h o l e s i n t h e p l u n g e ro v e r l o p o n d t h u s t h e
mixture is enriched outomoticclly.The driver
controls the richnessof the mixture by opening
or closing the choke throttle volve.

Auxiliory Devices

Vqcuum connection for the vocuum odvonce

control picks up vocuum (the underpressure)
obovethe throttling disc of stoge | (see Fig.
2.1st4).

The suction connecticri is led out of the cor-

burettor lower flonge os o tube from under the Fi1.2.1913- Econostot- Rich-mixtureSystem Fig.2
throttle disc of stoge ll. The suction prevents 13 - Econostotoir iet, 14 - Econostotpetrol iet,
o generotionof vocuum (underpressure)in the 15 - Econostotmixture iet "2" 23- Inie
p u m p ,c (
Acceler
v e n t in g

i:lr

I
32 and3
30 - Chol
Choke vr
volve

CARBUR
Fi1.2.1914 - StogeI Control Elements AND RE'
16 - Ffoot chomber cover, 17 - Floot chomber control oir volve - sttfge l, 22- Vocuum con- Diogno
body, 18 - Stoge ll control, complete, 19 - Dio- nection, 1 ST ond 2 ST - Corburettor stoge I rect chec
phrogm spring, 20 - Diophrogm,21- Diophrogm ond ll reossem
control oir volve - stoge ll, 21A - Diophrogm

62
 Y
t9
'o poJ D lJesu! ol Pepueuuocel sl r!) tuu 0L eq A ; u op u n o ; e q u D c l u a u d l n b e q c n g ' A l q u e s s o e r
looll eql +o d;; eq1 ueem r l e q l p u D s l . t o d . t o u a r n q r D c ; o6 u t l c a q o l c e l
lsnu lelsD6 ",,1tpuD'l;;oc11:an
-loq I e6o1
ocuoJDelc sql Jeloc aql ocDld -roc D ro; pel;nbe.rs1 luaurdlnbe c1lsou6og6 -uoc rui
'looll eql
1sn!po ueq] puD uollcnrlsu! sno
-1ne.rdoql ol 6ulp.roccoJeloc aql enouer lsJ!l Al8l !3SSV3UCNV
AISWf SSVSIO UOi.rsUnsUVC
lo^e'l lenJ 1snlpy o1
sAlD^
'erqlsseccD
s!
dll? elllorql - tt 'le! llo eloqc - gg 'en1or eloqc
e^lD^elpaaueqrmotfffuf{a6u;qslt }nopaqsnd - 79 '(.renocu1) ad;d o)toqC- L0 ']al sloqC -0t
Dugnoq reUD :a,roc dQi tuorl lDol, eq1 lorrto
'dous ol ']e>l u a l lt t p u e z e
6 t 6 ! r a q o l c o a c u t sp e l e l o p s L'Z
ll!'l ldo s! 1a1so6 elll eslMraqlo r.ualsAgaloq3 - 916L '6tJ
-so6 aq1 qlgrnt.req1a6ol reloc eql e^oual ol Inl
egttv0
- s r o c s g ' J s n o c e q l A o n r r oU l l p u o J e n o c e q ] u o l ,
I 1e 6 o 1 sJ o l l e J n q r D ca q l l o s l o r l u o o e q l e ^ o u l e u
le{sog JeAoC ;o luerueco;dag
'e^lD^ alpaeu eql -
lo lueruecoldar D rsUD lDol,
eql - la^el lenl eql lsnlpo o1 1a6Jo; ra^eN
'qdo.r6o:od 6 u 1 r r r o 1 1 a
o ql ol raler
1
-euo lv\3u D
JoAOCJollgJnqjos eql lo lD^otuel Jol
q l ! r l r ra ^ l D ^ 6 u r 1 o a 1o e c o l d e g ' p e n o u e r r o u D e l c
A11cel.rad eq lsnu lelur eLll u! Jeulorls lenl eql
' 6 u l l n s o e u l 6 u 1 . r n 6' s p u o o e s g . r a d ( 7 u c 7 6 > t
S OO )
Dd4 6t00'0 s! luaunrlsul 6ulrnsoau eql ]o uollD
- ! ^ a p o l q l s s l t u r a d y ' ( 7 u c 7 6 1 6 t ' 0 ) D d U 1 18 t 0 ' O
; o a l n s s e : d : o p u n u o u r D l u r D u rl s n t x a A I D Ae q l
e^lon elpeeN lo ssauloo.td>;na1
'lugl'u
-slour qlootus Jloql eJnsue o1 aptqd;nslp unugp 'a^lo^ 6u11uen
lDes e^lDn - 6Z
- q A l o t u l o s r s D q a q l u o p u n o d u o c 6 u 1 1 o c 1 L q no1 -J!V - 8Z 'ruoc 6u11on1codurnd uollDJeleccv
- 'eclttJo ssod-Aq dun4 - 'a1e;duoc'dund
q1;lrr s1.rod Jol!ru!s puD srelal lo sDsJo uo!] LZ 97
-c!Jl aq] lDoc 'rolleJnqJDceql eP!su! slueusle uollDraleccy- gZ 'Mercs dolS - y7 '.ro1ce!u1 - 97
'1e!
lDuollcunl o1 se;1ddo eulos aql'J!D pessard 6 u 1 1 u e nr l v r e q u o q C ;or1
-r.Iloc ql!/v\ Jlo Molq puD lol1ed qt!M acDlrns
l o o l J p u D d u n 6 u o t l o r a l e c c v- 9 / 6 1 ' Z ' 6 l l uelsrtg
sll uDelc'JolleJnqroc eqt 6u!1puoU arolaB
'(g'gg raldorlc)
lueLu
-gsnlpo unr elpr o!sDq eql Aq pepnlcuoc slonn
-lD aq plnoqs Aeqt puo 'suollcesqns 6uglrro;1o;
aql u! paq;:csap sqol epnlcu! Plnoqs sl33q3
l D n p ! ^ r p u r p u D u o l l c a d s u l p e l ! o t e p V '(tq' 9 1
.reldoqg u! peqlrcsap sl 'unr elp! ]o luelu1sn!
- p D c l s D q p u o ' D u g l s n l p ou n l e l p t ' J e u l D J l sl e n ]
a q l l o 6 u 1 u o a ; c' e ' ! ' e c u D u e l u ! D t ue u ; 1 n o y ( o
ecuDuelu!DW
sl lSrs^s 'lvNolrcNnJ Jo
IN:lWrSnfCV CNV 3CNVNAIN|VI l
'DqDJd'uo11o:odroC epoJj u61eto3491
-OIOIA eqt Aq .ro (ac1nolgpngglsaQ 'uo11o.tod
-roC lDuollDN UO1OU1;) leln1co;nuDurrolleJnq
-Joc eql iqs uo;1crulsu!]uaull:ad qtlrvr.req1a6ol
pera^!lep ueeq sDq lueudlnbe s!ql qc!qM ol suoqJDc
'sdoqs :1ode.r JOI SoAO
puDsuo!lols ec!^respazl;olcadsu;
 1. Excessi
rrr) - overfloc
//"\
'// o) leoky n
\
/\\
-.--- b) too hig
- incorrec
c) too lorg
d) too sm
I
(
I
V,I \trV e) oir-ven

2. lncorrec
- engine
o) choked

b ) choked

c) i ncorrec
d) defectiv
- errotic i
Fi1.2.1917- F l o o t A d j u s t i n gb y B e n d i n g F i g . 2 . 1 9 / 8- A d j u s t i n gT h r o t t l e D i s c s U s i n g e) portioll
the Lip of the Floot Honger MP 1-120'lndicotor
f) folse oi

10 mm in diometer between the gosket ond the it down till the pointer of the diol indicotor s ) l ncorrec
floot). The lip must lightly touch the spring- touches the disc. Zero the scole ond rotote the h ) too low
l o o d e db o l l i n t h e n e e d l ev o l v e . T h e l i p m u s t reguloting (odiusting) screw while forcing
not press- in the boll or move owoy from it. down the indicotor till the throttle disc porti' 3. lncorrec
T h e d o s h e dl i n e s s h o w t h e f l o o t i n i t s l o w e r olly opens (3 mm from the edge of the throttle o ) i ncorrec
position. d i s c ) o n d t h e i n d i c o t o rr e o d s 0 . 1 0 t o 0 . 1 2 m m . b ) i ncorrec
Proceed in the some woy to odiust the other
Petrol and Air Jets throttle disc. c) choked
C l e o nt h e m b y s w i l l i n g i n p e t r o lo n d b l o w i n g Setting ldle Run Adiusting Screws 4- Poor occ
t h o u g h w i t h c o m p r e s s e do i r . W h e n r e m o v i n g
A f t e r o d i s m o n t l i n g ,e t c . , s e t t h e s c r e w s i n o ) choked
t h e m , n o t e t h e i r l o c o t i o nt o f o c i l i t o t e r e i n s t o l -
t h e i r b o s i cp o s i t i o n ss o t h o t t h e e n g i n ec o n b e b ) leokyno
l o t i o n i n t h e i r p r o p e rp l o c e s .
storted up ond be kept running. c ) defectiv
Volume Iniected by Accelerotion Pump o) Rotote the oir correctionscrew (Fig. 14.3/9) 5 . Loss of p
ond Pump Hondling four times through 180" to closed position. stoge | |
Fill the corburettorwith fuel ond operotethe b) Rotote the idle run odiusting screw (Fig. o ) choked,
corburettorlever10 times through its full stroke 15.3/10)five times through 180oto closed b ) domoge
to iniet fuel. Operote the lever ot intervols of position.
3 to 4 secondsond cotch the fuel into o grodu- i ncorrec
Do not tighten the screws forcefully in their
o t e d v e s s e l . T h e i n i e c t e do m o u n t s h o u l d b e 7
to 9. c. c. lf necessory,deflect the injector so
thot the iet of fuel posses directly through the
c l o s e d p o s i t i o n s .T h e y m u s t b e o r o g o i n s t t h e i r
s e o t si u s t l i g h t l y s o o s n o t t o f o u l t h e m . ;i ostoge ||
mutuoll
ndll in
c h o m b e ro n d d o e s n o t f l o w d o w n i t s w o l l s . Testing the Operotion of Pilot Jet Seporotor 6. Engine w
When refitting the occelerotionpump cover, The pilot jet operotes correctly if switching
prelood the diophrogm by opening the throttle storting
on ond off of the current fed to the seporotor
disk of stoge I to its full stroke before retight- (by switching on the ignition,etc.) is moni- o ) choked <
ening the cover copscrews. fested by oudible clicks. The seporotorcloses b ) low fuel
the pilot iet when the current is switched off c ) i ncorrec
To Adiust Throttle Discs ( s w i t c h e do f f i g n i t i o n ) . (excess
Turn over the corburettor with the throttle o) lf no ner
discs on top ond loosen the reguloting screws Corburettor Defects ond Their Removol
hold the
in the flongetill the throttle discs ore fully Notice: Turn your ottention to the corburettor connecte
c l o s e d . P l o c e t h e i n d i c o t o r M P 1 - 1 2 8o n t h e o f t e r h o v i n g o s c e r t o i n e dt h o t t h e e n g i n e ,f u e l emergen(
flonge necr one of tlre throttle discs ond force supply, ond ignition operote correctly.

64
#
 99
'itllcelloc
'olnsDeul fuorodural puo Acue6.raua 'eu
lan;
u D s o p e J e p l s u o o ' J e A e M o q ' e q p l n o q s a l n p a c o . t ds l q I ' l t n c l l o - U o q s o 1 s u 1 o 6 oa l q D c P e l c e u u o c rollarnqJ
. s ! p e q l l c a l o r d ' 1 n u 6 u 1 s o 1 c a l p e e u o q l l l o M e r c s p u D l n u e l q n o p a q l A q . r o 1 o : o d a se q l p l o t i
,aiiread eql 6ugiotuer ueq6'l! llDlsular puD elpoeu sl! e^oruer
' a 1 q o ; 1 o n os 1 . t o l o : o d a s l l , r o uo u
ll (,, l
( c s 1 pa ; 1 1 o . r qp]e u a d oA q a n l s s e c x e )
unr olp! Aglcar.roc u n r a l p t p e l s n i p o, { l l c a r o c u g( c llo Paq
lsnlpo - sesolc J
looll eql lsn!Po raqrxoqclDoll ul ie^el lenl /r\ol (q - ! u D u Js
auo Meu o qllM 1gacolda.rlo 1a! aq1 uoalc 1a! a>1oqc lcarrocut ro PeIoLls(o
.rolorod
a u 1 6 u ep g o c6 u 1 1 . r o -1 s 6utqcl!t
'9
uDls lou !|1rrtau16u3 rolDJ
slueu.tela anlloelap.rosa6ols qloq ul ll puo '
sluaurale lcelJoc llDlstl! 1 e 6 o 1 sl o s l u e u J e l ep a 6 u o q c . r a 1Au l 1 o n 1 n u( p
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l;1ca.r:oc1sn!po r t t e r c s 6 u 1 1 p 1 - 1 s op1a l s n l p o A l l c a : : o c u l ( c
J!D
pesserduoc Llllm saclllro eql q6no:q1 rvro;q unr elpl lo seclllro Palor.{c(q
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ureql aco1dal puo 'ueql lceqc PUD uoolc sta! rottd peloqc
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seuo lceJloc tlllM eco;del PUD lceqc sla! ulotu a6.ro1oo1
slel 1o sezts lcelJoou! I
looll eql tsnlPo la^el lenl q6rq oo1 ( q
euo Meu D
qlllrr ecolde: Jo 'uDe;c
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lceqc
rollernqloc 1o Du;pooglJelo*
'L
uolldurnsuoC lenl e^lssocxf
d ) choke plunger sticking in its bottom
position
storting worm engine
e ) too high fuel level in floot chomber
f ) incorrectlyodiusted idle run
2.2O FUEL PUMP
Technicol DescriPtion
The model JIKOV MF 3407 fuel pump is of
the diophrogmond lever type, controlledby 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
p r i m i n g o f t h e f u e l . T h e m o v i n g m e c h o n i s mi s
l u b r i c o t e dw i t h o i l s p l o s h e df r o m t h e c y l i n d e r
block.
S t r o k eo f t h e d r i v i n g d i s k
Suction heod
Deliveryheod.
Pump dischorge ot 2,000 strokes
per minute ond free outflowwithout
counter-pressure
Mointenonce, Repoirs, Disossembly
ond Reossembly
For routine mointenonce (cleoning of the
mud-tropscreen) see Chopter 15.3.After hoving
operoted the hond-priming lever lift it till it
engogessofely in its locked position.
ln the cose of o defect,inspectthe diophrogm
ond check the volves for leokoge.After hoving
removedthe pump from the engine, removethe
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'
pressedoir. Reploce domoged ports with new
ones.
lf necessory,removethe diophrogmfrom the
octuoting lever in the lower port of the fuel
pump (its monufocturerrecommendsthe dio-
phrogm to be reploced ofter obout 50,000 kilo-
rnetreswith o new one). Do not stretch the
spring of the diophrogm ond do not olter its
compressionforce chorocteristicin ony woy.
Do not forget to put fibre pocking rings under
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
unstick the plunger or reploce it with
o new one
o d j u s tt h e f l o o t
odiust idle run correctlY
the volves when reossemblingthe fuel PumP.
Put o spocerring 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 compressthe 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
4 mm
viewing the pump from obove ond the fostening
1.5 mm
flonge from the front. Use spring woshers
2mm
u n d e rt h e c l o m p i n g b o l t s .
30 ltrs/hr.
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 pressureof 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.
cleon it
reploce it with o new one
wosh them in petrol, reploce defective
volves with new ones
66
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t; ,t

F i g . 3 1 1 - C l r r t c l r- S e c t i o n c r V
l iew

Alternative Diaphram Clutch available,

Center Plate,Bearingand arm of LP type.

68
 69
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+! puo qclnlc aql ,o [;quesso eq] ro] pesn ueeq sJeAel
lou sDLl 601-Z dtA e1o1d IlqLuassD aq] +l 't e s D e l o Uq c l n l C r o 1 d 1 1 3 l : o d d n g LIL't,'6!J
'ssn ejnln]
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r o p u n u o . r 4 s d g l c 6 u 1 l . r o d d n sa q l M o r p q l l r , l . 1 . Z
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lo opls aql uroJl a u r 6 u a e q l ) l e e q n n A 1p1u o q c l n l o a q l , o u o g l l s o d
e q l o l u l e s o e r F e c J o J ' l l D q s ) u D J ca q l u l 6 u u o a q e ^ r l D l s r a q l ) r D r u o l 6 u r . r . r o a 6 l e e q n n A l ;e q t p u o
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u e q m A 1 1 u n 1 . r o d de oq l e l D t r ' e u ! 1 , o q 1 6 u e 1 o
Jol uo11o:edo ur ueeq sDq eu16ue eql Jl 'qclnlc eql o] ssecco ulo6 o1 loe6 uotssttu
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:INleNS WOdJ HCInIC 9NlnOW:lU L't
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puo ZIL't, puo L/L'C 's6r3 ur uMor1s sD sre^el eq1 '6u;co; uo!lclrl uo - pala^rJtll!M ]!un 6ullds
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zt-tt
 Turn the flonge on the centeringorbor so thot 2. Instoll retoining plotes on the clutch
the longer, cylindricol port foces the clutch, springs ond fit the clutch cover with releose
p u s h i t o g o i n s tt h e f r i c t i o n p l o t e h u b , o n d o l i g n l e v e r s p r i n g s i n p o s i t i o n . A s s e m b l et h e c l u t c h
the ends of the levers to touch the flonge. cover with the pressure plote, observing the
A d e v i o t i o n f r o m t h e p l o n e n e s so f 0 . 1 m m i s m o r k s i n d i c o t i n gt h e i r r e l o t i v ep o s i t i o n s .W h e n
p e r m i s s i b l e .U s e f e e l e r g o u g e s f o r c h e c k i n g o s s e m b l i n gn e w p o t ' t s t, h e i r p o s i t i o n so r e o f n o
this deviotion. consequence.
lf it is not possibleto odiust the out-trovelof 3. Slip o 4.5 mm high pod over the ossembly
the clutch releoseleversto o volue given by the plote bolts (the plote con be used for Skodo
length of the flonge cylindricol port due to 1000 MB ond Skodo 100 cors os well, ond by
excessiveweor of the friction plote, odiust to u s i n g p o d s o f d i f f e r e n th e i g h t s t, h e p l o t e c o n b e
the next higher volue. Clinch nuts on the odopted for different types of clutches), fit the
odiusting nuts bocked off up to the end of the yokeof the iig on the plote bolt ond compress
threod ore o worning of o weor limit which pre- it by screwingdown the nut till the bottom port
cludes ony further odiustmentof the clutch. rests on the pod. When compressingthe clutch
4. After hoving reossembledthe engine with cover toke core thot the projections of the
o new or odiusted clutch, check ond, if necess- pressure plote ore correctly centered in the
ory, odiust the cleoronce between the releose cover slots to prevent o distortion of the clutch
levers ond the throw-out beoring - see Chop- cover.
ter 15.4. 4. Slip the bottom ends of the releose levers
u n d e rt h e s p r i n g si n s t o l l e di n t h e c o v e r o n d f i t
t h e m w i t h t h e i r l o n g i t u d i n o ls l o t s o n t h e s u p - Fig.3
p o r t s .S l i p o d i u s t i n gw o s h e r so n t h e b o l t s o f t h e Dim
3.3 CLUTCH DISMANTLING pressureplote ond screw down the nuts with
t h e i r c y l i n d r i c o lp o r t f o c i n g t h e w o s h e r s .T h e n
O w i n g t o i t s s i m p l i c i t y ,i t i s n o t n e c e s s o r yt o odjust the height of the releoselevers with
plote be
d e s c r i b ei n d e t o i l t h e d i s m o n t l i n go f t h e c l u t c h , t h e s en u t s s o t h o t t h e i r e n d st o u c h t h e s h o u l d e r
of the yoke bottom port. The difference of the simuloti
but some speciol feoturesdeserveottention. For on<
1. lf the friction plote ond clutch cover ore lever height should not exceed 0.'l mm. This
porogrop
intended to be re-used, mork their relotive o d i u s t m e no t l s os e t st h e r e c o m m e n d e d i s t o n c e
The cl
positions using centre punch morks to preserve of the levers from the pressureplote beoring
surfoce. with the
t h e o r i g i n o l b o l o n c eo f t h e o s s e m b l y . friction ;
U s e c l i n c h n u t s f o r l o c k i n gt h e o d i u s t i n gn u t s
2 . T o d i s m o n t l et h e c l u t c h , i t i s n e c e s s o r yt o ports of '
compressthe clutch cover to relieve the stress i n p o s i t i o n ,p u t s u p p o r t i n gc l i p s u n d e r t h e r e -
clutch on
of the releose lever bolts. For this purposeuse l e o s efe v e re n d s o s s h o w n i n F i g . 3 . 1 1 1o n d 3 . 2 1 2 ,
To bol
t h e M P 2 - 1 0 1o s s e m b l yp l o t e s h o w n i n F i g . 3 . 4 / 1 . o n d s l o c k e nt h e n u t s o f t h e o s s e m b l yp l o t e .T h e
centering
A f t e r s c r e w i n g o f f t h e r e l e o s el e v e r n u t s o n d c l i p s o r e u s e f u lw h e n f i t t i n g t h e c l u t c h t o t h e pressure
c o m p r e s s i n gt h e c l u t c h c o v e r , t h e c l u t c h i s f lywheel since it is not necessoryto overcome
the chips
r e o d yf o r d i s m o n t l i n g . t h e t e n s i o no f t h e c l u t c h s p r i n g s .
lf thes
boloncing
To Check Adiustment ond Bolance ing holes
in o circk
3.4 CLUTCH REASSEMBLY The describedodjustmentof the releoselevers
4mmof
in the iig is the most occurote,the ossembly
between
1. Locote the clutch pressure plote on the fostening
M P 2 - 1 0 1o s s e m b l yp l o t e o n d f i t s p r i n g so n t h e
c y l i n d r i c o lb o s s e s .B e f o r ef i t t i n g t h e s p r i n g s ,i t
3.5 FR|C
i s o d v i s o b l et o c h e c k t h e m f o r c o m p l i o n c ew i t h
t h e v o l u e ss p e c i f i e di n t h e f o l l o w i n g T o b l e . lf the f
it is odvi
Toble of Clutch Springs 8.5 mm th
When r
-Lood
rrr"ltp1 the frictio
L e n g t ho f s p r i n gi n m m ond only r
lin
complicot
After hr
5'10+36 the plote
Mountedlength 31.5 (s2t3.6) if necess
recheckin
L e n g t ho f c o m p r e s s e sdp r i n g 2 9 . 5 I 5 8 0 ( 5 9 )
F i g . 3 . 4 l 1- I A P2 l o l A s s e m b l yP l o t ew i t h C l u t c h quired.

70
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A 1 1 o c o ;p l n o M q o ! q M p s u r . r o ' e J D s r r n q o u l D r { } ruc6 67 ol pacuolDq llun D s! qclnlc orll ecuDls
'g qdo.tDotod
e l o c 6 u r > ; o 1a l l q M ' t u t u Z 1 o q l d e p D o l c r D t u r o ] ' 7 ' 6 l e 1 d o q 3 e a sp o q l e u 6 u 1 1 s n l proe q l o u DJ o l s!r,|I't
- ! u n D u ! a c u e r e l u n c J l o s l ! 6 u o 1 o1 1 6 u r p u u D A q aql ,o
'a1o1duo!lc!rl urom l1lq61lsro Meu o 6u;1o1nu;s
e 1 o 1 du o g l c l J le q l e c u D l D q ' A l o s s o c e ul l ' a l q l s s r u .!oPlno
-led sg tuc6 g uinrrtlxoru
lo acuolDq-lo-lno uV ,,a1o;dqclnlc lDop!,, uD sD pasn 6utaq epld q]!M sJ
ueql '8
ql!M sl
Me!n e l o l d o J n s s a J ud ! s a l o 8 l o s u o l s u e u l c eql lo s
rrrnu!xDlN - 6 u g c u o l o gq o l n l C- Z l v ' t , ' 6 l J -dns aq
l D u o l l c a s- r e p u ; g I 3e ^ o l S q o l n l C- L l g ' t ' 6 l J
lll Puo
sro^gl s
8S9
Z I ? L) O
qclnlc 0
aql u!
oql lo
qclnlc e
l.rod uro
sssidt!
eql lll '
eq uoc
Aqpuo
oPols r
Alques
ou lo e
uaqM'
eql 6u!
qclnlc
esDelej
qclnlc
 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 comporedwith 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
Fig.3.612- Clutch Moster Cylinder1 Sectionol line compriseso high-pressurebroke hose. No
View speciol position or fostening ore recommended.

l'

I
N
I

72
.t*
til : i'*
lt ;:
..:t
., oilfl
 T,L
JeJDsSssoic oL't
lD!luorall!c 6't
a^!rc JDa6le^og g'?
sJDoeM/c uor.lso^!rc l'v
sjoae M/c uo!uld 9't
JaAOC luorj g't
surs!uDqcewuo!ss!rxsuorl6u!lluorus!c v'v
a^!r6 lou!l 6u;lquassy tn
xoqJDee6u;lquessy Z'V
Ilquessy
puo Dulnouag L'V
lcDd reMod 6u91111e6
'Pepue
uo31d1rcse6 oN 'es
LL locluqcel c1;no:pl
't'
a6o6 '6ugc1r
releuD!
rolourD
aql lo
sasudtu
-tVN
SAIUO l J O N V X O S U V SD
S W S IN V H ) l W N O I S S I W S N V U I U l r t \ O d - 7 aorl lD
puD Je
eql lo I
 DK122ya
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47.
E
52---

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2 ( .
'' -'

,tx
I
t

22--'
F i g . 4 / 1 - G e o r b o x ,F i n o l D r i v e , o n d C l u t c h
Throwout Mechonism .&

74
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sullsnlc uvlt0 xoguvlg
FqE.
---'lz
- -f-----tz
r%I 9
:
qs rs ffi'
ll=:-\ 0t oa
tB$
 Technico
The gec
tegrol uni
N e i t h e ro f
Sincec
19
2A tionollytc
16. 17
'll " g e o r b o x"

4 2 'u., ts m o l l yt o d
respecti ve
I The geo
from the c
Fbb reor oxle c
the so-co
r8
4.1 DtSM
PACK

q The pov
t r o n s mi s s i
"b plete with
Fi9.4.111
Removql
o) Prelim

,w
12 1. Jock r
the reorwl
ik"-n
ond remov
13 TO Drointh
6 see Chopt
q b) Operot
2 . P r i s er
of the reo
cobles ofte
F I N A L D R I V EA S S E M B L Y 3. Remo
behindthe
bottery. Re
e n g o g et h e
lever, loos
fronr the gr
it from tht
housing to
getting int
pressed on
h o u s i n gw i
4. Proce
bockrest, fr
detoch the
obsorbers,,
c) Operoti
5. Remo
connection
cooling sys
see choPte
d) Operotic
6. Disco
motor.

76

I
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repun 1co! .roc-o-1lor D e^ol eq1 Q1!Mstu.to
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' a l x Da q ]
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puo 'elxDeql lo 6u1nns-unta oq p l 6 u l t ! r u l lo > 1 o A - . r o ;A g u o p s s n e J D , , s nr J p l o u ! 1 , p u D , , x o q l o e 6 , ,
e q l , o s l l o q r D e r a L l l e ^ o u r e l' ( u n l p e l D l q o q l
s e r u D u e l l l ' s ] l u n I D O ! u D t l c a uqr l o q o l A l l D u o l l
r e p u nl c o l a q t 6 u r ; 1 o 1 s uar l)x o r D a re q l l , ! l ' 8 - c u r r ; 6 u o 1 a q s 1 . r o dl u a u o d t u o c u t D l r e c a 3 u t S ot
J a u u D uer l q D l ! n sD u l J a l l D L U 'dnot6 r u e q l
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u 6 1 e . r o;;o s s a r 6 u l l s u ! o 6 o l a p u l l A c l a o q M a q ] '6ugsnoq uourtuoo o u! palquesso 11un
1ot6a1
otr uollcsuuoc aLll puo sesoq aql lcelotd puo - u r u D L L r . r os]^ r J p ! o u r , o t l l p u o x o q ; D s 6 a q t
'uelsAs a l o l q e q l u l o r l s a s o q e l o t q lsauuoos!P
' s o l q D ce ) D r q p u D L lq l o g , { 1 1 o t } : ol d 'l uolldqrcseg lDcluqcel
no llnd
 r
t
i

4 . F i t t l r e M P 3 - 1 0 9j i g i n t o t h e f r e e h o l e s f o r 5. Prc
striking fork rods (both pins of the iig), ond scribed
p r o c e e d i n gt h r o u g h t h e h o l e i n i t s s i d e o n d rods onc
r _-_-- - 4th spee
u s i n go s t i c k o r o l e n g t ho f w i r e , p u s h t h e l o c k
p i n i n t o t h e h o u s i n go s f o r o s i t w i l l g o . P r o c e e d fork rod
i n t h e s o m e m o n n e rf o r i n s e r t i n gt h e n e x t p i n irr the b
(useone pirrof the iig). Shift it iust so thot 6. lns
t h e c e n t r e l r o l e r e m o i n s f r e e f o r i n s e r t i n gt h e guide bu
striking rod. Puslr the lock pin into the end cover in
g u i d e o f t h e s t r i k i r r gf o r k r o d s o l s o o s f o r o s i t heods.S
w i l l g o . T h e i i g i s n o t r e q u i r e df o r t h e i n s t o l - tob wos
l q t i o no f t h i s p i n . e d g e so f
Fi t t h r
stri ki ng
weoker s
ing forks
7. Tigl
the forks
fork rod
the strik
. i\:r,,,
function
\ .
4 3
Fig. A.1l'l- Power Pock Reverse-
-
1 e n g i n e w i t h m o u n t i n g ,2 - g e o r b o x /i fn o l
d r i v e w i t h m o u n t i n g ,3 - r e o r o x l e ( h o l f - o x l e s ) ,
4 - r o d i u so r m s
Fig.4.2l1- Clomping Georbox Housing in Stond
r e t i g h t e n i t u s i n g t h e r e c o m m e n d e dt o r q u e
( C h o p t e r1 . 8 ) o n d s c r e w d o w n t h e c l i n c h n u t . Using MP 3-101Rock
l f n e c e s s o r yt o, p u p e n g i n eo i l , f i l l t h e c o o l i n g
s y s t e mw i t l r o n q n t i f r e e z eb, l e e d t h e b r o k e s y s -
t e m , o n d o d i u s t t h e h o n d b r o k e .F o r t h e f o s t e n -
i n g o f b r o k e h o s e s( r o u t i n g ) s e e C h o p t e r9 . 7 .

4.2 ASSEMBLING GEARBOX

G e n e r o l l yt,h e r e o s s e m b l yp ' r o c e d u rdee p e n d s Fig

o n t h e e x t e n t ,t o w l r i c h t h e u n i t h o s b e e n t o k e n
o p o r t . F o r b e t t e r u n d e r s t o n d i nwg ,e s h o l l d e s - -1-
c r i b e t h e p r o c e d u r eo n d p e c u l i e o r i t i e so f r e o s - Rever
s e m b l yo f o c o m p l e t e l yd i s o s s e m b l e du n i t . 2-1st-o
F i g . 4 . 2 1 2- L o c k i n g S t r i k i n g F o r k R o d s i n 3-3rd- o
Gear Chonge Mechonism P o s i t i o nb v M e o n s o f L o c k P i n s o n d B o l l s 4 - Rever
. 1 . C l o m p t h e r i g h t - h o n dh o l f o f t h e h o u s i n g
( w h e n v i e w e d f r o m t h e f l o n g e s e c u r i n gi t t o
the engine) in the MP 9-101 stond com- 8. Inst
p l e m e n t e dw i t h t h e M P 3 - 1 0 1g e o r b o xr o c k , o n d press-fittr
c h e c kt h e h o u s i n gf o r c o m p l e t e n e s s . verse-spe
2 . I n s t o l lc i r c l i p so n t h e s t r i k i n gf o r k r o d s o f inside th
t h e r e v e r s eo n d 1 s t o n d 2 n d s p e e d .T h e r i n g through t
with the lower nose is to be fitted on the 1st-- Turn tl'
ond 2nd-speedrods. end foces
3 . l n s e r t t h e r e v e r s es p e e d s t r i k i n g f o r k r o d lock it in
i n t o t h e h o u s i n gs o t h o t t h e i n s e r t e de n d p r o - hole.Tig
trudesslightly from its guide, slip on it the
strikingfork with the longerside of its heod Pinion Ar
first,- ond push the striking fork rod through
the fork ond the end of the guide os for os=it F i g . 4 . 2 l 3- I n s t o l l i n gL o c k P i n s U s i n g 9. Instc
will go. MP 3-109Jig ing ond,

78
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ZgL-S dtA aq1 6u1sn
( q s o g > 1 c o q )u o g l ; s o d p u o ( s r v r o . r . rqDl l / ! [ p e l r o t u ) - s n o q s q l o 1 u 1u o ; u 1 d p e l q u e s s D e q l l l D l s u l ' 6 6ug
s . l o a 6 ; o s e c D l r n s l D c ! u o c 6 u t p n . r 1 o . r dA ; 1 o c l l 1 a r u
- u i s a q l o 1 6 u r p . r o c c o s 6 u g . r6 u ; z l u o . r q c u A s ; o guaulsn!py uo!u!d
l o l d a a r ; l o u o t t r n q ! r l s ! pa t D r x l x o r d d y - g l z ' V ' B l J
']nu D qllM 'epoq
ll ernces puD lloq eq1 ua1q611
s t q l o l u ! l l o q D E u l n n a l c s, t q u o r l r s o d u l l t l c o l
puo 6ulsnoq sLll ul aloq pepDarLle l ql socol puo
s l ! l D > 1 . r o uq c u n d e q ] 1 o q 1 o s : o e 6 e q l u J n I
'ralpr aLl] puo s6n; 6ulsnoq aq1 q6norqt
urd ;oa6 oll] poerql puD 'xoqlDe6 oq1 eplsur
6 u q c o l q l e e l e q t q l ! M ) r o l 6 u 1 1 1 . r 1psa e d s - a s . r e n
-el eql olul qsnq ozuolq pello puD pe111;-sserd
a q l q l ! M r D e B p e e d s - a s : e n e . ra L l t l l o t s u l ' 8
loa6 paads-asroneu -t
s l l D Bp
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p o i p u D 1 r o 16 u g 1 u 1 sp e a d s - p u 7p u D- l s L- Z
p o : p u D 1 r o 16 u r 1 u 1 sp e a d s - a s l e ^ e- uL
loag paads-esra^oupuD
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lo pue eql lo uorl!
- s o d a q l 1 . r o r uu r o 6 o p u o ' l o a 6 r a q t o e q l q 1 M
'de1s Aq dals po.r
luaua6o6ue eql lceLlo 1-ro1
6 u 1 > 1 g . ra1qs1 1 1 n dA 1 1 o u r 3 ' 6 u r s n o qa L l l l o p u a
a q ] l o u o r g g s o de q l l l u o u r o 6 o l i D u r p u D l o . r l n a L l
' 1 1 c u a do
e q l o ] p o l I l o + 6 u t 1 t . l 1 sa q l L l r n l a u
L l l ! M p o l 1 . r o ; 6 u 1 1 r . r t r se q t r u o 6 u r s n o q a L l l l o
pue eLll lJoru puD a6oBua q3lnlo aq] lael noA so
uoos so pol aql 6urqsnd dols '.roa6 paads"
- l s L e q l l n o q o 1 r ( a 1 o 1 o r ) 6 u g r ' n sp u D p o r ) r o J
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ir.\\
s l r o J 6 u 1 1 ; r 1 gp u o
soqrlnlC BulzluorqcuAg lsnlpy o1
' 1 a 1 s o 6J e ^ o c a r r r l c e d s a le q ] 6 u l u a 6 l o j
lou slnLt roeg paeds-osJo^eU
a a J q l l o s u D a u r. { q 6 u r s n o r -el L l l 0 1 6 u u o a q ; a ; ; o . r
pe.redol lDrluerajlrp €ri] ]o.re^oc aLll t.rolsDJ
' - r e u ! D l a ra q 1 6 u g u a 1 q 6 1 1 aAr q u n n o p L u e q l p l o L l ' l l o q l l M s a p 1 n 6i l e L l l i l t o c ! r q n l p u o u o t l c L t n ]
p u o a 6 u o l r r 6 u g r o a q a q l J e p u n s u r ! L l sp a l c a l a s l c t l " r J o oJ o j u a q l ) c a q c o ] s p o J > 1 : o 16 u r 1 u 1 s a q 1
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' e 3 u D J D a l c6 u u o e q '2
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' s 1 r o 16 u g
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'uoruld oql
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+ o s u D e u l A q u o 1 l 1 s o du l 1 ! ) c o l
l o l l u e r e ] , r p e q l l o a r o q e L i l q 6 n o . r l 111t 6 u r p o a r q ] p a e d s - o s r a n a la L l ] o 1 6 u 1 . r d sr a 6 u o l 1 s a q l l l J
' s 1 . r o ;6 u r l u l s a q l
F u g s n o qo q t o l u r a 6 n o 6 t g L - S d l 1 l a q l l n d ' 0 1 ;o sa6pa
'sMeJcs a q l r l r r ; , s ' o . rA o q l l D r { } o s p e c o ; d s J e q s D Mq o l
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puD-pie aql puo 'paads-pu3 puo -]sL aLil Isol llo(j a(il -rapLrn s r a L l s p M6 u r - r d s6 u r ; ; o l s u r r a , r o c pue eql
p u o u o r u r d e r l l M D r p q l l M ' g l z ' v ' 6 t l q + l t us' tp u o d s a q l L r o i l l o q p u D ' 6 u r 1 c o d a q ] ] l l ' s e r - 1 s naqp r n 6 eql 6ulu
- a r r o 3 u o l l r s o d l D i l n a u u | ( ' c 1 a ' r a n g : p M a r c sD a L l ] r . r ! s 6 u r " r d sp u o ( ' u r g / t ) s l l o q l o l s u l ' g lDrl] os l
'sMaj3s u 1 dl x e u
q ] ! / ! ^ ) s a q c l n l c 6 u r z r u o . t q c u l sa q l o l u l p a q s n d les q]lM aJoq 3ql U!
s 6 u 1 . r 6 u r z r u o . r q c u A sl o s A o l d ' o u o l l n q l r l s ! p s u l c i > 1 c o 1a r j t r r o , s a i o q a r l l o s o l o p u D ' p o J ) r o J peacoJd'
a q 1 l l ! l s l r o ; 6 u r q r r l s a q ] e n o u ' A . t o s s e c o uJ l 6 u 1 > 1 i . r tpr es e d s - a s . r e n eer L l ] L l l l M q s n l l p a e d s q l i Icol aql
'alqlssod sD lDl p u o P J e p u o ' p u z p u D t r s La q ] l o s > l r o , p u D s p o r puD opl
so 6ugsnoqeql olul paqsnd sr uotutd arll lDLll > 1 . r o61u r 1 r " r 1 as q l l r e s u r ' g q d o r B o : o d u r p e q r " r c s puo '(6g
o s 6 u r s n o u ;a r l l ] s u 1 o 6 o 6 u t l o a q u o 1 u 1 do q 1 s s a . r c i - a i ) s D J e u u D r . r- -r ro l r u J l sD u r 6 u t p e e c o rl ' g .rolseloq
 Proceed in the some woy with the 3rd- ond 17. Proceedingthrough the bore of the differ- from the
4th-speedgeors. e n t i o l b e o r i n gi n t h e u p p e r h o l f o f t h e h o u s i n g , Determir
l f t h e m o r k e dp o s i t i o n o f t h e n e u t r o l i s n o t fit another iig, the MP 5-104,on to the differen- swivelli
m i d w o y b e t w e e nt h e s i d e m o r k s ( c h e c k v i s u - t i o l w i t h f l o n g e sc l o m p e ds o o s t o f i t i n t o t h e To rotr
o l l y ) , r e m o v et h e p i n i o n , m o r k t h e p o s i t i o n so f topered roller beoring cover, locote the cover iig with
the striking forks on their rods (preferobly ' r n o v e on pocking,ond fosten the cover by meonsof three tiol stor
e i t h e r s i d e ) , s l o c k e nt h e f o r k s o n d them n u t s . l f t h e c l o m p i n go r d r o w i n g c l o s e o f t h e 21. Ins
toword the required centre by the distonce of f l o n g e s o f t h i s j i g p r o v e s i n o d e q u o t e ,i t i s on the b
the deviotion of the neutrol morking.Then lock necessoryto drow close the flonges olso of the rotote th
the striking forks in position with screws. f i r s t , p r e v i o u s l yi n s e r t e di i g . the diol
For the striking fork tightening torgue see 18. Drive the guide of the clutch throwout ible to th
Chopter 1.8. s l e e v ei n t o t h e h o u s i n gu s i n gt h e M P 3 - 1 0 3d r i f t , Retoin
13. Adiust the reverse geor position so thot top home the drive shoft, ond insert two od- ogoinst 1
there is o gop of obout 2 mm between its teeth i u s t i n g w o s h e r su n d e r t h e c o l l o r o f t h e p i n i o n cover. Tl
o n d t h e o d i o i n i n gt e e t h , o n d s w i n g t h e s t r i k i n g s h o f t b o l l b e o r i n go n b o t h h o l v e so f t h e h o u s i n g teeth chc
fork of the first ond second speedto moke sure ofter hoving determined their thickness by losh on t
thot it connot foul the teeth. meosuring. of the ho
1 4 . R e i n s t o l lt h e p i n i o n w i t h i t s r e s p e c t i v e Using o wire needleinsertedinto the holes of wheelsic
w o s h e r so n d l o c k i t i n p o s i t i o n .S h i f t t h e s t r i k - the tobs of the woshersorrongethe woshers so fied volu
ing fork rods to moke sure thot, for exomple, thot they do not overlop the porting plone of the hond
o movementoppositeto the requiredone of the t h e h o u s i n g ,t h e n i n s t o l l t h e c o v e r o n d s p r i n g fully its c
s t r i k i n gf o r k s d i d n o t t o k e p l o c e ,i . e . t h o t t h e wosherso , nd tightenthe nuts(seeChopte1 r .8). ( preferob
neutrol is midwoy betvr'eenthe engogement 1 9 .F o s t e nt h e h o u s i n gb y t i g h t e n i n gt h e n u t s wheel). I
p o s i t i o n so f t h e s y n c h r o n i z i n cg l u t c h e s C. orrect ( s e eC h o p t e r1 . 8 ) o n d l o c k i n p o s i t i o nt h e g u i d e opened f1
o n y e r r o ro n d r e m o v eo g o i n t h e p i n i o n . of the clutch throwout sleeve with the respect- respectiv
i v e c l i p u s i n g t h e s p r i n g w o s h e r u n d e rt h e c l i p of the iig
Fitting Drive Geors ond Clutch Shqft nuts. Now tl"
iusted on
1 5 . l n s t o l l t h e o s s e m b l e dd r i v e s h o f t i n t o t h e flongeso
h o u s i n go n d s l i p t h e s p l i n e d b u s h o n i t . topered r
4 . 3 A S S E M B L I N GF I N A L D R I V E This situc
Top home the seol ring with its seoling lip
p o i n t i n g o u t w o r d si n t o t h e g u i d e o f t h e c l u t c h trot i o n.
t h r r o w o u ts l e e v e ,o n d s m e o r i t w i t h o i l . T h e n
Refitting Differentiol
threod the clutch shoft through the ring to
instoll it into the splinedbush ond put it into
t h e h o u s i n gt o g e t h e r w i t h t h e g u i d e p r o v i d e d
w i t h o c o o t i n g o f s e o l i n g c o m p o u n do n i t s c y l -
20. Turn the housing into the horizontol pos-
ition. Rotote the ends of the knurled hondles
of the inserted iigs MP 5-104to move the re-
q,
indricol bedding surfoce.Secureboth the shoft
i n s t o l l e dd i f f e r e n t i o l ( s e e p r e v i o u sp o r o g r o p h s
o n d t h e s l e e v ew i t h c i r c l i p s .
16 ond 17) until the crown wheel withdrows
lnstoll the sleeveguide with its droin hole
l e v e l w i t h t h e p o r t i n g p l o n e o f t h e h o u s i n go n d
f o c i n gt h e p i n i o n .
F o r t h e s p e c i o l s e o l i n g c o m p o u n ds e e t h e
note in Chopter 10.1.
16. Put the pinion with geors into the housing
ond oil oll synchronizing r i n g s .F i t t h e M P 5 - 1 0 4
iig for setting the crown wheel bocklosh into
ry
Fig. a3fi
the bore of the differentiol beoning ond the for tc
fitted cover, fit the ossembleddifferentiol in it, 1
o n d c l o s e t h e h o u s i n gw i t h t h e o t h e r h o u s i n g
holf ofter hoving cooted the seoling surfoces 22. Rem
w i t h o s e o l i n gc o m p o u n d . side (turn
F i t o r u b b e r r i n g i n t h e r e c e s so f t h e b o s s withdrow
beside the stud bolt ond put o spring wosher dimension
under the nut. Tighten the remoining nuts hos to be
without ony woshers (the stressof the bolts roller beor
ofter the tightening of the nuts provides for'
t h e i r s u f fi c i e n t s e c u r i n g ) . T i g h t e n t h e n u t s Measuring
F i g .4 . 3 1 1 -A d i u s t i n g B e v e lG e o rB o c k l o s h
m o d e r o t e l yf o r t h e t i m e b e i n g . 23. Unsc
For the speciol seoling compoundrefer to the 1 - MP 5-104iig, 2 - M P 5 - 1 0 1i i g , the topere
locote it o
note in Chooter 10.'1. 3 - M P 5 - 1 0 6i i g , 4 - Screwdriver

80
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p l n o q s ( a ; q g s s o dl s s l l o t u s e q l ) r e q u n u p e r n b p u e e q l 6 u y u . r nA1g ' . r o 1 o c l p ul D lo e q ] u o q sl oo l
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'r{}ool to!-
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t

F
i

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I {.3-4.4
4.3-4.4
r

6. Remo
lf the shims connot be set up exoctly to the S e t t i n g :P r e l o a dO . O b- O . 1 0 m m b) Crownw
colculoted thickness, determine o thickness 1. Before assembling Transmissioncasing Tools
which would result in o prelood due to on removeouter crown wheel bearing races.Leave
overoll increose of 0.03 to 0.07 mnr of the di- t h e b e a r i n g so n t h e d i f f e r e n t i ahl o u s i n g .
r n e n s i o no f t h e s h i m s . 2. Assemble transmission.DO NOT carry out Settin
27. Ploce the topered roller beoring on the operation17 above. not le
respective bore, bolt the other MP 5-107iig on 3 . F i t t h e o u t e r r a c e si n t o c a s i n gp r e s s i n gi n t o 1. Insta
the housing ond rotote the centre bolt to press place using coned cover. Do not forget to fit
one of the
the beoring into the housing os for os it will go. gaskets.On the SelectorShaftside (side B) of the
Glave Cyli
R e m o v e t h e i i g , f i t t h e s h r u n k - o nr i n g o n t h e c a s i n g f i t a p p r o x i m a t e l yO . 6 0 m m o f s h i m s that the p
stor pinion,and lock the ring in position using betweenthe coned coverand outer races.Ensure pendicula
o c i r c l i p . L u b r i c o t et h e b e o r i n g w i t h o i l , f i t t h e there is backlash between crownwheel and 2. Lock
respectiveshims on the beoring ond the gosket p i n i o n ,i n c r e a s et h e s h i m t h i c k n e s si f r e q u i r e d .
between tl"
on the cover, ond bolt down the cover. 4 . F i t D i a l t e s t g a u g e s o t h a t p o i n t e rr e s t s o n cover.
T u r n o v e r t h e h o u s i n g o n d p r e s s - i nt h e o t h e r t h e d i f f e r e n t i aal s s h o w n i n f i g . 4 . 3 / 1 A . 3. Using
beoring in the some monner (the press-fitting back and
iig is olreody in position), instoll the preporred c l e a r a n c eI
shims, ond bolt down the cover with its gosket. teeth. This
28. Meosure how deep is tlre drive shoft gauge, anc
beoring below the level of tlre housing surfoce wheel(see
ond compensote the difference with shims up legible the
t o o m o x i m u m p r o t r r r s i o no f 0 . I m m - F 0 . 0 5r n n r . O . 1 8 m mb i
4. lnsuff
wheel is tc
increase tl
from the nc
the equiva
This will p
increaseth
Excessc
thickness
F i s .4 . 3 / 1 A Selector S
To worl
shims to n
(a) Bac
(b) Act
5. Lift Crownwheel assembly to determine
clearance b e t w e e nb e a r i n g s( a ) . . . l f t h i s e x c e e d s To
O . 2 Om m d e c r e a s et h e c l e a r a n c e t o b e t w e e nO . O 1 (a) O.3
a n d0 . 2 0 m m b y f i t t i n gs h i m st o N o n - s e l e c t osri d e (b) o.2
F i g . 4 . 3 / 4 - P r e s s - ift t i n g o f D i f f e r e n t i o l T o p e r e c l o f c a s i n g .( b ) . . . W h e n t h e c l e a r a n c ei s b e t w e e n
R o l l r : rB e o r i n g s U s i n g M P 5 - 1 0 7J i g 0 . 0 1 a n d 0 . 2 0 m m t a k ea r e a d i n gA . ddtothis0.OS
t o 0 . 1 0 m m . M a k e a s h i m p a c kt o t h i s t h i c k n e s s
and fit to non-selector side(sideA) of transmission
casingC . h e c ks o m e b a c k l a s hs t i l l e x i s t sb e t w e e n
Shims 0.1 nrm to 0.2 mm thick ore ovoiloble. t h e C r o w n w h e ea l nd pinion.
Fit the gosket ond the ossembledcover on the
housing ond fosten it with nuts ond spring Example
woshers (for the cover refer to Chopter 4.5).
1 s t D i a l r e a d i n g0 . 3 O m m
Swing down the beoring with the speedo-
0.20 mm Shim fitted on non-selectorside.
meter drive geors in the cover into engoge-
n r e r r tw i t h t h e p i n i o n d r i v e g e o r o n d l o c k t h e 2 n d D i a l r e a d i n g0 . 0 7 m m
beoringin position by tighteningthe nut of the Shim pack requiredbetween
b e o r i n gc l i p . 0 . 0 7+ O . O 5= O . 1 2 m ma n d 0 . O 7 m m *O.1Omm
= 0 . 1 7m m
Adjusting crownwheel Bearing S h i m s i z e sa v a i l a b l e . Refitting C
0 . 0 8 , O . 1 4 ,O . 2 Oa n d O . S O m m Assembly
Alternative Method S h i m s i z e s e l e c t e dO . 1 4 m m .T h i s w i l l g i v e 29. Instc
O.07mm preload tension to crownwheel
a) Crown Wheel Bearing Preload. ond the re
b e a rni g s .
Tools Dial Test Gauge and Stand The Crownwheelshould now turn freely with it with nut
-looded brc
M P s- 1 O Gl e v e r little drag.

82
 t8
6 t f Z O I - g6 y 1 6 u r s n e p t n e l e > l r D r qp o p D o l -
b u g r o e gl n o M o r r l l q c l n l C 6 u 1 n o u a 5- L l V ' V ' 6 l J - 6 u 1 r d se q l J e ^ o s J a q s o M6 u r L d sp L t os l n u q l l M l l qllM
' 1 - r o d d n se q l u o J e ^ a l a s D a l a ra L l l p u D
uelsD, puo
s l 1 o q 6 u r s n o q a q t r u o l - r o d d n sa q l l l D l s u l ' 6 2 laeq
enr6
A;quessy
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urLu
'ep!
uaa^l
uorss
sseul
'uoLls qclnlc aql 90'0 s
uoa^l
M D l p q ] ! r l ' rp u n r e p u r ; A o o s o a l a r p a ^ o L U a ro q ] q Jolsuejl ol suilqs LuLuoe'o= 9'I x 0z'0 (q) aprslo
U e l e l o q a q ] q 6 n o r q l U D L I se q l l o d r ; c , u c 1 u o . r 1 ecualoj]lp LULUOZ = tuur$t'O- 9e'0 (e) [0'0u
o q l t o p u e a q l l l l t ' ( a u r l e d r d e : r 1 u aa q ] p a e l q ralsuerl ol st!rqs alelnclec01 spaec
ol sADq ol ]ou sD os esoq aLl] tuoJl ;eputlr\c autuJ
aql lcauuocs!p lou op) raputlAc (anols qc1nlc) Lurugt'O qsellceq lenlcv (q)
a q l I D r v r Di ] ! l p u D a u l D u e a q l a ^ o u e : ' a s o d . i n d ururgl'O parrnberqsellceg {e)
s l r . l ]r o J ' J o c a q l u r o : l s u r s r u D q o a u a q 1 6 u l n o r u e . r -:elntlJol 0urilrro;;o1 eql esn anour ol surtls
tnoq]lM pacoldel aq uDc loes Uoqs qclnlc eqf lo ssoulcrql aleuirxorddeaql lno 'aprs )Jorlt 01
rolcal0s
-uou oql ol eprs lolcelos eql uloll sseulc!tll v L/t'
loes llDrlS qclnlC 6ugcoldeg
urqs Burnou lq palceroo sr eouereelcssacx3
'qsellseq aql asearcul
st/\tstNVHclt l pue esec ssoJceloaq/lAuMorc aql qsnd ll!/v1 s!t{I
N O I S S I t A S N V U T9 N r l r N v l t S r C V ' V 'oprs rolcolas aqr uo ssaulcil.ll luele^rnba atll
aceldpue 6ursecoqllo oprsroloalas-uouaql uroJl
ssaulcrql urqs e^ourer ocueJealcaql osPolcul
'Iurlraurqs o1 'uorurdaql qtrm tlsoul ut Aldaapool st leeqm
6 u r s r e n a .arq l a ^ o q o e l o q e p l s e q l o l u ! ( s d u o ; - u M o r cl e q l s e l e c r p u ar c u e l e o l cl u e l c l # n s u'lt
' q s e l ) c e qu L u S
6 u 1 s ; e n eqr l r v r p e d d r n b as 1 J D ce L l l J a q l e q Mu o l'0
- tt'O uaaMlaq salnBrleql asn ueqt agqr6e;
6 u t p u a d e pM ) a r c s6 n 1 do r o q o l ! M Sd t u o ;6 u l s . r a n
-ar e q l 'eloq a p l s e q g 6 n 1 do l lou sl slqlll
'(zuarl
L / 8 ' v ' 6 l J 7 9 a 6 e de a s ) l e a q m
l l D t s u l l e u B o uo
's1ou6oruq]!M s/v\eJss esn uMoJc oq] uo uaurlM se eq plnoqs pue 'a6ne6
]noqll/v\Marcs D puD 'ql00l
saloq urogoq eql 6n1d o1 'doc >1caurelp+ eq] letp aql ulorl peor aq uec luouanotu srql
6ursn ursluDqceureql esolc 'pe:;nba.rsV 'tt uorurdpup looqruru^ olc aql uaamlaq scuelealc
' : a p u 1 1 I ce q l
l o 6 u r : d se l l l r a p u n lo lunoure eql aurruJalapol tluol pue lceq
J o n o cD 6 u r p e s u li q r - u s ; u o q c aouq l o l u r s s a c c o leaq^^u^/\orceql elelor gOt - gdt^ Uu'tlr"io,
6 u r n r D6 u l u e d o e q l a s o l c p u o ' . r a p u r l A cp u D uo slse
6urureleu r o r u r de q l p u e l n u u o t u t da q l u o e m l o q 'pelrn
J e ^ e le s D o l e e r q l u o s B u u d sy l o - 1 1 n1dr 1' . r a p u r ; A c
J o ^ a l e l q e l r n se 6 u r s n A q u o r u t d a q l I O o l ' Z
o q ] o t r u l- r e 6 u rp; u D l n u q l l M p o r a q l t r a s u l ' Z t 'qlool oql ol elqrssodse le;nctpuad
pue la
' s l n u e q l J a p u ns J O Q r - D6M uuds laaqlr,rr o r n s u l'
-led se sr rolecrpur lerp or.ll ;o lutod aql leql
o s l D U a s u ! ' s 6 u 1 . r dosp r s e g ' s l n u q l ! M y u e l s o l os loaLl^/\u^/\orc eql oleloJ uaql 'lapullA3enel9
sr!rqs l
puD 'raloc eq] io 6ugrdseql puD 6urlcod ql1rvr aql lo (
qslnlc aql oururelaltol pasn spnls aql lo ouo
repu;1IcesDala.!qclnlc eql ll uo alocol 'lo)3Drq uorolecrpur q l r / ' / lr0\ l - 9 d t / \ l l o o l l l e l s u l' l lll ol lo
Alquassoaql uoJI uJs!uDq3eu eql e^oureu'Lt ' rluerrupg - olur6ur
'Je^eleql o1 uo 6u1.rds l ' O t ! ' O o s n a ; q t B e1 ; ou
eql )oor] 'leoq^^uMorJuo paUtcodssV :s6ulgag
p u o ' s p u a 6 u 1 . r desq 1 u e d o ' 6 u ; r o e qa q l p u D l l a M +l 'uorutd lno fule
lool ol Ja^el '
lro eLll uoaMleq 6u1.rds aql llDlsul 'a^aals or..ll
'r{rosseoau 9 0 t - 9 d 1l
'g't raldoq3 a^eal 's
1o rlel aql uo 11odup 1 to t- gdt^ :slool
o l 6 u l p . r o c c op a l q r u a s s De n e e l s a q l u o r l g s o d 'qsellcPq (q 6ursec
uotutd
u! ]t, puD eprn6 e^aatsaql l!o qlltlrrrDeLuS'0t ' e O n e D ;aaqlrrunrrol3
l e r Oe ^ o r u a U ' g
tt-et
 R e m o v et h e c l i p o f t h e c l u t c h t h r o w o u t b e o r - Assembling Front Cover dismo
i n g g u i d e ,i n s e r tt h e M P 3 - 1 0 2i i g i n t o t h e g u i d e , wheel
open its iows, ond withdrow the guide.After 1. Slip the rubberseol ring on the speedo- sure t
h c v i n g r e n e w e dt h e s e o l r i n g , d r i v e h o m e t h e m e t e r b e o r i n g o s s e m b l y( b e o r i n g w i t h g e o r s ) Only c
g u i d e u s i n g t h e M P 3 - 1 0 3d r i f t . T h e d r o i n h o l e o n d p u s h c o r e f u l l y t h e b e o r i n g , p r e f e r o b l yb y wheel
in the guidemust foce downword. o steody rotory motion, into the cover iust for m itted
The lotest desing of the extroctingiig hos enoughto be oble to instoll the key without drive.
t h e t y p e d c s i q n o t i o nM P 3 - 1 1 2 .S c r e w t h e i i g d o m o g i n gt h e s e o l r i n g b y t h e s h o r p e d g e o f 4.8.
b o l t i n t o t h e i i g n u t i n s e r t e di n t o t h e m e c h - the keywoy. Whe
o n i s m t h r o u g h t h e h o l e c l e o r e db y t h e r e m o v o l F o r t h e s o m er e o s o n c, h o m f e rt h e e d g e o f t h e olso tl
o f t h e c l u t c h r e l e o s ec y l i n d e r .J e r k t h e i i g t o beoring bore before instolling the beoring in o new
d r i v et h e g u i d eo u t o f t h e h o u s i n g . o new cover. one is
2 . L o c k t h e b e o r i n gi n t h e o x i o l d i r e c t i o n b y
Dismontling the Power Pock i n s t o l l i n gt h e k e y o n d s p r i n g w o s h e r s ,o n d b y Assem
s c r e w i n gd o w n t h e n u t . S l i p t h e c l i p o n t h e
F o r c o m p l e t ed i s m o n t l i n go f t h e p o w e r p o c k , p r o t r u d i n gp c r t o f t h e b e o r i n g o n d l o c k i t o l s o 1 . P
remove it from the cor - see Chopter 4.-1, i n t h e o x i o l d i r e c t i o nw i t h o b o l t ,s p r i n gw o s h e r , the pi
" R e r n o v oo lf ond nut. Do not tighten the nuts fully.
Power Pock from the Cor". Then the or
p r o c e e do s f o l l o w s : 3. Instollthe oiled geor chonge lever in the thrust
1 . R e m o v et h e f r o n t c o v e r o n d t h e c o v e r o f c o v e rw h i l e p u s h i n gi t o n l y o s f o r o s t h e g r o o v e toworc
t h e p i n i o n b o l l b e o r i n g ,t h e c l u t c h r e l e o s e f o r t h e s e o l r i n g . W i t h t h e l e v e ri n t h i s p o s i t i o n , 3-104p
m e c h o n i s mo, n d t h e c l i p o f t h e g u i d e o f t h e i n s e n tt h e s e o l r i n g i n i t s g r o o v e o n d p u s h ground
clutch throwout sleeve, i.e., oll component f o r t h e rt h e l e v e rt h r o u g ht h e r i n g . S l i p t h e d u s t the be
p o r t s o t t o c h e dt o b o t h h o l v e so f t h e h o u s i n g . boot on the lever ond ottoch it to the cover must t
2 . R e m o v et h e c o n n e c t i n gb o l t s o f t h e f l o n - w i t h o l e n g t h o f l o c k i n gw i r e . meosu
ges. Force oport the f longesusing o screwdriverr 4 . A t t o c h t h e f o s t e n i n g( m o u n t i n g )l u g s u s i n g 2.S
i n s e r t e di n t o t h e c h o m b e r so f t h e f l o n g e f e e t c o p s c r e w so n d s p r i n gw o s h e r s T . hereis o right- collorI
( l u g s ) . L i f t i n g o w o y o l l c o m p o n e n tp o r t s o n e - h o n d o n d o l e f t - h o n dl u g , o n d t h e i r s l o t s m u s t ring ir
b y o n e i s t h e u s u o l p r o c e d u r eo f d i s m o n t l i n g . be turned owov from the cover. the grr
Toking oport of lorger units (pinion, etc.) is The rir
d e s c r i b e di n d i v i d u o l l yi n t h e f o l l o w i n gc h o p t e r s . 3.5 to I
3. Press out the beoring cups which hove th icke
r e m o i n e di n t h e h o u s i n go f t e r i t s h o l v e s h o v e ond pu
been seporoted.Use the MP 5-107iig supported speed
b y t h e M P 5 - 1 0 8i i g . 3.H
'
it the
selecte
toword
dismo
(by tol
i t i n p
free to
Clon
FK 1t't4 MP 3.1
Note
F i g . 4 . 5 l 1 - F r o n t C o v e ' rA s s e m b l y innerb
toining
either r
Dismontling Front Cover -speed
Fig.4.al2- PressingOut the Cup of the Topered ports.
Lift owoy the speedometer beoring ofter
R o l l e rB e o r i n gU s i n g M P 5 - 1 0 7o n d M P 5 - 1 0 8J i g s h o v i n g r e m o v e dt h e s l e e v ec l o m p i n g b o l t o n d 4. Tr
the key (helddown by the nut). Thenwithdrow groovir
t h e g e o r c h o n g el e v e r b y s i m p l y p u l l i n g i t o u t . pinion
friction
4.5 FRONT COVER groove
4.6 PINION WITH GEARS groove
The front cover ossembly forms o self-con- 5. On
t o i n e d u n i t f i t t e d t o t h e g e o r b o x .F o r b o t h t h e The pinion with geors forms o self-contoined ond fit
r e o s s e m b l yo n d d i s m o n t l i n gp l o c e i t o n o w o r k unit to be instolled in the georbox.Use o work the nex
bench. bench ond o press fon both its ossembly ond sizes3

84
 98
6 u 1 . ra q l ; o a 6 u o q c p u D l D ^ o u l a : p e l o a d a l o I q euo sql asn puo ruur gg't puD tg't '09.t sezls puo l1q
p a l s n l p o a q u D c l l p u o r . u u rl O ' 0 + L ' 0 ] o s l l r u r l eq16uotuoluo:; 6ur.reql esooqC'anoo.r6 lxeu eql lJoM D a
aouojelol u!ql!M eq plnoqs ocuDrDalc s!ql olu! sapls Llloquo sanoo.r6qllM Du!J oql }tl puD peu!olu
'roa6 eq1
, o e c u D J D a l cl D r x Da q ] e J n s D e u {r 1 1 o u 1 1 6ur.r 1co; aql JoJanoo:6 6u;rvro11o1 aql r!u,O.S
p u o ' g q d o . r B o r o dq l l l u r e c u D ! ; d t u o c u r p a ! r ] p u o '(sep1sqtoq uo senool6
p a u l r u J a l a p 6 u r . ro q l l r l t u o ! } ! s o d u r 1 1> 1 c o 1 '.roe6
p e e d s - p u 7e q l l l D l s u t ' e n o o l 6 p a l l t r u o I l s n o l n e l d
llo qilM 6u1: auo puo apls euo uo sanoorD
uo qrtrt JDI!ujrsor"rr1) pe}il1 eq o1 s6u;t uollct4
e q l o l u ! 7 q d o . r 6 o . r o du 1 p e u o ! ] u e u s 6 u g . r ; o 'tno
6 u r u g o u r aa: q l l l o o 1 s a r ; d d oe r u D se q l . u o r u r d l! 6
a 6 u o . ra q l l o 6 u r . rp e l c a l a s A g l r o . r l r q : ou D ] ! J - g eql u! anoorB eq] lcn:lsqo lou saop 6u1noo.r6 ,v\DrPqll
'ep!sD
l ! l n d p u o 6 u 1 . re q l a ^ o u a r eql lo 6op aql loql os Dur.raql urnl .t puD lloq
ueql 'ulrrt Z0'0+0 lo eouorDelc D qltM anoolD 'sUod reUD 6u
aql u! ltl o1 sDrl ll 'sl!ru!l aouDrelol o1 p:o6e-r -.roe6peads-
u!-unr Jo] op ll!M llo 6u11ocr.rqn1
tlll/!{ lselc!91 aq1 asn ol puD ssol3 sseulctLll - ] s L M e u o . r o ' u o r u l dM e u o ' : o a 6 r v r e uD J o q l t e
a u o , o s E u r . r; o l a n a s A r l o ] p a p u e u r u o c e J s ! l l
.Zlg'n.6H o1 6u1p.roco 6 u r s n u e q M ( e p r q d g n s r pu n u a p q l ; o r , u6 u 1 u r o 1
6 u 1 . re q l -uoc) alsod o1Ago61 Al
A . r 1' a n o o . r 6e q t u ! l r , l s e l q B r t a q l a q l l ! r l , rq c t q M eLll rlllrlt s.roe6;o eJoqreuu!
eql elDc!rqnl ol PePueuu.tocer s! ll :aloN
'(u61sep rvrau)e.rn1x!t
LLL-tdhl ?t?,t )t{t
ro ggl-t dt/\ eql olu! uorurd aql duolg
s s a u 1 3 tq I
6 u 1 g u o r l c r r J l o u o t l o u ! r u r e l e C- Z l S ' V ' 6 l J sr :oe' eqrr'ql arnsororuor" ;;L?ll.::t;til
l c o l o l ( a : n l . r e d o s l t u r U t r p o q l t r l r rE u r d d o l I q )
qclgd anoor6 o {q 6ur.r aq} ulng '6u1;luDulstp {
6 u 1 . r n pp e ^ o L u e r6 u r . rp ; o e q l r o . r o a Ba q l s p J D M o l
sa,roo:6 l!o sll rlll/\,\ 6u1l uotlclJl pelceles
A ; s n o l n a r d e q l l r e s u ! r v r o 1 1' . r o a 6 p a e d s - 1 s ; e q l t !
u o d 3 1 s' l ! o r { 1 M q s n q e q } p s : o o r u s 6 u r n o g . g
-lsLsLrl;o Du11co1 ,o, "0,.o'!i?"oo";i;
ronlue^e
anoor6 eql u! lll rq6l] D sr qcrqM euo ]se{crql
aql lcelas 'uur L'0 {q dn peddals uru g'C ol g.t
rlorl sassoulclql rnol u! pel;ddns elo s6uu aq1
'Iypqolns s1; I.r1
o l q s n q o q l p u o e n o o . r 6e q l
1o e6pe eq] uoeMtaq enoo.r6llDqs eql ur 6uir lsnu slo
u o ! l c ! r + e q l l l o l s u ! p u o 6 u r . r o e qa q l p r o M o l r o l l o c -]t{6!ro s
s l ! q l l M q s n q : o a 6 p a a d s . l s 1 -a q ] u o d t t s . z 6 u 1 s ns 6
i6ug:nsoau
( o p l l t r v rl . r o d d n s p u o e 1 o l d 1 o
,t,o,pasn s! lt aJuls peDotuop eq Je^au lsnul re^oc eq
u o g u g de q l l o a c o ; p u n o . r 6 a q l ' e c o r 6 u u o e q a q 1 ]snp eql
a d r t l A u o ' a l q D l ! o ^ D] o u J l : s r D c 0 0 1 o p o l g 1 o )
u o - 6 u r s s e - r du e q n n u o l u ; d a q l , o a c o ; p u n o r O qsnd pu
pDeH lsnrql puD atDld tgL-t 661 6ursn
a q l l c a 1 o . r do t p o a q t r s n r q l a L l l r { } l M a 1 o 1 d9 6 ; . 6 'uo11gs
6 u r . r o a g u o r u ! d ; e n e g u o - 6 u t s s e . t d- L l g ' V ' 6 l J 'lxau pelll,
dn aql esn aq o1 sloa6 sql promol anoo;6e
'a 'l ']Joqs uoguld
oql ulor+ ionrro 6urr 1snlq1 aql u! rs
relno sl! qllM 6ulrDaq eql 1o grod relno eql .
11 uo dr;s puD po r{}!M }l roeus .uolugd eqi 'leqsonn 6
uo a3Dr 6ugroeq Jallor Jeuu! eqi sseJd.! oslo 1! Ic
aq1 uo d
uo!u!d 6u;lquassy Aq puo '
Aq uo;1c
'uolloredo Isrou esnoc o1 gdo
sl auo
Meu D qlim Dulqsau .roe6 plo uV 'euo.Mau o u1 6u1:o
qllM UDqs 3^trp eql uo :oa6 6utqsau aLll oslo aq1 1o e6
a c o ; d a . r ' s r o a 6 a q l ] o a u o s 6 u l r v r a u e Ju o q 6
'8't
1o a6pa
l e l d o q 3 a a s 6 u 1 1 t o t uI D O ! J a u n uJ t a q l J o J ' e ^ ! J p 1noq11 I
lourl puD xoqloaD euo olu! pel1, aq o] pelllur .ro; 1sn!.r
-red s1 Jaqtrtnu euos eql ql!rlrr palJotu
leeqm {q ilqore
u M o r o p u o u o l u g d a q l q l ! M . r r o dp e q c l o r u o A 1 u 6 (s.roa6q
'6ugqsau -opaeds e
lsaq aLll puo ostou lsertrrol aql oJns
-ue ol ,{lquasso e^r}cales Aq paqcloul alo
leeqM
u r v r o : ca q l p u o u o r u r d l g ^ a q e q t ' 6 u r ; l u o u r s r p
in the other groove. Chose the ring olso with
regord to toleronces cvoiloble in one closs of
the rings os mentioned in the previous Pqro-
groph. Check the cleoronce of the geor with
the oid of o diol indicotor.
Then remove the geor including the friction
ring in the second groove of the shoft.
7. Ploce the lock of the 1st' ond 2nd'speed
s y n c h r o ni z i n g c l u t c h o n t h e b e n c h w i t h i t s
teeth downword. lnstoll springs in the clutch
core securing them with greose ogoinst folling
out ond insert the clutclr core with the shorter
side of the inner heod on top in the respective
geor.
Locote bclls (dio. 1ir in.) on the springs,com-
p,ressthe springs with the fingers or using
o suitoble rod, cnd fit the complete core itrto
the geor.
8. Hoving thus osembled the synchronizing
F i g . 4 . 6 l a- A s s e m b l i n g1 s t ' o n d 2 n d - s p e e d
c l u t c h l o c k , i n s t o l l t h e s y n c h r o n i z i n gr i n g f r o n r
Synchronizing C l u t c h - l n s t o l l i n gt h e C o r e
the opposite side of the geor. Now threod the
o n d P n e s s i n gi n t h e B o l l s 1 -
lock on the oiled shoft with the geor focing
owoy from the shoft.
9. Instoll in position the previously selected
friction ring with its groove focing owoy from
the shoft (toword the geor) ond insert the the previously selected friction ring on the
synchronizing ring into the fitted lock of the oiled shoft.
synchronizing clutch. Slip the oiled geor ond 10. Slip on the 3rd - speed geor ond secureit
with on orbitrorily chosen ring from the ronge
o f f r i c t i o n r i n g s i n c o m p l i o n c ew i t h t h e p o r o -
groph 2. Meosurethe oxiol cleoronceond odiust
it to 0.1*0.07 mm by o repeoted exchonge of
the frictionring.
N o w r e m o v et h e g e o r , l u b r i c o t ei t , s l i p i t o n
t h e o i l e d s h o f t o n d l o c k i t i n p o s i t i o nw i t h t h e
ring with the oil groove focing the geor.
11. Proceeding occording to porogroph 2,
insert on orbitroryfriction ring into the lost
groove,slip on the 4th-speedgeor ond tighten
t h e p i n i o n n u t o v e r o p i l o t c o l l o r r e p l o c i n gt h e
beoring (for exomple of dimensions dio.
25.5/38x26with edges of the inner bore chom-
f e r e d t o 1 x 4 5 o ) .M o r k t h e s i d e o f t h e p i l o t c o l -
l o r w h i c h w i l l b e t u r n e dt o w o r d t h e n u t s o t h o t
the side focing the geor connot be domoged by
impression.Adiust the cleoronce of the geor
to 0.1+0.07mm by o repeoted trying on (ex-
c h o n g e ) o f t h e f r i c t i o n r i n g s . T h e n r e m o v et h e
geor ond the ring from the shoft.
12. Assemblethe 3rd- ond 4th-speedsynchon-
izing clutch using the some method os when
hoving ossembled thot of the 1st ond 2nd
speed. lnsert the synchronizing ring into the
clutch ond slip the clutch on the oiled shoft
with the short side of the lock first.
13. Instoll the selected friction ring in the
locking position into the groove with its oil
groove focing owoy from the shoft. Push or top
F i g . 4 . 6 / 3- L o c k i n g 1 s t - s p e e dG e o r i n P o s i t i o n home the key into the spline of the shoft so Fig. 4.
( t u r n i n gt h e r i n g w i t h o d r i f t ) w i t h t h e P i n i o n thot it possesthrough oll friction rings ond its
C l o m p e ciln M P 3 - 1 0 5o r M P 3 1 1 1 J i g end is ot leost flush with the splined shoft end.

86
 L8
'pue
l
r u l " r u t ! x D r uD ( ) 1 l l p u l J 6 ' , 6 u l J D a ql e l l o J a q l , o 6tf lli-e dn ro sl! p
'6!l
a c D l J e u u t e q l e ^ o u l e j o l A l D S S o c e us ! l l J l . Z
' s J D a 6a q l u o l l r s o d u g 6 u r 1 c o ; s 6 u 1 - r S g L - t c J t Au ! 1 r N u o r u r d 6 u r u a 1 q 6 r -1 g / g ' t os u
uottctJl aql do1 .r
{ 1 1 q D r 16s u 1 u . r n p1 u o ( t L q d o : B o r o d a a s ) i e 1 e q 1 lto st
6 u 1 r , r o . r p q 1 1rMe U D l l o q s a q t ] l o u e q l 6 u r d d r g s eql u
Aldurls iq penoruel eq ol Apoe: puD posDelor
erD seqolnlc 6urzluo:qculs puo sloe6 ;;o *o[u, uDqs
eql o
- J D e qe q l e l o u e r o ] l l o q s l ! a l D l o J p u o 6 u r . r o e q
Puz
e q l u o r e 1 1 n d8 0 1 - t d 6 a q ] l ! J ' l n u s l ! l l o M a r c s ueq
puD (tig'V puo 979'y s6;3 u! uo!lDrlsnlr slt -uor.l
e a s ) 6 1 19 0 1 - ed r u o q l u ! u o 1 u 1 de q l d L u D l C' !
all] e
A;quessos;O uo!u!d -xe)
'ruru g'0 ol .ioe6
0 jo esuDJoolcD e^Del ol lnq euoq
A 1 1 n ;r o e 6 e q l s s a . r d o l l o u p e p u e t u t u o o o r s ! ] l Aq pa
'uo1u;d eql puD ssa.rd
eql ueeMleq 11 ezeenbs loLll o
-lo3 1
o l l o u s D o s A ; 1 n 1 a r o c: o e 6 o q l u o - s s e J d
' ( u r d u o - p e s s a l dq l r m -ruor.
'o!p
roa6) :oa6 a^lrp raleuopaeds eql uo-6u!ssard
Aq u o r u r d a q l I ; q u a s s o a q l e l a l d u o C 'gI a q 16
, o
' l J D q so q l ue1q
lo eur;ds
eqt olul aLuoq loeu s1r do1 puD '(g'L reldoq3 lsDl e
'z q
aas anbtol 6uruelqBrl s1r .ro;) ]nu eql uMop
M e J c s ' u o ! ] o l o . r o e r l i o l s . r o e 6 1 1 o) o e q C ' l r D L l s
a q l u o r ] I o n n o 6 u r c D Jr o l l o c e q l q l l M 6 u 1 . r o a q eql ql
'-roe6 p a p o o q ] u o d 1 1 sp u o uoll
lloq eql uo sserd
'UDqs eql ' q c l n l c 6 u l z g u o . r q c u Aesq l
llo +o 1col
aql olul 6u1r6urzluorqcuis lsDl eq] lresul 'tl 1o e6
'pelDltIcDl lsnlpo
-olod
oq l l l M A a > g1 o n 1 c oa q l ] o 6 u t r r t l e q ] s n q l p u D
sDug.u r orlcli] peurnl Auo uBllo lllM 1'eu11ds aEuo.
a q l o l u ! p a q s n d u € q n n ' 1 u 1 o dD q l ! / v \A a > 1( 1 o 1 r d ) l! gJn
A r l o q ; g x n uo D a I D t ! o l p e p u e u u o c e J s t 1 r ' I l 1 u a n b
-oll euop arD sqol Ilquassoa.r aql u
Jl :e I o N
L l s l n l c6 u t z t u o l q c u r {pse a d s - q l t p u D - p J e- g ' r l c } n l c 6 u r z r u o : q c u ^ sp e a d s
- p u Z p u o - l s L - g ' : o e 6 p e a d s - r l ] t - y ' ; o a 6 p a a d s - p r t '-.er o e 6p e a d s - p u Z - 7 ' n a } p e a d s - 1 s 1 - - ; _
u o r u r d p e l q u a s s v A ; e 1 a ; d u o 3- S / g ' t ' 6 ! J eJo
p30
I
 length ond depth ond strike it off while still Dismontling Drive Shoft 4.8 B
hot from grinding.
Co u t io n ! The iig used for other types of 1 . C l o m p t h e s h o f t i n o v i c e o c r o s st h e f o c e
S k o d o c o r s c o n n o t b e u s e d f o r r e m o v i n gt h i s of the 4th-speedgeor ond screw off the nut. Generr
roce! I n s t o l lt h e s h o f t i n t h e M p 3 - 1 0 6s u p p o r tb y t h e
Although the ports ore identicol ot f irst sight, outer beoringroce ond press off the beoring. The
the teeth of the pinion ore lorger ond they 2. Press the shoft out of the beorings by i. e., th
w o u l d n o t p o s s w i t h o u t o d o m o g et h r o u g h t h e p l o c i n g t h e s u p p o r ts u c c e s s i v e l yu n d e r t h e i n - ferenti,
iig. dividuol geors ond the second beoring. protect togethr
W h e n d i s m o n t l i n g t h e s y n c h r o n i z i n gl o c k s , the shoft sphericol end - use the buttress plote checke
support the clutch core with on obiect obout for pressing off- see porogroph2 of the previ- (mesh
2 0 m m h i g h , t o k e t h e l o c k b e t w e e nt h e p o l m s ous section. on the
o f b o t h h o n d s ,o n d p u l l i t o f f t h e c o r e .T h e b o l l s Only
c n d s p r i n g se i e c t e d f r o m t h e c o , r ew i l l f o l l i n crown '
yourpolms. con be

Bevel (
4.7 DRIVE SHAFT C/W GEARS Spor
with n
trotion
L i k e t h e d r i v e n s h o f t ,i . e . t h e p i n i o n w i t h The ;
g e o r s ,t h e d r i v e s h o f t w i t h i t s g e o r s f o r m s o ( 175) v
u n i t t o b e i n s t o l l e di n t h e g e o r b o i . F o r o s s e m b - like the
ling the drive shoft,use ogoin the work bench first po
o n d - o p r e s s .W h e n r e p l o c i n go n e o f t h e d r i v e froction
shoft geors with o new one, it is necessoryto the pini
r e n e w o l s o i t s m e s h i n gg e o r o n t h e d r i v e ns h o f t crossin
(pinion). port of I
in hund
AssemblingDrive Shoft missing
1 . U s i n g o g r i n d s t o n ec, h o m f e rt h e s h o r p e d - Adjustir
ges of both geors ot the point of their inner
cylindricol bores ond the loterol chomfer of To od
these bores. set the ,
2. H,ug-tup the 3rd-speed geor to o tempero_ the oxis
.
ture of-80 up to 100oC,insert it with the longer the flon
side of the inner heod first into the Mp 3-106 the MP I
s u p p o r to n d s h r i n k -ift t h e s h o f t . ' U s et h e o t h e r 1. Fos
port of the support, the buttress plote, slipped the diol
o v e r t h e s p h e r i c o le n d o f t h e d i i v e s h o i t ' o s Fig. 4.711- Shrink-fitting of Geo,rs on Drive
o thrust pod between the shrink-fitted shoft Shoft Using MP 3.106 Support (two-port iig
o n d t h e p r e s ss p i n d l e . c o n s i s t i n go f t h e s u p p o r tp r o p e r o n d t h e b u t t -
3. Heot up the 4th-speedgeor like the previ- r e s sp l o t e )
9t1;.geor ond shrink-fit it on the shoft _ see Fig.
4.7t2.
4. Pressthe boll beoring with its outer thrust
ring owoy from the shoft to the th-speedgeon,
ond onother boll beoring to the 1st-sireed
Use the other holf of the Mp 3-106supporl [eor.
for
pressing-on the beorings.
.5. Clomp the shoft in o vice (providing the
v.iceiows with sheet linings) Uy'the floriks of
the 4th-speedgeor ond tighteh the nut. Hommer
down the nut neck into the shoft qroove.
Use o new nut if the neck of thle old one is
domoged.
E l i m i n o t eo n y s t r e s sr e s u l t i n gf r o m s h r i n k i n g Fig.4.712- Drive Shoft c/w Geors
on the geors by topping the geors ond the shofl - 1st-speedgeor,2- reversegeor,3 - 2nd-speed
willr o mollet. geor, 4 - 3rd-speedgeor, 5- 4th-speedgeor 1- MP

88
 68
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'e6no6 6urlsnlpo
r e u l o l e r 6 u l r o a q Z g L - gd t 4 l g ' 6 u 1 1 1 eas6 n o 6 ; o 6 u 1 > 1 . r -o7u e g L - Sd h t - t
u o r l r s o du o r u ! d 6 u g r n s o a 6- ;Z l g ' V' 6 1 ) paa
-ilnq
6t! l
eArr
'uor11sod - J n s o e us q l 6 u ! s nt ! t s n l p o r o r o l o c r p u ll D l pa q l
'!
o.rez lasald €ql LuoJl 'la1u1odeqI Jo uo!lcell o e r l c p u o 6 u r s n o qo q l o l a 6 n o 6s q l u a l s D l
l'ocuDlsrp
ap eql 'a 'r 'uo11ot^ee Pq l 'uo111sod eql 6ulrnsDaurol e6no6 eOL-gdn eql
lJo pDer
s r r t l u ! d r 1 l o l o c ; p u ! l D ! p e l l l q l l 6 ' u o ! ] D l o rs t l a s n ' 6 u l r o e ql l o q r e l n o u o ! u l d a q 11 o e 6 u o l le q t
t p e q l s a 6 u o q cl e 1 u ; o dJ o l D c ! p u a
] o u o ! l c e 'i 1 ! q] J o p u ns u ! q s U e s u ! ' 6 u g s s o ..rrco a 6e q l , o s r x oo q l
q c l q M u 1 u g o da q l l D 6 u 1 d d o 1 as c D , s l q l r e ^ o urorl ocDl punor6 uo1u1daql lo ecuDlslpeql los
dtt etlr A11ue6o^or.rlMoN 'ecD, punol6 uo1u1d o l ' a ' ! ' 6 u 1 s n o qa q ] u l u o r u r de q 1 l s n l p o o 1
e q l l s u l D 6 od 1 1r , o 1 o c ; p ul D ! l p e q +1 s a 5 ' 6 u 1 s n o q
e q 1 1 s u 1 o 6 oD u u o e q u o 1 u 1 de q 1 q s n d o l l ! e s n Oulsnog u! uoluld Du;gsnlpy
puo 6ulsnoq e^l.rplDu!j/xoqrDa6eqt lo lloq oqt
'ruur gL'0 +- '6u1ss;ru
uo JaulDla: 6ur.roaqZgL-gdt1l oql llDlsul 'Z tL'0 eq plnoqs qsDllcoq aq1
'luaulsnlpo ero DIDPeseql ll 'ssilaLu!ll!rulo sqlPerPunq ul
e u ! l r o l e l D c sl o r e q d r L a e d q l 1 1 1 q 6 1 1u sr n l u o r l l rlsDllcDqeq1 6u;toclpu! (gz) requnu aq1;o lrod
p u o r a p l o q a q l u ! r o l D c t p u !l D ! p a q l 9 1 1{ 1 1 q 6 r 1 s puocasaql'(V ecuolsrp)seJlet-u!ll!r.u ug 6ulssorc
'6u!]les q6no.ro Jol 'oJezo1 1u1odlsnu suolsrArp .roe6eq] lo slxD oql uoJl eco; puno:6 uoguldaql
rur.uL0'0 qllM (a1ocs ;o.leqdl.rad)alocs e6ro; '(09'69) ou!l uotlcD4
lo ecuDlslp allt seloclpu!
eql ,o raluqod eql puD 'suo!s!A!pLur,uL qllM eq] aroleq 'a'g ':eqtunupuoces eql lo lrod gsrl;
elDcs llDrusaql |o (euo) ; e:n6r; sr{l rl}lM aplc aql 'looq/v\uMorc sql uo glL raqunu eLll elll
-uloc lsnu .re1ulodaq1 'a6no6eql lo lcoluoc 6u! s.roe61o .rgodaqt lo requnu aql sl ilctqM (97L)
requrnu e;6u;s o qllrl,rpe)rDur s; uolugdeq1
'{g-te'V '6g1) uo;1ot1
( p a t r ! t u oa q A o u A e q l ) o l o p u o r l c n p o . r-dg - s n l p e q l u ! u M o q s s l o q u A s l D c r J a u n uq 1 M
'o1op IlquessD - 'tes .roe6 requlnu-
Z ;o L s:oa6 eql 6ur1loru .rol pasn s1 uolso.ra-4rodg
sles roee le^eg 1o 6u11.ro1tr1 - Llg'v '6lJ
6u;4roy1 rDee te^eg
'6ugsnoquoululocJlaql u! pellDlsuleq uDg
'6ug1.roru
locrJstilnueuDs eql qllM laoqm uMorc
-./,: D p u o u o 1 u 1 dD ' ' e ' ! ' s : o a 6 p e q c l o r u A g u g
'ueql uo
pslJor.u eJD olDp enllcadsa.r oql puD '(6u1qseu) -1ne:
r.lsDllcoqsnoe6otruonpD lsour oql Jol pelceqo e1o1
puo polsal 'eu!LlcDLu1o;cedsD uo :aq1a6o1 lceloJ
u!-unr arD s1.rod qlog 'leaqm uMoJo lDlluaJel -u! eq
-l!p eql puo 'xoqloe6 eq1 ;o llDr.ls e^lrp aql ''e'l Iq s6
'uo;u1deql Iq peuJol s! a^!rp '6u
.roebleneq aq1
aql lq
']nu e
uollDrurotul lDJoue9
ecDl e
TT Sntuc uv39 llnf8 8't
t Z
L't-9't
 4 . 9 - 4 r. O

3. To evoluotethe doto obtoinedfrom the diol pointer ofter pushing the pinion into the
indicotor reoding ond the doto of the geor set, h o u s i n g i s t h e m e o s u r e( t h i c k n e s s ) o f t h e
^ l ;
odopt the following procedure: shims. e i l
The setting distonce of the gouge- 60.00mm e l l
€; \l-
- is morked on the gouge orm; the reoding of I
the diol indicotor hos shown o deviotion of e. g. 4.9 DIFFERENTIAL
plus 66 divisions, i. e. 0.66 millimetres (plus
m e o n s t h o t t h e t i p o f t h e g o u g e i s p u s h e di n - I
word from the set zero position ond the in- Assembly ((
dicotor reoding is higher; o reverse deviotion -
1. Instollthe sun geor (plonet) without the
m i n u s r e o d i n g- c o n n o t p r o c t i c o l l y o c c u r ) . B y
friction wosher,the two stor pinions (sotellites),
subtroctingthis deviotion from the meosureon
ond the pilot pin for the stor pinions into the
the gouge, the octuol distonce between the
pinion ground foce ond the geor cross oxis will left-hondholf of the differentiol cose (with the
be obtoined, i. e. 60.00 mm minus 0.66 mm : flonge for the crown wheel). The originol dif-
59.34mm. ferentiol pinion shoft pressed into the cose
The meosureon the crown wheel indicoting must be reploced tempororily by the pilot pin
the ossembly distonce of the pinion is, foi to focilitote hondling.
exomple,59.60.Accordingly,the pinion must be 2. Push the sun geor from outside into en-
m o v e ds l i g h t l y o u t o f t h e h o u s i n g0 . 2 6m m , i . e . , gogement with the stor pinion teeth ond use
by the differenceof the two meosurings(59.60 o depth gouge to meosure the dimension by
minus59.34:0.26 mm). which it protrudesfrom the housing.Then, pro-
4. Preporeodiusting sirims 0.30 mm thick to ceeding from inside, push the sun geor into the
be insertedunder the flonge of the pinion beor- obutment surfoce of the differentiol cose ond
ing on further ossemblyof the housing. meosureogoin by how much lt protrudesfrom
Shims 0.14, O.2, 0.3, ond 0.5 mm thick ore the housing.The difference of both meosure-
ovoiloble.lf the requiredoccuroteoutword shift- ments determinesthe gop for the sliding ring.
ing of the pinion connot be ochievedwith shims The rings ore suppliedin thlcknessesof 1.8, 1.9,
o f o n y o f t h e s p e c i if e d t h i c k n e s sc, o m b i n et h e m 2 , 2 . 1 , 2 . 2 ,o n d 2 . 3 m m . S e l e c tt h e r i n g w h l c h i s
to obtoin the next higher volue. 0 . 1 m m t h i n n e r t h o n t h e c o l c u l o t e dd i m e n s i o n Fig.
of the gop.
Note:
The thickness of shims required for the od-
i u s t m e n to f t h e p i n i o n c o n b e o l s o c o l c u l o t e d
in the followingwoy:
o ) S e t t h e d i o l i n d i c o t o ro f t h e M p 5 - 1 0 3g o u g e
o s i n p o r o g r o p h1 o f t h e p r e c e d i n gt e x i i . 6 . ,
with the gouge odiusted on the meosuring
contoct, the reoding of the diol indicoto-r
w i l l b e 1 . 0 0m m .
b) ,'
. S w i n gt h e t i p o f t h e d i o l i n d i c o t o r o g o i n s t
t h e p i n i o n g r o u n df o c e o n d p u s h t h e
iinion
by meons of the Mp 5-102 beorinq retoiner
i n t o t h e h o u s i n gt i l l t h e d i o l i n d i c i t o r r e o d s
1.00mm.
c ) P u s h ,t h e p i n - i o nf u r t h e r i n t o t h e h o u s i n g
l|i
{while w.otchingthe deflection of the poin-.
ter) until the ossembly meosuringis ob-
toined (the 59.60 meosure on th; crown
w h e e l ), i . e . , b y t h e d i ff e r e n c e o f t h i s
meosuring from 60.00mm - in our exomple
6 0 . 0 0m i n u s 5 9 . 6 0 : 0 . 4 0 m m .
d ) Without chongingthe position of the F i g . 4 . 9 / 1 - S e c t i o n o lV i e w o f D i f f e r e n t i o l
diol
I n d i c o t o r ,p u s h t h e p i n i o n i n t o t h e h o u s i n g
g s f o r o s i t w i l l g o - t h e d i f f e r e n c eo f t h 6 The orrow points to the mork indicoting the
d.iol reoding from the previous0.40 mm is side for pressing-on the differentiol pinion
the thicknessof the requiredshims (0.26 shoft. Any symbol con be used (o figure, o let-
mm). Or, without chongingthe position of ter) but it must be identicol for both ports of Fig-
the diol indicotor on tfrJ pinion, trin tf,e the differentiol. lt olso indicotes the correct
scole to zero (0). The deilection of the relotive position of the two differentiol ports.

90
 r6
'su
'6n1aq1 6lf OOI-g6 6 1 6 u r s n 6rri,ioeg r a l l o u ]caJ
lo (lols) ssacor 3qt olu! sU] pDeq ]loq aql Jo pa-redo1lDrlueiallC jlo 6 u r 1 1 n 6v l 6 ' v ' 6 t J
lo
esou oql lDql eJns a)Dul 'slnu eq1 6uruelq6rla-r -lel
ueqg 'xoq.roa6 eql lo 6n1 oql elD] 01 q6noua :, t,ti;:::'::
"' :i:... uol
e6ro1 lsrp racods eql puo pDaq lloq aLll ueaM eql
-1eqdo6 D ulDlqo ol slnu aql uelcols 'xoq:oa6
eq] qllrur Jeroaq ssorc eql 6urlqruasso ueqM
'sle6ul; eqt Aluo l
6u1snAq lloq eql uo ]nu aql uMop Marcs ueql
p u D ' J a q s D M6 u r r d s a q l ' J o q s D Ml s n l q l u r o ; d a q l
q l ! M J e q l e 6 o l a p t s a U s o d d o e q l L t od n c l a ; ; o r u s
a q l o l u t - r a c o d sa q l l o l c a u e q l r a ^ o l c o l q l u e l t s
a d A l - 6 u r - r' r a q l o e q ] l l D l s u l ' r a r D e q s s o l c a q l
'racods adAl->1srp
t r o s d' )ncco leqql lu aoll!usl l l o q a q l p u o
aql raqqnr aql ]!, '[;qtuesso u6
U=IUV:|8 SSOdC Ot't
l-
' s e 3 D Jr ! e q l q i l M s e 6 o F r , r o
]! toql os 1r la^lMs puD 6ur:oeq eql lo srellor
p a - r o d o 1e q ] r e ^ o 6 t l a q r r g ' 6 t ! o O r - s d W a q l
esn esDc lolluerel,rp aql uror] s6uuoaq ;a11o.r
paledol a r , ; 1 l o s a u o o e q l , l o 6 u r 1 ; n d ro3
'€sDc aql
Jo aloq
p e l l o r " u u na q l l o a p l s e L l ] L u o l l U D q s u o l u l c l 1 o r 1
' u e J e l l r p e q l l n o s s e r d ' a J n p a c o . r dA l q u s s s o s r p
l L r a " u n cD s r l D r l u a r a l l p e q l ] o 6 u 1 ; 1 u o t u s 1 q
6u;1luorusg6 lDorql 6ursnog s^oqD
LrolsnJloJdJ D e e u n S 6 u r r n s o a 6 l- e / 6 ' t ' 6 l J uo!
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lcol laeqs aqt 6ug
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- u r p u D s s D c l D r l u a J a ] ] ! pa q ] p u D l o e q M u M o J s '6
a q ] l o s a c o l 6 u r 1 D L ue q t A l q 6 n o . r o q l u D a l C -eJ
'(llDqsuoluld
uro
lDrluaral,!p eLll lo aloLl )col eql rol pepualul pu
sr urd eql qt!M lloq aLll) sreqsoMaql 6ulus6iol aqt
l o u s l l o q q l r M a s o c a q l - r e q 1 a 6 o d1 u r o l c n n < l J 1 .or
't puD
Aq
7 sqdo-rDorod:ed so s6ur.r6urprls eLl] )oaLlc esn
puD eu!urelop o] paecord puo reqlaDol sa^loq -ue
asoc eq] ]loq'esDc lD!luerelj!Paql lo llDq
reqlo aql o1u1roe6 uns raqlo eq] llDlsul 'S u!d
' 6 u r s s a l da q 1 6 u r l a l d u o c e l ! q M o l o q s l q ]
es
q l ! M l u e u r u 6 1 ; o. r a d o . r rdo l ] ! l c e q 3 p u o ' 6 u 1 s n o q 1!P
eql lo eloq papoerLll aqi allsoddo illcerlP eqt
sr oloq lcol aqt llll llDrls eql elDlol'u1 1t 6ur eqt
- s s e . r de r o l a g ' L 1 6 ' V ' 6 l J a a s - l s r ] e l o q 6 u r 1 c o ; '(s
eql lnoqllM pue eql qllM Bulsnoq eLll u! eloq eqt
p e l r o u . t a q ] o l u l r e u D l e L l l s s a r d p u o 1 1 o q su o r u t d
'? ( I - r o r l r q r o a l o d r - r 6e L l l ] o s u or s u a ur rp)
1 o u r 6 1 . r oo q l q l r v r u r d l o p d a q l e J D' ul doegul o : a d o s u o r Lrrd " l Ds. l. r o j L l r d 1 o i l c l' z 1 6 ' v' 6 t J
Aslou puD qlaal aql lo 6ur:a11oqcesnDO ol !89 !o
' q l e e l r - r o 1 u 1Jdo l s e q l
1 d o s 1 L l s D l l c o qa ^ r s s e c x f I
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lo rlsDllcDq urnurulur D r1llM Alaei; olDloJ lsnur e Tt o
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6 _L___i1
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r D l s e q ] l r l e r p u D ' 6 u r s n o q e q l u ! 1 g ; 1 o } s u g' . r o a 6 I
u n s e q ] u o 6 u g . r6 u r p r l s p a l r o o q l d r ; s ' s r o e 6 e q l -n,: etll
'e eql
l l D p u D u r d 1 o 1 r du o r u l d r D l s a q ] a ^ o u e 6
6't-l't
 86
rlolls elxo-llDH l'9
sloo8 lsnc elxD-ilDH 9'9
Arlauoag alxV roeu S'g
6 u ; s n o ge l x V q l ! M s a l x o - l l D H
6ullquassy t'g
s u . r r v s n l p D pu u o s e l x D - l l D H
6uglluotus!c t'S
surrvsnlpoupuo solxo-lloH6u;lquessy Z'g
roc u! alxv
. r o a g6 u 1 ; q u e s s o apUu o 6 u 1 ; l u o r u s l O
L'S
96 u o r l d u c s e 6l D c ! u q c a l
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Fig.5/1 - Reor Axle

94
 96
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ttDqs eq] uo 61!ZLL-9d6 aql Marcs .rusluoqcsul
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dn Luoqlx!tu ol lou lap.rour (puoq
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Uot 'qnq l e e q Me q l A l q o l r n sl r D l 4
aql oarl ol d;aq 1;rrrrsserls lcodur
eql 'rauriloq D qllM ]loq eq] do1 ,qnq
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11
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6rp (uogs.ren 6utln '619 aas -
e1o;d 6ui4coq a1org oqi
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6 u r s 6 1q n H l e a q 4 41 1 o6 u r 1 1 n-6 L I L ' g ' 6 l J r . u o r lp l n l l e l o l q e q l l o l u n o u D l l D u t s o
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JDc eql elncas ',laoqM pDoi eq] a^ouau .!
6u!u
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sseocv puo EuqroeAllog ;o luarueco;deX
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l l o q l a a q M p D o Je q ] ] o l u e u e c o l d a : e q 1 p u o
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-stp aql erD'nl!s u! elxD r D a i a q l q l l M lno petr
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lxou eql aes) 6t! tt-t--SaW '(p qdolDorod
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]! luane.rdo1 uo111sod ul UDqs oq] )co-l .t aas 'sa;qoc elDrq
lo 6ullceuuoc
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oq plnoqs 6tl ef f-S dti\lorll 'reAeMoH':edo1puo lcoqs cldocselal cllnorpAq gl!rrr palueuua;d
pDeJqlUDqs eLll o1 aDouop p!o^D o1 pod alqo -dns 'paplno.rds1 uolsuedsns6uuds-;ro3 'rtpoq
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e u o q q s n d o l s l t D l 6 t ! e q t l l ' e l x D - l l o qa q l , o u o p e l u n o r rill p r D r . 'rs u r D s n ! p D Jl o p u o 6 u r s n o q
l n o u u t I l n o q o 6 u r : o a q l l D q e q l q l r n na 1 e ; d e^rJp lou!l puD xoqJDeD",.1t uo palunou-1urol
-uto3 uDqs aql a^out 'uollceJ!p e1;soddoeql u! s o l x o - l l D q6 u r 6 u r r v rt so s l s t s u o oe l x o J D a Je q l
q c u e r Ma q l 6 u 1 u r n I] q ' p u o ( u , u O l l n o q o ) e c r o ;
a n p u nl n o q l l M o 6 ; 1 r r vl lr s D r D ] s D e l x D - l l D qo q l uo;ldrrcseCloc!uqcel
 o f t h e b r o k e m e c h o n i s mo d h e r i n g t o t h e i n - 5.
s t r u c t i o n so f t h e o b o v e - m e n t i o n ecdh o p t e r , l o '
c o t e t h e b e o r i n gs h i m 0 . 3 m m t h i c k , o n d c o m '
plete the ossembly.
rl
N o t e : T h e 3 m m s h i m s h o u l db e u s e do n l y in
w h e n r e p l o c i n gt h e w h e e l h u b o r w h e n e l i m i r r -
o t i n g o n o s c e r t o i n e ds h o f t p l o y , t h o t i s t o s o y t-o
i f t h e s h o f t m o v e so x i o l l y o n d k n o c k s .H o w e v e r , o
i t i s r e c o m m e n d e dn e v e r t o u s e m o r e s h i m s
thon three. el
5 . A d o m o g e ds e o l i n g r i n g c o n b e r e m o v e d st
w i t h o h o o k o r o n e e d l e ,o n d o n e w o n e d r i v e n th
or pressed-on.The lotter olternotive should be
preferredwith regord to the visuol checking of w
t h e p r e s s i n g - o no p e r o t i o n .T h e t i g h t e n i n g f i n ce
ond spring of the pocking hove to be tunnedin- re
side the holf-oxle.
When driving home the seol ring, slip the
M P 5 - 1 1 4p i l o t t o p e r ( s e eF i g . 5 . 2 1 3o) n t h e s h o f t ,
F i g . 5 . 1 i 3- F o r c i n g S l r o f t o u t o f B e o r i n g U s i n g smeor it with oil, ond move the seoling ring
MP 5-113Jigs ond Jirrs os per Fig. 5."1/1 olong it to drive it finolly into the holf-oxle
u s i n g t l r e M P 5 - 1 1 6d r i f t o s s h o w n i n F i g - 5 - 2 1 2 .
F o r p r e s s i n g - o tnh e s e o l i n gr i n g , u s e t h e M P
The oxle shoft moy Inove out of the holf-oxle 5-112iig (see Fig. 5.214)ond the, sleeve with
only to such on extent thot the reor edge of the t o p e r o s p e r F i g . 5 . - 1 l 4P.u l l t h e s h o f t s l i g h t l yo u t
beoring thrust ring is flush with the holf-oxle o f ' t h e h o l f - o x l e s, l i p o n i t t h e o i l e d t o p e r o s
socket. Otherrwise it is opt to foll out of the s h o w n i n t h e i l l u s t r o t i o n t, h e n t h e s e o l i n g r i n g
epicyclic geor ond its refitting would require o n d f i n o l l y t h e s l e e v e .F o s t e nt h e M P 5 - 1 1 2i i g
the removol of the holf-oxle from the georbox s c r e w i n gi t s h e o d o n t h e h o l f - o x l et h r e o d , s l i p -
housing. t h e s e o l i n gr i n g o n t h e t h r u s t r i n g b y m e o n so f
4. To fit o new boll beoring proceed occording the sleeve,ond turn the wrench to press the
t o C h o p t e ' r5 . 2 . P u l l o u t o g o i n t h e s h o f t s l i g h t l y s e o l i n gr i n g i n t o t h e h o l f - o x l e .
until the thrust ring con be seen,fit the beoring N o w t h e b e o r i n gc o n b e p r e s s e do t t .

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H o l f t - A x l eS e o l i n g R i n g ( t o p e r s u r f o c e
s m o o t h e do u t d u r i n g m o n u f o c t u r e )

96
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6 u r s 6U
1 D q Se l x D - ; 1 o 6g u r l l o l s u -t t i z . g ' 6 r r
I
6 u g n o q r a u o 6 t ! Z L L - Sd h t e q l J o l l o q s r l u e o
aq] lo olpuDrleql elolou '6urloeq llDq aql qtrM
1 r e c o ; d a . rp u D e ^ e o l s l o 1 r d e q t e ^ o u e U . Z
l
{$$"\s 'elxo-lloq aql qDnorql
'lro qynn 6ur.r
ltDqs eq] pDarq] puD lsnrql lloqs
aLll puo a^aols aLll rDaus 'ljoqs alxo eql lo pua
r e l n o 3 L l 1L r oa ^ 3 e l s l o l l d t L L - g d n a q t l l D l s u l
' e c r AD
ut padurolcelxo-lloq (aplsur) pauoalc Alq6nor
-otjl D o 1 u 1 6 u 1 . r6 u r ; o a s a q l euoq e^trc -L -
'LiS'6!J u! uaes eq uo3
a c u o . l o e d d ol a q ] u l
s a o u e r e l l t p e q 1 ' u 6 r s e p p u b q - 1 ; e 1p u o p u o q - 1 q 6 u
l o o r D s u i l D s n t p D _ tp u D s a l x o - i l D r l a q l q l o B
S!UUV
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 f l o n g e .T h e i i g o f t h e l o t e s t d e s i g n p e r m i t s i t s 5.:
s i m p l e f o s t e n i n gb y e n g o g e m e n w t ith the holf-
oxle flonge (fit the iig ond rotote it to lock it
in position).
I n s t o l lt h e l o r g e rl i n e r b e t w e e nt h e b o l l b e o r - pr
i r r g o n d t h e i i g h e o d ,o n d p r e s st h e b o l l b e o r i r r g stl
on the shoft by turningthe iig wrench. bc
3 . R e p l o c et h e l o r g e r l i n e r w i t h t h e s m o l l e r
o n e ( r e s t i t o g o i n s tt h e i i g b o l t h e o d ) , o n d t u r n
the wrench in the opposite direction to press 5-t
t h e b e o r i n g i n t o t h e h o l f - o x l es o c k e t .

Fitting Broke Mechonismond Wheel Hub

bo
4. Instollthe brokebocking plote complete thr
F i g . 5 . 2 l 5- P r e s s i n gB o l l B e o r i n go n S h o f t w i t h t h e b r o k e m e c h o n i s mo n t h e h o l f - o x l e u*,
U s i n g M P 5 - 1 1 2J i g o n d l t s L i n e r ( s m o l l e r ) s o c k e t ,s l i p o n t h e " O " s e o l i n g r i n g o n d t h e
c o p w i t h t h e s e o l i n gr i n g ( w i t h t h e t i g h t e n i n g on
f i n f o c i n g t o w o r d t h e h o l f - o x l e ) ,o n d f o s t e n o l l
the porrtswith bolts, spring woshers, ond nuts. dit
T h e s e o l i n gr i n g s h o u l d b e d r i v e n o r p r e s s e d on
i n t o t h e c o p s o t h o t t h e t i g h t e n i n g l i p f o c e st h e arI
b e o r i n go n d i u s t s o t h o t t h e r e r e m o i n so g o p o f
1 t o 2 m m b e t w e e nt h e p o c k i n g o n d t h e c o p ioi
sPl
flonge. SW
5 . l n s e r tt h e k e y i n t h e s h o f t w i t h i t s b e v e l l e d I
end into the runout of the keywoy, smeor the gor
hub neck with oil so thot it does not drog in :
t h e s e o l i n gr i n g , o n d f i t t h e h u b w i t h t h e b r o k e wo
drum in position. Moke surethot the key did bol
n o t m o v e f u r t h e ro l o n g t h e s h o f t ( i t s l i f t e d e n d cyl
in the keywoy would couse the hub to burst) del
ond tighten lightlythe nut.Sinceo high torque \
i s r e q u i r e df o r f i n o l t i g h t e n i n g o f t h e n u t , p u t mo
off the tightening ond locking of the nut till th€
o f t e r i n s t o l l o t i o ni n t h e c o r . T h e n t i g h t e n t h e hot
nut with full torque (see Chopter 1.8),top on WO
the hub to relieve the possive stress of the
toper, retighten to the specified torque, ond
lock the nut with o cotter pin.
DK ?EI
Fitting Rodius Arms
F
6. Instoll the spocer into the rodius orm, fit clo
the knurled woshers (with the knurling toword POS
t h e o r m ) t o e i t h e r s i d e o f t h e e l l i p t i c o l h o l e so f
+:
nec
the rodius orm, ond fosten them with bolts ond
wol
nuts not forgetting the spring woshers. Do not
reo
tighten the connection fully. Threod the bolts
toe
through the bolt holes so thot their nuts foce
wit
into the cor ofter fitting the rodiusorm to the
T
holf-oxle.
o)
F i t t h e r o d i u sa r m o n t h e p r o t r u d i n gh o l f - o x l e
b)
p i n o n d t h r e o d t h e b o l t t h r o u g ht h e h o l e o f t h e
F i g . 5 . 2 1 6- C o n n e c t i o no f H o l f - o x l e s secrt.Slip spocing tubes on the bolt ond pin Alil
w i t h R o d i u sA r m s together with sheet shims with rubber liners
ond fosten lightly (without tightening) the 1
rodius orm to the holf-oxleusing nuts ond lock con
il woshers.Tighten fully the connection ofter fit- sloc
l o r g e r o n d o n e s m o l l e r ,o n d t h e f o r k e d p l o t e ) , seo
screw down the iig on the threod of the shoft, ting the ossemblyin the cor when odiusting the
i
reor wheel olignment (geometry). i n t
ond use nuts to ottoch it to the holf-oxlesocket

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 66
r u r v s n r P D Up L r D I r D g t r J D s n r p D , rs r . l l l o a ; o q l o c r l d t l l a a r l l u l
'bti aq]
alxo-llDH lo uorlseuuoc 6utuasool z / Ec l l o q e q l u n n o pD u r p l o q ( Z t n ) i n u e q l p u o l o e s -1!,
eq] 'o Luolloq eqt ]D (yl n) slnu eql 6ugue;1co1s
A q u l o s n t p D J e q ] u l o r l a l x o - l l o L le q l l c e u u o o lcol
-srp puD rD3 eql -l at{t
Jo sleaqM ]uor] oql >lcorlc SJO
selxv ;o lueuuO;gy u!
etlt
l u e u l s n ! p o u 1 - e o 1( q elx
selxD lo lueuuBr;o (o
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'Ll9'S'6!J qltM aq
ac
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sll
aql lsnlpo ol puo olxD luo:l aql qllm alxD Joar
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5.5-5.7
the toe-in of the reor wheels using olso the
M P 8 - 1 5 2g o u g eo r o n o t h e rs p e c i o lg o u g eo v o i l -
o b l e i n y o u r w o r k s h o p .T o o b t o i n t h e r e q u i r e d
s h i f t o f t h e h o l f - o x l e s( s y m m e t r i c osl o o s n o t t o
d i s t u r b t h e o x l e o l i g n m e n t ) ,s t r i k e o g o i n t h e
h o l f - o x l e sw i t h o r u b b e r m o l l e t o s p e r p o r o -
groph 2.
4" Retighten the slockened connections
( r o d i u s o r m b o l t s ) o n d , o c c o r d i n gt o t h e p r o -
g r e s so f t h e r e o s s e m b l yo, l s o t h e n u t s o f t h e
h o l f - o x l es h o f t ( s e e C h o p t e r 5 . 2 , p o r o g r o p h5 ) .
C o m p l e t et h e o p e r o t i o nb y l o c k i n g t h e n u t s .
F i g . 5 . 5 / 3- C h e c k i n gA l i g n m e n to f R e o r A x l e
w i t h C o r C e n t r e L i n e U s i n g M P 8 - 1 5 8G o u g e
100
5.6 HALF.AXLEDUST BOOTS
T o p r e v e n to i l f r o m l e o k i n gt h r o u g ht h e i o i n t
gop between the dust boot ond the joint guord
os well os ony twisting of the boot during
the oction of the rood spring, or its domoge by
contoct with other cor ports, it is importont to
observe its correct position on the holf-oxle.lt
s h o u l d b e l o c o t e dw i t h i t s f l o n g e sf o c i n g r e o r -
wqrd ond tilted upword ot on ongle of obout
45o.For better occess,ploce the clips fostening
the dust boot to the holf-oxle ond cover with
t h e i r s c r e w s o n t o p . W i t h t h e r i g h t - h o n db o o t ,
screw in the clip screws from the front, with
t h e l e f t - h o n db o o t t h e s c r e w o n t h e h o l f - o x l e
from the reor ond on the cover from the front.
Connect the dust boot flongeswith hollow
r i v e t s u s i n g s u i t o b l ep l i e r s .l f r i v e t i n g p l i e r s o r e
n o t o v o i l o b l e ,b o l t t h e f l o n g e s t o g e t h e ni n s t o l -
ling odequotely dimensionedploin woshers
u n d e rt h e b o l t h e o d so n d n u t s .
5.7 HALF.AXLESHAFT
T h e t h r u s t r i n g o f t h e b e o r i n g( b e h i n d t h e
s h o f t t o p e r ) i s p r e s s e do n t h e s h o f t . l f i t i s n e -
c e s s o r yt o r e n e w t h i s r i n g , f o r e x o m p l e o f t e r
repeoted replocements of the beoring (see
Chopter 5.1, porogrroph4), press it on so thot
it is removed76 to 78 mm from the edge of the
toper behindthe shoft threod.
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Fig 6/1 - Front Axle - Sectionol View of Holf-oxle ond Steering Knuckle Arnr

102
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 refer to the proceduresrecommendedby the
monufocturersof the gouges.
The check lood con be formed by blocking the
wishbones with bors occording to Fig. 6.1/5.
Press down the cor with the hond, insert the
bors under the wishbones so thot they beor
ogoinst the oxle brocket,ond releosethe cor to
let the bors be clomped.lf clomping of the bors
does not toke ploce (which con hoppen on on
o l d e r c o r w i t h w e o k e n e ds p r i n g s ) ,c o n s i d e rt h e
c o n d i t i o n o s i f t h e b o r s w e r e c l o m p e d ,i . e ' ,
correspondingto the position of the front oxle
ot check looding.
The words "ot full lood" describe o vehicle
looded so thot the distonce of the rubber deod
stop from the bottom of the lower wishbone
stop is 20 mm (see olso porogroph18) ond the
comber ongle of the reor wheels is 1". Meosure
t h e s e v o l u e so n o l l w h e e l s ( n o t o n l y o n e f r o n t
o n d o n e r e o r w h e e l ) o n d d i s t r i b u t et h e l o o d o s
necessory.
Fig. 6.1/4- Costor Angle
It is imperotiveto set the ongle with regord to Toe-in
the direction of forword trovel os indicoted
by the orrow T o o d i u s tt h e t o e - i n ,s c r e wt h e r i g h t - h o n do n d
l e f t - h o n ds t e e r i n gr o d s s y m m e t r i c o l l y( o c h o n g e
up to 1 mm con be effected by one rod) ot
check lood so thot the distonce between the
w h e e l r i m s ( o r o c r o s st h e m ) b e h i n d t h e o x l e
( A + o ) i s l o r g e rb y t h e t o e - i nv o l u e ( o ) t h o n t h e
distonce between the rims in front of the oxle
(A).
To verify steering symmetry (correct screw- *
ing of steering rods during toe-in odiusting),
check the wheel lock position ot the 20" lock
ongle of the neorsidewheel - for the respective
volues refer to Chopter 1.7.
Slocken the steering rod nuts ond rotote the
Fi
s t e e r i n g r o d s u s i n g o n o l l i g o t o rw r e n c h ( F i g .
6.1/6).
In oddition to the correct inflotion pressure
of the tyres, poy ottention to severol essentiol
p o i n t s w h e n c h e c k i n gt h e w h e e l o l i g n m e n t :
o ) P l o c et h e w h e e l i n t h e s t r o i g h t o h e o dt r o v e l '
ling direction;
b) The steeringrod ond the trock rod must not
F i g . 6 . 1 / 5 - P r e p o r i nfgr o n t o x l e f o r t h e c o n d i t i o n
be stressed.The stresscon be eliminoted by il
of check lood by inserting steel bors of 181 mm
letting the cor swing up ond down in its .-q
in diometer ond obout 220 mm long suspensionunder the pressureof your honds
(olternotely press down ond releose the
wings)
The most importont points from the point of c ) P r e p o r et h e o x l e o s s h o w n i n F i g . 6 . 1 / 5 ;
view of driving ore the toe-in ond the comber d) lf o speciolgouge with o scole for wheel
ongle, the odiustmentof which is permitted by lock ongle setting is ovoiloble, odiust the cor'
the oxle design. rect length of steering rods in occordoncewith
Adiust first the comber ond then the toe-in t h e p o s i t i o no f w h e e l s i n c h e c k l o c k p o s i t i o n s .
since o chonged comber offects the toe-in. Y o u w i l l f i n d t h e r e s p e c t i v ev o l u e s i n C h o p t e r
We refroin from describing in detoil ony 1 . 7 " S t e e r i n g " .S e t t h e l o c k o n g l e o f t h e w h e e l
meosuringmethod in view of the lorge number on one side to 20' (on o turn-toble) ond screw
o f e x i s t i n g g o u g e s .I n s t e o d ,w e o d v i s e y o u t o the steering rod of the other wheel to odiust

104
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e q l u l l e s s l e a q M e q l q l l M ( e 6 o > 1 u r 1 ): o a 6 o
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2 0-t'o
exomple 50,000km ond more, check the wheel
comber ond prepore suitoble woshers for its
correction.
2. Jock up the cor ond support the body on
both sides to relieve the front wheels, ond
remove the wheels.
3. Proceedingfrom inside the luggoge boot,
remove covers protecting the threods of the
shock-obsorberpiston rods ond screw off the
nuts. Retoin the piston rod by holding its flot-
tened end.
b) Operotionsinside the cor
4. Remove the steering wheel, the steering
c o l u m n c o w l i n g , o n d d e t o c h t h e s t e e r i n gs h o f t
from the body - see Chopter 7.8.
c) Operotions from under the cor
5. Removethe bolt of the connection of the
steeringshoftwith the steeringbox ond releose
the shoft sleeve from the connection by pull-
i n g t h e s t e e r i n gg e o r i n s i d e t h e c o r .
6. Slocken the nuts of the bottom wishbone
pins fostening the front oxle to the brocket on
the body until the woshers of the brockets ore
releosed.
7. Detoch the onti-roll bor brockets from the
body ond disconnect the rubber broke hoses
from the front broke systems. Before discon-
n e c t i n g t h e h o s e , c l e o n t h o r o u g h l yt h e h o s e
connector ond its surroundings to prevent
foreign motter from getting into the broke
system. For the some reoson,wrop the hose
ends in o cleon rog. Toke the some precoutions
w i t h t h e d i s c o n n e c t e db r o k e p i p i n g .
8 . P l o c e o r o l l - o - c o ri o c k u n d e r t h e o x l e o n d
removethe bolts (two on either side of the tele-
scopic shock obsorber) fostening the oxle to
the body from obove.
9. Compressthe telescopic shock obsorbers,
lower the iock, ond move it with the oxle from
under the cor.
6.3 REFITTINGFRONT AXLE IN CAR
1 . T o r e i n s t o l lt h e o x l e i n t h e c o r , r e v e r s et h e
p r o c e d u r eo f i t s r e m o v o l ,i . e . , b e g i n w i t h t h e
porogroph9 ond proceed to the porogroph 1.
Coot the rubber cup with greose ot the point
of its contoct with the steering shoft.
2 . W h i l e r e c o n n e c t i n gt h e b r o k e h o s e s ,o b -
servethe utmost cleonlinessond bleed the front
wheel brokes if no other ports of the broke
s y s t e m h o s b e e n d i s m o n t l e d .( l f s u c h o d i s -
m o n t l i n g h o s t o k e n p l o c e , b l e e d t h e b r o k e so f
o l l w h e e l s o f t e r h o v i n g f u l l y r e c l o s e dt h e b r o k e
circuit).
3. Turn the wheels in the stroight oheod di-
rection before connecting the steering shoft
with the steering box. Fit the steering wheel
106
tentotively ond odiust the direction indicotor
switch - see Chopter 13.17.
4. Using the steering wheel, tunn the wheels
i n t o f u l l l o c k p o s i t i o n st o m o k e s u r e t h o t t h e
l o c k o n g l e i s c o r r e c t l yl i m i t e d b y t h e k i n g p i n
socket stops - see Chopter 6.5, porogroph 36.
5. Adiust the toe-in - see Chopter 6.1.
6.4 DISMANTLING FRONT AXLE
No speciol instructions ore required for dis-
m o n t l i n g m o n y o f t h e s u b o s s e m b l i e sA.c c o r d -
ingly, only the bosic dismontling procedure
w i l l b e d e o l t h w i t h o n d p o r t i c u l o r sw i l l b e m e n -
tioned only os fon os they ore necessoryfor the
sequenceof operotionsond the use of iigs.
Ports which con be dismontled witlrout re-
moving them from the cor ore the wheel hubs
a n d b e o r i n g s t, h e b r o k e m e c h o n i s m ss, t e e r i n g
orms, shock obsorbers,ond the onti-roll bor.
l f o n y o d d i t i o n o lp o r t s h o v e t o b e d i s m o n t l e d ,
remove the oxle from the cor ond dismontle it
on the stond. wi
prl
tht
Dismontling Wheel Hubs ond Beorings rer
1 . D i s m o n t l e t h e b r o k e m e c h o n i s mo s p e r
Chopter 9.1 ond remove the wheel hub cop ou
using the MP 6-124drog. When using the MP MT
6-136pull-off cortridge, the hub cop hos to be ott
prised off with o tyre lever or o similor tool. rec
Now removethe costellotednutwith its wosher
o n d p u l l o u t t h e h u b ,o s s i s t i n gt h e r e m o v o lw i t h
l i g h t b l o w s o f o m o l l e t ,i f n e c e s s o r y .
2. Toke out the inner port of the outer beor-
i n g , t h e n t h e s e o l i n gr i n g , o n d ,f i n o l l y ,t h e i n n e r
port of the reor beoring (cone with topered
rollers). Prise out the seoling ring using o
scrrewdriver.Proceed corefully olong the ring
circumferenceto ovoid distorting the ring which
.a
Fig
Dis
S
bol
6-1C
F i g . 6 . 4 / 1- R e m o v i n gH u b C o p U s i n g rub
MP 6-124Drog ovo
 LOI
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re
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 Remove the csstelloted nut ond wosher from
the steering orm, screw down the MP 6-105
cotridge on the threod of the orm, ond drive out
the orm.
Removing Steering Knuckles, Springs,
ond Wishbone Suspension
1. Remove tlre shock obsorber ond fit the
M P 6 - 1 0 6s p r i n g i n s t o l l e r i n i t s p l o c e f r o m o b o v e .
l n s t o l l o h o r s e s h o ew o s h e r o n t h e s p h e r i c o l e n d
of the instoller tie-rod possing tlrrough the coil
spring ond the bottom wishbone, ond compress
portly the spring (for fitting the instollersee
Fig.6.5/4).
2. Screw off the costellqted nuts of the upper
wishbone pin ond the bolt of the lower wish-
b o n e s u s p e n s i o n ,o n d d r i v e o u t t h e w i s h b o n e
F i g . 6 . 4 1 5- P r e s s i n g O u t P i n s o f S t e e r i n g B c r l l
J o i n t s U s i n g M P 6 - 1 3 8D r o g
F i g . 6 . 4 1 -6 D r i v i n gO u t S t e e r i n gA r m U s i n g
M P 6 - 1 0 5C o r t r i d g e
108
p i n . l f d r i v i n g o u t i s i m p o s s i b l e ,u s e t h e M P
6-107drrog(remover).
Rotote slightly the flonges of the drog to
breok it up in two ports, fit it os o yoke over
t h e u p p e r w i s h b o n e ,c l o m p i t i n p o s i t i o n b y
rototing its heod, ond screw in the centre bolt
t o p r e s so u t t h e w i s h b o n e p i n .
3. Drive out the bolt of the lower wishbone
s u s p e n s i o no n d r e m o v e t h e s t e e r i n g k n u c k l e
from the lowerwishbone.
4 . S c r e wo f f t h e n u t o f t h e k i n g p i n o n d p u l l
o f f t h e k i n g p i n s o c k e tu s i n g t h e M P 6 ' 1 1 1d r o g .
Refer to the following chopters for further
d i s m o n t l i n go f t h e s t e e r i n g k n u c k l e ,t h e k i n g
p i n o n d i t s s o c k e t ,o n d t h e i r r e p o i r s .
H o v i n g r e m o v e dt h e s p r i n g i n s t o l l e r , l i f to w o y
t h e s p r i n g o n d r e m o v et h e w i s h b o n e s . Fig.
5 . W h e n r e m o v i n gt h e u p p e rw i s h b o n e ,m o r k
t h e t h i c k n e s so f t h e o p e n ( h o r s e s h o e )w o s h e r s
irrsertedbetween the brocket ond oxle body on
Hol
t l r e i n d i v i d u o lb r o c k e t s .T h e w o s h e r so r e 3 m m
over t
o n c t1 m m t h i c k s o t h o t i f t h e r e o r e ,f o r e x o m p l e ,
remo!
one 3 mm ond two 1 mm woshe'rsm , ork the
t h i c k n e s so f 5 m m o n t h e b r o c k e t . A l s o t o k e
i n t o o c c o u n tt h e l i k e l y n e c e s s i t yo f o c o r r e c t i o n 6.5 F
o f t h e w o s h e rt h i c k n e s s- s e e C h o p t e r6 . 2 ,p o r o -
g r o p h1 . The
W h e n r e i n s t o l l i n gt h e u p P e r w i s h b o n e , f i t which
w o ; h e r s o f t h e m o r k e dd o w n t h i c k n e s st o s i m ' provid
p l i f y t h e c d j u s t n r e not f t h e w h e e l c o m b e r .
F i g . 6 . 4 l 7- P r e s s i n gO u t U p p e r W i s h b o n e P i n
Using MP 6-'107
6. Removethe nuts of the wishbone pin,
Drog
c l o m p t h e e y e o f t h e w i s h b o n eo n d b r o c k e t i n
$
o v i c e ( s e e F i g . 6 . 5 / 3 )o n d u s e o s c r e w d r i v e tr o
push the circlip out of the groove to the nor'
rowed down port of the pin. Sllp the pin out of
the other eye of the wishbone ond push out olso
the other circlip.
 60r
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'u;d repoc D qllM 'lnu pelDllelsDc -es aq] 'uog1oru.ro1u1
l! Icol puD 1se1e;dtuocaql aplnold 'ul
eql uetq6!] 'sreqsDM 6ur1snlpo pelce;es llsno oI 'PalluDruslpuesq sDq elxD luorl eql qclqM
- 1 n a l da q l 1 ! u o d 1 1 s ' u 1 da q 1 u o r a ^ o l a q l l l J o] luelxo aq] uo spuedap llquessoel aql r!
'saqsnq eql
l o s l l D / v \e q l u o .DJ
asoarOJootrts puD saqsnq Jenal eql uearrrleq do6 f'lXV INOUJ eNl]8U\|3SSV:|U 9'9
e q l e s o a . r Dq l ! M l l l l e s ! r v r a l ! - l' a s o a . r 6q l ! M r e ^ s l
uo
oql puo 6u;: eql ueeMleq do6 eql lcod puo
ar
'u1d a q 1 enoueJ aq
Ja^al aql 1o u1druollog eql uo 6u1.r cnoc c11so1d 'el
eql dlls 'esoar6 qllM uld eql puD roqsDM eq] puo ugdeuoqqslMaL1+ fo i.rodlsarvroljDu eql JeAo
' s : a 1 1 du r s d l 1 c . r recq 1 6 u 1 p g o 1 1 ut
rDaus 'JeqsoM aql lllel puD reqsoM ulolloq eq] llo ueql drls
Jepun JeqsDM reqqnr o 1r; ':anal eql eloueu
uo
' A 1 e e l 1o l o l o l o l r a ^ o l e q l sJ
lltu.rad lltM qcrqM
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6o16 1.1.9"-9 IJD
6 u 1 1 s n l p oo M l x ) e u o p p o ' l o ; d o u s o q J o n e l 6u1s1 lolcos u16 8u1; 6u;noueg - 8/t'9 '6!J
eqr 1 'lnu o Ll]!M A;quesso eqt ualq6;l puo
Ao
utd aql uo JeqsDMJeqlouD puo 'saqsnq pallo
ql!M Je^el lolel eql 'raqsort eql llDlsul 't 6u
'g'g leldoq3 ees Jet
'6o
a n b . r o l 6 u ! u e r q D g e q l r o l ' u 3 d . r a 1 1 o cD q ] t M l n u
eql lsol puD 'lnu pelDllelsDc eql uMop Mercs lln
' l e r e 1 l o l e l 6 u g . r e a 1 se q l utd eq1 Uasul 'Z
' s d n c a n r l c a d s e -Jl l e q ll oo l u l ( s d o 1 sa u o q q s r M ell
terurol) sdols poep raqqnr eql uesul puo a1o1d
eu
6urdruo;c LgL-gdl l redo.rd eql qllM pelaldruoc
p u D l s L 0 L - 6d 6 o r l l u ! A p o q a ; x o a q 1 d u o 1 3 ' 1 llo
Iq
r e n a l A o ; e g 6 u ; r e e 1 g 1 o 6 u 1 1 1 1 3p u o A p o g a l x y JeA
'1xa1 6u1,rno; ol
- l o l e q l u 1 u a n ; 6 e J D l s a : e l u l r o l n c g l . r o d; o s l u r o d
e u o s p u o s u o 1 1 o : a d oi ; q u e s s o e q l l o a c u e n b dh
 Pock with greose the plostic dust cup ond
press it over the nut till it snops home in po-
sition on the lever.
Refitting Upper Wishbones
4. When refitting wishbones which hove
been olreody used in the cor ond which ore
rother doubtful (for exomple, o distortion is
suspectedos o result of o crosh), inspect them
corefullyond stroighten them, if necessory.
5. Pressrubber bushesinto the eyes from the
outer side. To focilitote their sliding in, dip
them in petrol or soop woter (suds). Put the
bushesinto the wishbone eyes with their lorger
diometer first ond push them so for thot they
protrude from the eye by the some length on
either side. Blow off the soop woter with com-
p r e s s e do i r s o t h o t i t d o e s n o o s s i s tt h e s l i p p i n g
of the bush during the next operotion.
6. Slip the spocing tube on the MP 6-122driIt,
dip the drift in petrol or soopwoter, ond,forcing
it through the rubber bush, press the spocing
tube into the bush.
B e f o r ep r e s s i n gi t i n ,t u r n t h e s p o c i n gt u b e s o
thot the ioint of the pockoged bush foces the
top side of the wishbone.
7 . T h r e o dt h e w i s h b o n ep i n t h r o u g ht h e e y e ,
slip on it the cup with its dished port focing
the bush, two wishbone brocketswith the lugs
pointing owoy from the wishbone,ond the other
cup with its dishedport tbword the other rubber
bush, ond threod the pin through the other eye.
8. Push the brockets towords the eyes ond
slip two circlips on the norrowest port of the
pin. To slip them on, hold them with their un-
connectedends on the pin ond press down. Use
o screwdriverto move one of the circlips into
the grooveof the pin, ond push the pin with the
circlip in position into the brocket. Clomp the
other brocket with the wishbone eye in o vice
t o c o m p r e s st h e r u b b e r b u s h , o n d s l i p o n t h e
other circlip.
9. lnsert the rubber deod stop into the wish'
bone.
n
v
t
e
t
rl
F i g . 6 . 5 / 3 - I n s t o l l i n gC i r c l i p i n t o P i n G r o o v e fr

\
1 0 . R e i n s t o l l t h e t w o o s s e n r b l e dw i s h b o n e s sl
o n t h e o x l e b o d y . F i t o p l o i n w o s h e r u n d e rt h e t(
spring woshersof the lug bolts. Instoll, from
'l
obove,one mm or one 3 mm open (horseshoe) b
wosher or the previouslyremoved woshers on ol
the horizontcrlbolts between the brocket ond nl
the oxle body lug.
First tighten the horizontolond then the ver- Rr
ticol bolts.
F i t t h e c u p s o n t h e w i s h b o n ep i n o n d s c r e w
down both nuts. st
Refitting Lower Wishbones o(
sp
11. Inspectthe wishbonesos per porogroph4. th
lnsert rubber bushesin the eyes of the wish-
bone fnom its inner side. Threod the wishbone er
p i n t h r o u g ht h e e y e , s l i p o n i t t h e c u p o s w i t h en
the upper wishbone,then two pin holders with in
the recesses ot the inner hole focing eoch ml
other, onother cup, ond complete the operotion se
by threoding the wishbone pin through the
other eye. thr
12. Slip circlips on the wishbone pin ond it
lock with them the wishbone brockets in po- 5tr
F i g . 6 . 5 / 2- P r e s s i n gS p o c i n g T u b e i n t o Rubber sition. Proceedin the some monner os with the bo
Bush Using MP 6-122Drift upper wishbone (porogroph8).

110
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tlllM slloq f'r 1co1
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'auoqqsgr*raMol eql urntop
o_ols! l! il 'qnq lseqM eql uo r! oulutl {q 1; ir1 l! u! lll 6u1r*g .21
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esoal6 oql uMop 6urmelcs Ig 'do1 uo s1u1ol eql q]tM
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o e s - e r u o se q l s ! u ; d 6 u 1 >e1q l I l u o p u o ' u 6 g s a p p u D p u D q - l q 6 r . ra q l s r e i e q l ' s l n u e L l l r e p u n s r a
puDq-UelpuD puDq-tq6;req1 ]o aro qc!qM sel -qsoM 6ur.rds
-lcnul 6u1lee1seq1 dn xlut ol lou InleJoceB llDlsut puD'e^oqD uoll seloq J!eq]
.411n1 ur slloq aql dlls '{poq a;xo eql euo seuoqqstM
'qsnq 1oulnq q l o q l l o l s u ! p u o ( Z L p u D L L s q d o r 6 o . r o d )l e u u o t u
eq] uo
l u a ! l l s a rs ] t q l l M l a l c o s u 1 d6 u r > 1 e r u D se L l l u ! e u o q q s t M - ! a q l o e L l ] e l q u a s s v . 0 1
s s e : dp u o ' u 1 de q l u o ( l e ) c o s u 1 d6 u r 1 a q l r a p u n
s D a u D Sa q l ) l l o u 1 p e d d r p6 u u u o l l c g . rD+d ! l S
'qsnq uolloq urd
6 u r 1 a q l o l l x o u a n o o r da q l o l u l 6 u r : B u r l o e s r e l l D l s L r l9 0 1 - 9d l A
r a q q n rp e l l o a q l l n d ' a l l c n u l 6 u 1 : a a 1os q l o l u r 6 u 1 s n 6 u r l d g p o 3 6 u r s s a : d r - u o 3- D i g g ' 6 r - J
l ! U e s u ! p u o u 1 d6 u r > 1 aq] llo qllM rDarts '02
' u 1 d6 u r > 1
e q l l o e n o o : 6a q t o l u ! l l l l l p u D s 6 u u a q 1 : a n o
d n c : e q q n . re q l d l l s ' q s n q l u e ! l g s a ru o - p o s s a : d
q 1 ; n tu r d 6 u ; 1 e q 1 u o u e q l l l l p u o ; r o u r ( s . r e
-qsont) s6u1.ruoglcul crlsold orvrlorll dtC -Ot.
lalcos puo
u14 6u;; rrt/c ellonuy 6u;rea1g6u;11;1ag -r
'I:teuoa6
e
e l x D l u o r ] a q t 6 u 1 t s n ! p Du o q r v tp u D s a u o q q s r r l t
e
e q l u o r l s o q s n qr a q q n J1 1 o6 u r 1 1 nuda q n np o s n s l
e
l ! p u o ' . r o cp a p o o l 4 1 1 na1q 1 u 1 u o r l g s o ds l l q l l M
s p u o d s a . u o ce u o q q s ! , vst q l ] o u o l l r s o d s r q l E
'do1sauoqqslMleMol aql ol
lo ruolioq sql a
puo dols pDap raqqnr €q] uaaMlaq ulur OZ to -
a o u D l s ! pD s ! a r e q l l D q l o s 6 u r . r d sa q l s s e l d u o l
M o N ' o u o q q s r l vr ar m o lo r { }p u D6 u u d ss q t rq 6 n o J q i e
p
6 u ; s s o d ' p o r - e ! t J e l l D l s u la q l ' o p u a l o c l . r a q d s 'g
eq] uo raqsDMuedo oq] l!' puo Apoq alxn
aql uo rollDlsur6u;.rdsggL"gdt4 eLll ecDld 'gL la
 23- Fit the disk broke bock plote on the
s t e e r i n gk n u c k l eo n d f o s t e n i t b y b o l t i n g d o w n
t h e b r o k e b r o c k e t .U s e s p r i n g w o s h e r st o l o c k
the bolts. Drive home the wheel hub on the
s t e e r i n gk n u c k l ew i t h l i g h t t o p s o n d u s e o t u b e
t o t o p h o m e t h e b e o r i n gc o n e .
24. Fit the greose-pockedcone of the outer
beoring on the steering knuckie, locote the
s h i m o n t h e b e o r i n g ,o n d t i g h t e n t h e n u t w i t h
o t o r q u eo f 1 . 5 k p n r ( 1 5 N m ) w h i l e r o t o t i n g t h e
wheel hub.
25. Top the wheel hub ond the broke disk 1

with o mollet ond rototethe wheel hub to bed \

in the beoringsB . o c k o f f t h e n u t t h r o u g ho b o u t I
-180o (
ond retighten it with o torque of obout 5 Nm
( 0 . 5 k p m ) w h i l e r o t o t i n gt h e h u b . T h e n b o c k o f f
the nut to the neorest cotter pin slot (ot the r
m o s t t h r o u g h3 0 " ) , o n d l o c k i t i n t h i s p o s i t i o n t
b y i n s e r t i n gt h e c o t t e r p i n . (
26. Check whether the wheel hub rototes
f r e e l y b r - rw
t i t h o u t o n y n o t i c e o b l ec l e o r o n c ei n
t h e b e o r i n g so, n d s e c u r et h e n u t w i t h t h e c o t t e r
pin.
sI
I

Fittirrg Steering Knucklesond Wheel Hub

into Wishbones
(
S
2 7 . H o v i n g t h u s o s s e m b l e dt h e w h e e l , i n s t o l l
lf
i i i n t o t h e l o w e r w i s h b o n e ,f i t o s h i m b e t w e e n
t l - r ew i s h b o n er e o r e y e o n d t h e r e s i l i e n tb u s h i n
F i g . 6 . 5 / 5- P r e s s i n g - i nB e o r i n g C u p s U s i n g t h e k i n g p i n s o c k e t ,t h r e o d i n t h e e c c e n t r i cp i n ,
c i n ds c r e w d o w n t h e n u t w i t h o u t t i g h t e n i n g i t . tr
MP 6-130 Jig
28. Press the wheel ogoinst tlre upper wish- Cl

b o r r eo n d c o n n e c t i t w i t h i t b y t o p p i n g h o m e
t h e w i s h b o n ep i n f r o m t h e r e o r s i d e o f t h e o x l e , A
i. e., from the side of the shorter port of the
k i n g p i n s o c k e t .S l i p t h e M P 6 - 1 0 8p i l o t p i n o n 6-
t h e w i s h b o n ep i n t h r e o d t o f o c i l i t o t e t h r e o d i n g tl-
of the pin throughthe hole in the wishbone. th
T i g h t e ns l i g h t l y t h e c o n n e c t i o nw i t h t h e c o s t e l - th
loted nut. m
gr
lir
O1
sy
ro
po
th
th

th
tir
on
m€

tht
of
DK ? 2r + on
F i g . 6 . 5 / 5- I n s t o l l i n g S e o l i n g R i n g U s i n g Fig. 6.517- MP 6--108Pilot Pin for Upper I
M P 6 - 1 3 1J i g W i s h b o n eP i n l n s t o l l o t i o n by

112
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t o
(Z) relcoS ur6 6ury u! u!d clrlueccf a ; 6 u o r e q u o c e i l l s a 6 u D q o ) t c ! q ] t u r , uL t u ! q s V
a q 1 6 u 1 u r n 1l q p u o ( ; ) l e q c o : g a u o q q s r M 'e;6uo
tadd61puo itpog elxv uearvrlegsrutrls 6urllasu; l.aquDc e q l l o u o l l c s r : o c r e l D l D ro1 u1d aql lo
l q : a q u o 3 l e e q 4 761u r l s n l p y - 6 / 9 ' 9 ' 6 l J A 1 1 c g : l u a c c ee 1 q ; s s o d1 s e 1 o a . r 6 e q l s u l D u l e Je r e q l
lDql os elnr slql e^rasqo o1 guollodtu! s! ll
' , 0 1 o 0o l
5ts , g o 0l o u o l l D ! ^ e p u l n t u l x D t ! D r . l l ! M l u e r !
- 1 s n ! p ol o u r l e q l . r o 1u r d c l r l u e J c a e q l a s n o ] p u o
l
sur!qs o plo aql qllM Alq6no: al6uo aql ls.tll
1 s n ! p oo l e l q D S l ^ p Ds l l l ' o 7 o 1 e ; 6 u o r e q u o c e q l
'6lS'9'6lJ o 1 6 u l p l o c c o
lsnlpo 6urpaecord .tg
.u.ro e6no6 eql
lo alocs aql uo e;6uo raquoc eq] llo poer ueql
p u o ' e 1 o 1 da q l q o n o l t u l o e 6 n o 6 e L l t l o ( s l u r o d
lcoluoc) slcDluoc llD lDql os sleaqm pDor
eql acold'spo: 6ur:aa1s qloq Allocg.rlauuAs
6 u r l r r e : c s p u D M e l c s 6 u 1 . r a a 1 se q l 6 u 1 1 o r c d g
'uo!lceuuoo
eql ualq6!l puo'ugd 6ur1 aql ]o eurl
o r l u a c s q l q l l M ; a 1 1 o . r oAd; a g o l u l x o . r d d os 1 a n o o . r 6
eql l?qr os sPrDMuMop pD3r.l slt uo polJDtu
anoolb eql qllM ouoqqsrM aql qllM leeqM eqt -
lo uollcauuoo ulolloq eql u! u1d cl.rluecce eql C
urnf 'qnq laeqM aqt o] e6no6 s!qr Jo a1old aqt
puo lpoq elxD eql ]o epts reLlye uo e6no6 69;-9
dl l ro tzl-g dW aql lo urrD aql uelsDj -gt
o;6uy requoC 6ur1snlpy
( g ; ' r o d r a d s o 6 u 1 . r dps o o . r a
pesserduoc qlgm) a6noe 6CL-9dlA ro tZL.9 d6 'surd -
6u1s1-1
al6uy raquoC 6ur>1caq3 - B/g'9 '6;3 1 1 o qa q l l o s l n u p a l o l l e l s D c 'l
a q l A l l q 6 r l s u e 1 r 1 6 1'1s p o l 6 u r l a e l s p u o p o r I O D r I
e q l q l l M ( s t u t o ) a 6 o > ; u r ;6 u 1 . r e a 1 a s ql lceuuoc
)*s puD spor 6uueels eql,o {r6ua1 eql loeqC -Zt
'le^Drl s1ryo lonnprur
I;olorurxo.rddo s3 r.ulo (uoLulrd) do.rp 6u1laa1s t
a q l l D q l o s e r l u e c e q l o l A l a l o u r x o . r d d o( 1 1 o q s )
Mercs 6uuaals sql uJnf 'slloq eql Jepun sJaqsDM
6 u r . r d s6 u r 1 1 n de l ! q M x o q 6 u u o e l s a q l l l D l s u l
'eNl
-Uf:t-LS uollces eq] ol la;a.l 'a6o>;ur;puo .roa6
JC
6uuaels eql lo Ilqtuasso lDlnoD aLl] ro3 -!t
roeg 6ulree1g 6u;lquassy
s
' e l x De q l
]o
erluso aq] spJDMol (puaqlno) uorlcallap .le{l
qllM paurnl aq lsnu Aeql 'u6;sap puoq-q6u o
puD puDr.l-llel s q ] e J D s u l o 6 u g . r e a l se q 1 ,
' u 1 d . r e 1 1 o co q l l Ml o > l c o l p u D u
l! lnu pelollelsDs
eql uMop Malcs 'turo Duuaels aql lo poerql l
aql uo JaqsDM o peddrgs 6urnoq JaUV 'aJlM
1o q16ua; D ro alpasu D rlllM lel eql 6ururol ll
' . r o a 66 u r - e J a l ! q M u . r o 6 u 1 . r a a t re sLll uogllsod u! l!l puo
-reels eql ( e g 1 c n u 16 u 1 . r a e 1es q l u ! ) u r o 6 u 1 r a a 1 se q l ' r o l e
; o A l q u a s s D ] c o " r o ca q ] 6 u ! l c e q c _ l o l q
s D l l e M s o u o l l o l e d o . r o 1l p o a . r s ! l D o e q ] u a r l M e l o q a q l u r A o r v r l a >e; q l o l u ! l a 1 a q 1 u e s u l . O t
6 u g 1 1 a ss n o r p e l 6 u r n o s u ! - e o l a q l J o l u a u l s n l
'acuols!p prDseqt
1 a s 6 u 1 n o qJ a U o u a q l l ! l a r e
, p o r 1 6 n o r J o f s o A J e se l n p a c o l d p e q t J O S a pa q . t o1 puo seoLls alDiq sql lsjll e^oueJ ol alqo J
-sr^po s! l! 'uo!]Dredo slql alDll!cDl oj 'slloq
luaurlsnlpy u!-aol Aroulrug;er6 a q l u o s J e q s D M6 u r . r d s] n d ' e l D . r q e q l l l o l s u l e
p u o L I Z ' 6 ' 6 t J t l r t m e o u D p r o c 3 Du ! t u u l L + 6 1 o t g
',8Lo0T puD 't'0 'g-0 ),
;o a6uo: eq] utqltM pa6uoqc eq uDc ecuDls!p s!ql lsnlpD 'lc!ql utu
a ; 6 u o J e q u D O a q 1 ' ( a l q o l r o n o r t l r c r . r l u e c c el l D ' L s L u ! q s 6 u r s 6 ' I s ! p e l o r q e q ] Lo' 0l a l e
la1colq r
gl
r l l l r v r )u r d o r J l u e o o ea q 1 6 u r s n u a q M ' ( s a n ; o n 1 o c elDjq aql io acuDlsrp eql eJnsDau /v\oN '62
 3 5 . U s i n g o m e o s u r i n gr o d o n w h i c h t h e d i s - Fitting Anti-roll Bor
tonces con be morked with o line, meosurethe
distoncebetween the gouge ploteswhen tunned 3 9 . S l i p r u b b e r b u s h e so n t h e c e n t r e p o r t o f
forwords ond reorwords (the plotes must be the onti-rrob l l o r ( c l o s eb e h i n dt h e o b l i q u eb e n d )
o p p r o x i m o t e l yh o r i z o n t o l ) . B y t u r n i n g b o t h ond fit on them the holder. After hoving
s t e e r i n gr o d s ,o d i u s tt h e r o o dw h e e l s s o t h o t t l r e t h r e o d e dt h e o t h e r r u b b e r b u s h e so n t h e e n d s
d i s t o n c eb e t w e e nt h e p l o t e s b e h i n d t h e o x l e i s o f t h e o n t i - r o l lb o r , i n s t o l l i t i n t h e b r o c k e t so n
3 m m l o r g e rt h o n t h e d i s t o n c e i n f r o n t o f t h e t h e l o w e rw i s h b o n e s o , n d l o c k i t i n p o s i t i o nb y
o x l e , o n d l o c k t h e s t e e r i n gr o d s i n t h i s p o s i t i o n clomping the rubber bush by onotherholder.
b y m e o n so f n u t s . S e c u r et h e b o l t o f t h e h o l d e r w i t h o s p r i n g
wosher.

Reinstolling Shock Absorbers ond Completing

Front Axle Reossembly
4 0 . U s i n g t h e s p r i n g i n s t o l l e rr e l e o s et h e r o o d
s p r i n g o n d t h e n r e m o v et h e i n s t o l l e r . F i t t h e
shock obsorber holder to the shock obsorber
e y e o n d c o n n e c tt h e m w i t h o b o l t w i t h o c o s t e l -
loted nut.Lockthe nut with o cotter pin.
Threod the shock obsorberthrough the lower
w i s h b o n eo n d t h e c o i l s p n i n go n d f o s t e n i t w i t h
b o l t s o n d s p r i n gw o s h e r s .
41. Fill the wheel hub cop with the recom-
m e n d e d g r e o s ec n d d r i v e i t h o m e i n t h e h u b .
T h e g r e o s ew i l l p e n e t r o t ei n t o t h e b e o r i n g o n d
l u b r i c o t ei t . U s e t h e M P 6 - 1 2 5 d r i f t t o o v o i d
d o m o g i n gt h e c o p .
F i g . 6 . 5 / 1 0- M e o s u r i n gF r o n t W h e e l T o e - i n 42. Screw down o greose nipple on the bot-
t o m b e o r i n go f b o t h k i n g p i n s o n d l u b r i c o t et h e
enti,reoxle with the recommendedgreose.
36. Rotote the steering screw to check the
correctnessof the steering geor reossembly.
With the wheels in the right-hond ond left-
h o n d l o c k p o s i t i o n w h e n t h e s t e e r i n gk n u c k l e
o b u t s o g o i n s tt h e b o s s o n t h e k i n g p i r - rs o c k e t ,
both extreme positions in the steering box
m u s t b e r e s i l i e n t ,w i t h o u t o n y h o r d i m p o c t s .
lf this is not the cose ond there is o hord
impoct, correct the odiustment by shortening
o n e s t e e r i n gn o d o n d l e n g t h e n i n gt h e o t h e r o n e .
3 7 .H o v i n g o d i u s t e dt h e c o m b e ro n g l e o n d t h e
t o e - i n ,r e t i g h t e n
o ) t h e n u t s o f t h e e c c e n t r i cp i n s o n d l o c k t h e m
with cotter pins
b ) t h e n u t s o f t h e u p p e r w i s h b o n e so n d l o c k
them with cotter pins
c ) t h e b o l t s o f t h e u p p e rw i s h b o n eb r o c k e t
d) the nuts of the upperwishbone pins ond R
l o c k t h e m b y t i g h t e n i n gt h e t h i n n u t s F i g . 6 . 5 / 1 1 -D r i v i n g - o nW h e e l H u b C o p U s i n g
e) the nuts of the lower wishbones ond lock MP 6-125Drift
them by tighteningthe thin nuts
f) the nuts of the boll ioint pins (boll pins). o
tl
For tightening torques see Chopter 1.8. 6.6 STEERINGKNUCKLE

The steering knuckle is o unit formed by the tr

38. Recheck the wheel comber,remove the
el
gouge,ond screw down loosely nuts ond wosh- swivel pin, the broke bock plote brocket ond
ers on to the protrudingends of the lower wish- g u o r d ,s p e c i o l s e l f - l u b r i c o t i n g
b u s h e s ,o n d t h e
b o n e p i n s i n t h e f o l l o w i n go r d e r :t h i n n u t ,s p r i n g spocing tube. The right-hond ond left-hond P
wosher, two ploin woshers, onother spring steeringknucklecon be identified bythe greose e1
w o s h e r ,o n d o t h i n n u t . nipple or nipple hole which must foce forwords. th

114
 sir
'seqsnq -uour slql esn 'lerpuoruDugsserdseL-g dn eql '
eql oulujoar rol JeruoeJttl-g dt^l or{l osn 6u;sn rep;noqs reMol .eql lo uolsuaulp arllue
'z19'9 sql ultlllM u1d eql olur eqnl 6ulcods eq1 sse.rd
'6lJ ut umorls uotsueurlpeql ol .ro 6ug.t6u;goes 'seuo Meu rlllrvrseqsnq eql burcolda.r
ueq6
eql rol ssocer eql qllM qsnll qsnq reqlo eql 'sPue
u1 sserd ueql 'o6 lllm r! sD rDl sD r.lsnq.raddn relno eql uoJl seqsnq aql 1no ssald puD aqnl
eql u! ssetd '11 lceqc oI 'uollceuuoc eql lo oql lno 'pasn oq
lnc louuDc poqleu slqf ll
sseulqBlyeloan pellnbel ar.ll sernsue 6u1dtuolc
s1q1 'pedtuolc Agu.r;;s! aqnl Eulcods eq1 llp qsnq urolloq eLll
pod laano;aql olu! qsnq JeAol lsJll sql sseJd q6norql qsnq do1 eq] puD eqnl 6ulcods eq1 1no
'eqnl ssa:d '1e:puoru6ugsse:dSCt-gdW eql 6u1s1-1
6ulcods eq1 1su1o6osroeq l! ll!r u!d eq1 ;o yod 6
leddn eq1 olu! qsnq aql 6u1sse.rd.ro; oslo leJp seqsn€ 6u;coldeX
6ululqcotu rlaql puD seqsnqaql uo 6ugsse.rdxll
suolsueurlg
ellcnu) 6u1.ree1g
- Zi9'9 '6!J
e
-1
p!
'Pq
- Ll.
ql
JO
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ro
e
p u o q - 1 q 6 -1Zr ' p u D q - t l e l - L P
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6
6
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uo
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6u
(p
lo
DimensionolCorrelotionof King Pin ond Bushes The cylindricol surfoceof the king pin connot
be reconditioned. Grinding or ony other mo-
chining is opt to destroy its speciol surfoce
Bush inside diometer 1 8 J0 . 0 1 8 finish. When worn, the king pin must be re-
ploced with o new one.
pin diometer

Cleoronce of moximum
king pin ond bush weor

6.7 KING PIN

The king pin is formedbodily by the pin cnd
its resilient bush. For pressing the bush in crnd
o u t , u s e t h e M P 6 - - l - 1 2m o n d r e l .

a
a

F i g . 6 . 7 l 1- P r e s s i n g - i n
of King Pin Resilient
B r " r s hU s i n g M P 6 - 1 1 2M o n d r e l
T
C

6.8 KING PIN SOCKET o

1211 s
I t c o n s i s t so f t h e s o c k e t i t s e l f o n d t h e r e s i l i - 2
F i g 6 . 6 i 1 -3 P r e s s i n g i n o n d o u t K i n g P i n e n t b u s h .F o r p r e s s i n gt h e b u s h i n o n d o u t , u s e
l J u : ; h e sU . s i n g M O 6 1 3 5 P r e s s i n g M o n d r e l t h e M P 6 - 1 1 2m o n d r r eol s i n t h e c o s e o f t h e k i n g
pin bushes.
T h e r i g h t - h o n do n d l e f t - h o n d s o c k e t c o n b e sl
i d e n t i f i e db y t h e r e l o t i v e p o s i t i o n o f t h e h o l e a(
f o r t h e k i n g p i n o n d t h e c h o m f e r i n go f b o s s e s fil
limitingthe wheel lock positions.
1
al
(2
2.

PI

thr
ler

F i g . 6 . 8 / 1- K i n g P i n S o c k e t to
F i g . 6 . 6 i 4- R e o m i n gK i n g P i n B u s h e sU s i n g dti
M P 6 - 1 - 1R 4 e o m e ro n c l i t s P i l o t T o p e r 1 - l e f t - h o n d 2, - r i g h t - h o n d tht

116
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'surur a q l r a p u n ' r a q s e Mr o q q n ra 0 r e ;e q l p u e r a l p r a q l
9t lcNvMottv
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 5. Turning force of box and column only. The LENGTH OF ARM
m a x i m u mp e r m i t t e dt u r n i n gf o r c e o f t h e b o x a n d
c o l u m no n l y ( d r a g l i n k a t t a c h e dt o s t e e r i n gb o x
b u t a l l o w e dt o s l i d e f r e e l ya c r o s si d l e r )i s 1 . 2 k g
2 . 5 l b sw h e n t e s t i s c a r r i e do u t a s i n ( 2 ) .l f t h e f o r c e
i s e x c e s s i v el ,u b r i c a t eu n i v e r s ajlo i n t s a n d c h e c k
t h a t t h ed r a gl i n k a s s e m b l yi s f r e et o m o v e .R e p e a t
t e s t . l f s t i l l e x c e s s i v er e m o v et h e s t e e r i n gb o x ,
w h i c h c a n b e r e m o v e dw i t h t h e t r a c k r o d s t i l l
attached.
T I M EA L L O W A N C E 5 m i n s .
6. Turning force to rotate Steering Box input
'sSh' a f t .W i t h s o m ef o r m o f c o u p l i n g( c o u p l i n gf r o m
t y p e S t e e r i n gB o x ) t e s t t h e f o r c e r e q u i r e dt o
r o t a t et h e s h a f t ;m a x i m u mp r m i t t e dt o r q u e 0 . 16 k g
1 . 1 6 f tl b s .l f u s i n ga n a r m a n d s p r i n gb a l a n c ea s
shown the maximum force required can be
c a l c u l a t e db v e.g. wrth length of arm
160 1 . 1 6x 1 2 6 inches max.
permitted force
a r m l e n g t hi n c r n arm length in inches e q u a l s1 . 1 6 x 1 2
6
T h e s e t e s t s s h o u l d b e c a r r i e do u t w i t h t h e
= 2.32lbs
w o r m i n t h e c e n t r a lp o s i t i o n T. h e i n i t i a lf o r c ew i l l
b e 0 . 2 5 k g % l b g r e a t e rt h a n t h e a v e r a g ep u l l -
f o r c e .l f e x c e s s i v er,e m o v ei n p u ts h a f tt o p b e a r i n g
cap and adjust the bearing to give 0.OO to
0 . 0 5 m mp r e l o a d . DUST
S h i m P a r tN o . 1 1 O - 5 0 9 6 5 0S t e e lO . 3 m m COVER
1 1 0 - 5 9 O 9 0 OP a o e rO . 2 m m
1 1 0 - 5 9 0 9 0 2 P a p e rO . 7 m m
R e f i tt h e s h i m s a n d g a s k e t sa n d r e t a i n i n gc a p ,
f i t t h e r u b b e sr e a l i n gr i n gd i p p e di n o i l a n d f i t t h e
t h i n d u s t c o v e r .l f t h e d u s t c o v e rs e e m ss t r a i n e d ,
i n s t a l la p a p e rg a s k e tb e t w e e nt h e c a p a n d d u s t
cover.Part No. 1 1O-5909O0.
R e t e s tf o r t o r q u e a n d c h e c k r o c k e rs h a f t e n d
f l o a tw h i c h s h o u l db e b e t w e e nO . 4 a n d O . 5 m m .l f
excessive a n d u n a b l et o a d j u s t b y t h e a d j u s t i n g
bolt, replace steering box after contacting the
S e r v i c eD e p a r t m e n t .
R e a s s e m b l ec a r a n d c h e c k t h e m a x t m u m
p e r m i t t e df o r c e a t t h e s p o k e i s 2 . 4 k g 4 . 5 l b s .
C h e c k t h a t t h e w h e e l a n d i n d i c a t o rs w i t c h i s
c en t r al i s e d . 4 . 6 l b s w h e n a p p l i e dt o t h e i n b o a r de n d o f t h e
R o c k e rS h a f t N u t T o r q u e 1 0 0 N m ( 7 1 l b f t ) . t h r e a d e dp o r t i o n .
TIME ALLOWANCE 7O mins. (inctudes T I M EA L L O W A N C E - O f fV e h i c t e 1Omins.
c o s to f a d d i t i o n asl h i m s ) lf problems are experiencedwith wheel
7 . O t h e rp o i n t sw h i c h c a n a d v e r s e l ya f f e c tt h e v i b r a t i o no n t h e f r o n t a x l e i t i s n e c e s s a r tyo c h e c k
t u r n i n gf o r c e o f t h e S t e e r i n gm e c h a n i s m : t h e a m o u n to f w e i g h t a p p l i e dt o o n e h a l f o f t h e
a ) e x c e s s i v et e n s i o n o f t h e b a l l j o i n t s . w h e e l r i m w h i c h s h o u l d n o t e x c e e d5 0 g r a m s .
b ) W o r k s h o p M a n u a l 7 . 5 . 5 . e x c e s s i v et e n s t o n Y o u a r e r e m i n d e dt h a t c h e c k A 1 , k i n g p i n
o f t h e d r a g l i n k a r m s . T h e f o r c e r e q u i r e dt o adjustment,is requiredto be carriedogt at each of
m o v et h e a r m s h o u l d b e a p p r o x i m a t e l2yk g o r t h e s i x a n d 1 2 , 0 O Om i l e s e r v i c e s .

I
ADJU S T

UT 2KG {4.6lbs)

118
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Complete- Shoft wtth
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Box wlth Llnkoge

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eql qcDlep puD sdoc 6u;.toaq qroq lo slloq i o l c o l o t e n p U o q s u u n l o c 6 u r : e e 1 se q l q l l M
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 5 . P l o c et h e s t e e r i n gb o x w i t h i t s b o t t o m b o l l 4 . M e o s u r et h e h e i g h t o f t h e b e o r i n g p r o -
b e o r i n gr e s t i n g o n t h e M P 7 - 1 0 2j i g o n d p r e s s t r u d i n g f r o m t h e s t e e r i n gb o x o n d o d i u s t i t b y
t h e s t e e r i n gs c r e w w i t h b o t h b e o r i n g si n t o t h e f i t t i n g s h i m s i n t e r s p o c e dw i t h p o p e r g o s k e t s
i i g . E x t r o c t t h e b o t t o m b e o r i n gu s i n g t h e M P c o o t e d w i t h o s e o l i n gc o m p o u n d .F o s t e n d o w n
6 - 1 1 1k i n g p i n s o c k e t r e m o v e r o n d p u s h t h e the cop by tightening the bolts. Check the
s t e e n i n gs c r e w w i t h t h e t o p b e o r i n go e r to f t h e steeringscrewfor free rototion ond the obsence
steering box. Supportthe beoring by the Mp o f p l o y . T h e b e o r i n gs h o u l d b e w i t h o u t o c l e o r -
7-102iig crndpress it out. once or there hos to be o prestress of up to (
0.07 mm. t
5 . R e m o v et h e b o l t s o f t h e c o p , s l i p t h e r u b - t
b e r s e o l i n gr i n g d i p p e d i n o i l o n t o t h e s h o f t , s
7.3 REASSEMBLINGSTEERINGBOX ond fit the dust cup on the cop. lnstoll spring r
w o s h e r so n t h e b o l t s . S h o u l d t h e c u p b e o v e r -
stroined due to the toleronce of the recess for
1 . P r e s st h e d u s t c u p w i t h i t s s e o l i n g r i n g t h e s e o l i n gr i n g o r t h e r i n g i t s e l f, i n s t o l l o p o p e r
i n t o t h e s t e e r i n gb o x w i t h t h e p r e s s e d - i nb u s h g o s k e tu n d e ri t o s u n d e rt l r e c c r p .
o f t e r h o v i n g t h o r o u c h l yc l e o r r e dt h e b o x . N o w 6 . L o c o t e t h e s t e e r i n gn u t o n t h e s c r e w f o l - 1
pfoce the box on the MP 7-102iig oncl press-in lowecl by the rocker shoft with pin, spring,
t h e b o t t o m b o l l b e o r i n c tu s i n g t l r e i p r e s s i n g spring pin, ond the licl gosket cooted with
m a n d r e lM P 7 - 1 0 3 . o s e o l i n gc o m p o u n d ,o n d f i t t h e l i d w i t h b u s h
2 . F i t t h e l o w e r b e o r i n gc o p s e o l e d o f f w i t h in positionto close the steeringbox. Instoll
o poper gcsket ond seoling compound,slip s p r i n gw o s h e r su n d e rt h e b o l t s o r r d t i g h t e n t h e S
l p r i n g w o s h e r so n t o t h e b o l t s , o n d t i g h t e n t h e bolts with o torque os per Chopter 1.8. Screw t
bolts with o torque os per Chopter t.6. f it the the set screw into the lid ond rnove the steer- S
w o s h e r o n t h e s t e e r i n gs c r e w w i t h i t s d e f l e c - ing geor so thot the drop orrn is swivelled
tion focing the screw threod ond press the throughobout one holf of its trovel from the one n
t o p b e o r i n go n t h e s c r e w u s i n g t h e M p Z - 1 0 3 or the other extreme lock position.Witlr the o
p r e s s i n gm o n d r e l . drop ornr in this position, screw down the set
3 . T h e n p l o c e o g o i n t h e s t e e r i n gb o x o n t h e screwos for os it will go ond then bock it off
through obout 95 to '120'.This will provide for
fl
M P 7 - 1 0 2i i g o n d p r e s si n t o i t o n d i n t o t h e b o t - p
tom beoringthe steeringscrew with the pnessed- on odequote cleoronce of the steering geor. t\
- o n t o p b o l l b e o r i n g ,u s i n g o g o i n t h e M p 7 - 1 0 3 [.ock the set screw in position with the re- e
p r e s s i n gm o n d r e l .F o r f u r t h e ro s s e m b l y u, sethe spective nut. g
v i c e o n d t h e d u m m yb r o c k e t . 7. Drive the key on to the rocker shoft cone, tl
fit the drop orm ond hold it down lightly with
the nut. Clomp the drop orm in o vice, tighten S
fully the nut (for the tightening torque see T
C h o p t e r 1 . 8 ) , o n d s e c u r et l r e n u t w i t h o c o t t e r o
p in .
8 . C l o m p o g o i n t h e s t e e r i n gb o x b y m e o n so f e
t h e d u m m yb r o c k e to n d m o k e s u r et h o t t h e d n o p ir
orm con swivel from one extreme lock position h
to the other.A certoin resistonceshould olwoys
be present, but if the resistonce is too greot, el
decreoseit by o slight slockening of the set r€
screw in the lid. The rototing resistonceof the re
shaftshouldnot exceed20 Nm (O.2kpm).Referto
page 117/118 for testingprocedure.
9. Set the ossembledsteering box in its fit-
t i n g p o s i t i o n ( i n c l i n e d b y o b o u t 4 0 o )o n d p o u r
i n o i l t h r o u g ht h e h o l e i n t h e b b x l i d ( c o v e r )
till the oil level reochesthe bottom edge of the
f i l l i n g h o l e .T h e n s c r e w d o w n t h e t o p e r e dp l u g .

7.4 RELAY (TDLER)LEVER

F i g . 7 . 3 1 1- P r e s s i n g - i nB o t t o m B e o r i n g F o r i t s i n s t o l l o t i o n( o n d r e m o v i n gi n r e v e r s e
o n M P 7 - 1 0 2J i g ( s u p p o r tp l o t e ) U s i n g order) ond ony pertinent porticulors see the
M P 7 - 1 0 3P i r e s s i n q Mondrel Chopter 6.5, porogrophs2 ond 3.

122
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o d i u s t ,i f n e c e s s o r yt,h e d r i v i n g d o g o f t h e d i -
rection indicotor switch - see Chopter 13.17.
Refit the steering wheel so thot its spokes
o r e h o r i z o n t o l ,l o c k i t i n p o s i t i o n w i t h t h e n u t
(for tightening torque,see Chopter 1.8), ond
bolt down the spoke shroud.
7 . 8 S T E E R I N GW H E E L S H A F T A N D S H A F T
BEARING
T h e s t e e r i n gw h e e l ( c o l u m n )s h o f t i s b u i l t u p
of two ports with the beoring in the uPPerport.
Usuolly, it is not necessoryto disconnect the
two ports of the shoft or to removethe beoring
ond steering lock. lt con be removed from the
cor os o unit.
Removol
1. Removethe steering wheel - see Chop-
ter 7.7.
2. Remove the screws on the lower port of
t h e s h o f tc o w l i n g o n d p u l l t h e c o w l i n go f f . A f t e r
removing two bolts, detoch the cluster switch
on the shoft from the upper port of the shoft
cowling.
3. Removetwo front screws of the upper Port
o f t h e c o w l i n g o n d r e m o v et h e c o w l i n g .
4. Disconnect the leods from the switches
ond the switch box.
5. From under the cor, remove the bolt of the
c o u p l i n gc o n n e c t i n gt h e s t e e r i n gc o l u m n s h o f t
to the steering box ond detoch the dust boot
f r o m t h e f l o o r . R e m o v et h e b o l t s o f t h e s h o f t
beoring (from under the shoft) ond the bolts of
t h e s t e e r i n gl o c k ( f r o m t h e f r o n t ) f o s t e n i n gt h e
s h o f t t o t h e b o d y ,o n d p u l l o u t t h e s h o f t .
Refitting
T o r e fi t t h e s t e e r i n gc o l u m n s h o f t i n t h e c o r ,
r e v e r s et h e r e m o v i n gp r o c e d u r eW . hile reinstol-
ling the steering wheel (Chopter 7.7), do not
forget to check the direction indicotor switch
for correct function.
U s e p l o i n o n d s p r i n g w o s h e r su n d e rt h e b o l t s
o f t h e s t e e r i n gl o c k b r o c k e t .R e i n s t o l lt h e s h o f t
b e o r i n gu s i n g s p o c i n gt u b e s ,r u b b e rb u s h e so, n d
p l o i n w o s h e r s ,o n d s e c u r et h e b o l t o f t h e c o u p -
l i n g , c o n n e c t i n gt h e s t e e r i n gc o l u m ns h o f t w i t h
t h e s t e e r i n g b o x , w i t h o s e l f - l o c k i n gn u t ( f o r
t i g h t e n i n gt o r q u e ,s e e C h o p t e r1 . 8 ) .
To DisconnectShofts
R e m o v et h e b o l t o f t h e c r o s s - p i ni o i n t c o n -
nection.
Connectingof Shofts
F i t o f o s t e n i n g s l e e v eo n t h e t u b e w i t h t h e
s h o f t ,d i p t h e r i n g i n o i l o n d s l i p i t o n t o t h e
124
s h o f t e n d w i t h i t s w e d g e - s h o p e dp o r t t o w o r d
t h e b e o r i n g ,i n s t o l l t h e s p r i n g o n d t h e i o i n t
socket of the shoft bottom port. Tighten the
c o n n e c t i o nw i t h t h e b o l t w i t h s e l f - l o c k i n gn u t
( t i g h t e n i n gt o r q u eo s p e r C h o p t e r 1 . 8 ) . (
T h e s l e e v em u s t b e f i r s t b u i l t u p i f t h e s h o f t t
is refitted for the first time. Locote both holves t
of the sleeve on the tube ond fosten them t
l i g h t l y t o g e t h e rb y b e n d i n gt h e t o b o f o n e h o l f
of ttre sleeve over the other. The sleeve must ;
o n n o o c c o u n tc l o m p t h e t u b e t i g h t l y . (
Bottom Port of Steering Column Shoft (
T h e s h o f t i s p r o v i d e dw i t h c r o s s - p i n i o i n t s
o n d c o n n o t b e d i s m o n t l e d( t o k e n o p o r t ) . B e f o r e
f i t t i n g t h e s h o f t d u s t b o o t , s m e o ri t w i t h o i l t o
f o c i l i t o t ei t s s l i p p i n go v e r t h e p c r r t so f t h e j o i n t .
F o r t h i s p u r p o s e ,i t i s c l s o o d v i s o b l et o w r o p
the joint in o plostic foil or to moke o sleeve
with o pilot cone.
Top Port of Steering Column Shoft - Beoring
Removol
1 . l - i f t o w o y t h e f o s t e n i n gs l e e v e o n d c h e c k
whether the shoft rototes freely in the tube. lf
i t i s n o t t h e c o s e ,u n l o c kt h e s t e e r i n gl o c k o n d
press out the shoft proceedirrgfrom the side b
o f i t s s p l i n e de n d . tl
2. lf necessory, removethe circlip of the shoft ir
ond lift owoy the beoring. The other beoring tl
hos to be driven out by topping it corefully
t h r o u g ht h e c u t - o u t si n t h e t u b e t o o v o i d d o m o g - p
ing it. il
3. Removethe brocket with the steering lock o
- see Chopter 7.9. tl
R e fi t t i n g p
1 . S l i p t l r e b e o r i n gp o c k e d w i t h g r e o s eo n t o
t h e u p p e rp o r t o f t h e s h o f t , t h e n t h e r i n g w i t h
its wedge-shopedport focing the beoring, ond
lock both ports in position with the circlip.
Press the shoft into the tube ond press-inthe
b e o r i n g ( o g o i n p o c k e d w i t h g r e o s e )f r o m t h e
other end.
2 . l n s t o l l t h e b r o c k e tw i t h t h e s t e e r i n gl o c k -
s e e C h o p t e r7 . 9 .
Shoft Beorings
They hove to be thoroughly lubricoted first,
since ofter their reossemblywith the shoft od-
d i t i o n o l l u b r i c o t i o ni s n o t p o s s i b l e .l f t h e r e i s
ony doubt concerning the greose pocking, re-
move the circlip f rom the inner port of the
beoring, toke the beoring oport, cleon it, ond
r e o s s e m b l ei t o f t e r h o v i n g p o c k e d i t w i t h t h e
r e c o m m e n d e dg r e o s e ,i . e . , b r o n d N H 2 o f C z e -
choslovok provenience or one of the bronds
s p e c i if e d i n C h o p t e r7 . 5 , p o r o g r o p h3 .
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SONIUcIS UV:IU Z'8 u o ; 1 d ! J c s a Cl o s r u q c a l
er-i s
8.3 SHOCK ABSORBERS Both types of shock obsorbersore of similor Sh
design, only their bottom fostening is different
The shock obsorbers ore of the hydroulic, (the front shock obsorberhos o fostening eye,
telescopic,double-octingtype of the PAL moke. C
the reor shock obsorber hos o bolt ond locks cle
The dompingeffect dependson the speedof the the outer protective tube). They hove o differ-
relotive movementsof the oxle ond body. Doto the
ent stroke,domping force, ond filling copocity.
required for testing ond odiusting the shock 1
obsorbersore given in the following Tobles. fittr
Removingond Refitting bor
Front Shock Absorber - see Fig.8.3/1 (Im(
type PT 26x110, Ser. No.443.621-215.000 When removingor refitting o shock obsorber, 2
1977-74 19 7 8 o n retoin the piston rod (upper fostening) by hold- wit
ing the flottened end of the threod in o sponner. woI
Maximum stroks llO mm 110 mm
In the cose of the reor shock cbsorber, retoin pis
Damping torce during the piston rod in the bottom port by holding the wor
470N 500N
down stroke (compr€s- heod of the bolt connecting it to the shock the
sion
obsorbercylinder. loc<
Damping force during
The ossembly of the rubber bushes of the (11
upward stroke (expan- loSN 1300N
sion) respectiveshockobsorbermounting con be seen 3.
in Fig.8.3/1. obo
Filling capacity lOO cc 1OOcc 'the (M(
Access to the upper mountings of front I nst
shock obsorbers is from the luggoge boot rod
Reor Shock Absorber (under the floor). The threod is protected by the
type T 26x175; Ser. No. 443.621.247.OO1 o cop nut. The mountings of the reor shock oil'
1977-78 19 7 8 o n obsorbersore occessiblefrom the reor luggoge into
comportment behing the reor seot bockrests
Maximum stroke 175 mm 175 mm
ofter folding owoy the upholsteryon the wheel 4.
orch. The mounting is in the cyllndricol exten- witt
Damping force during
down stroke (compres- 470N 500N sion piece in the scuttle of the reor dosh. Con
ston, prot
Damping force during Shock Absorbor Dismcntling
upward stroke {expan- 950N r 200N
sronl
D i s m o n t l i n gi s o r o u t i n ep r o c e d u r eb e g i n n i n g
Filling capacity 160 cc 160 cc with screwing out the plug (1) ofter the pro-
tective sleeve (tube) hos been removed.Never
*) At o temperotureol 25 to 30oC, o frequency dismontlethe piston volves since there is o risk
of 100 strokes per minute, ond o stroke of of impoiring the domping force by mixlng up
100 mm. the volves.
Inod
On f(

Inod
oll c(

Exce
on c(
Fig.8.3/1- Front Shock Absorber- Sectionol View

130
 reL
Apoq en;on uollcns uo
sallol dod ;o Jequnu ocnper aco; 6u;1oese6rol oo1 'en1on uolssa:dtuocuo
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Jaqrosqo )coqs a-lllue a^lDA uollcns lo se^lD^ uolssalduoc tttt
qsnll 'rallDr-u u6ta:otr elotuaU dod uaervrlaq JellDu.r u61arc1 aoro; 6trtdurop alonbapoul
se^lDA dod 1o se^lDA
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sl!ru!l ecuDJelollgqo.replsuoc
seuo rttau qllM suDd speacxe:epu;;lc 6u1>;ror*
uronnaco;deJ 'ocuDrDelc lcaqC puo uolsrd ueeMloq ocuDloelC
ap;nD Meuau IsDls eplne
a A I D AM e u a u pel.rolsrpuo1s1deloqD a^lDn
palDes
reqJosqD lsoqs A;1ce.r.roc
lou uolsld e^oqD e^lD^ (uolsuodxe) punoqel uo
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lo ssol egduoxe lo; slcoleP Jeqlo ll {c
'(A:ossecausD 'dn ol ul (e ) 6u;.r6u;1oaseql llJ '.repugllc6u;>1.rotnt' eq
aql olu! Atfqbtl auoq ll do1 puo' po.t uolstd u!
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ol l!o dn dol '6u11codoql ro ;oes qlul.tAqolaqt (Z) po.r uo1s1daq1 {1gn;atDcuasu! MoN 'z 'rg
6u;co1de:ol!qg 'JeqrosqDlcoqs eql lo ocDl.rrrs 'l!o
aql uo s.roaddo;1o.raduop'esDcD qcns u1 '6n1d lunouo
'l(oF )
eqt ,o 6urlcod peBouropeql ro pol uolsgd eql t c o x a p e p u o u u r o c o ar q l q u M l ! l l ! J lerroq
paBor.uop eql ol anp a6o1oe1 r a p u l l A cr a l n o e q l o l u ! ( g ) e A I D Au o ! l c n s p e l l r l
lo loes qlul.rAqog oLll tll!M (9) tapulllc 6u11.rornt aql llDlsul '! 'A
ieqlosqD lcor{s sr }ce}ep luanber; }sou eql
'1ua5o 6u1uoa;c reqlouD ,ro 'Jel
;ol1edu! ueql
's1.rodlueuodtuoc rauu!
srgodeg- slcaleq reqrosqy lcoqS 111rvrg llD lo sseuuoalc sr
eLll ol uo!luellD ;otcadsIod 'I;quassDeJD uO 'e
' s a q s n qr e q q n l 'a';
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 Defect
Jerky upword stroke
Domping force increoses
on compression
Shock obsorberknockswhen
exponslonstorts. Domping
force poor ot first. loter rises
to normol
Check shock obsorbersfor correctoperotlondirect in position in the cor uslng o diognosticoppor'
otus or, ofter removol,on o test bench in comploncewith molntenonceinstructlons.
Airlock obove plston
Oil leokoge due to domoged
piston rod
Plug worked loose - oil leoks
post the threod
Suction volve does not closc,
oil is forced Into reservetube -
oir is sucked in obove the plston
E x c e s s i v eo i l f i l l i n g
Volve obovepiston sticking
132
Remedy
Flll shock obsorber correctly
wlth oil
Renew piston rod ond lobyrinth
seol - check shock obsorber
mountlng on cor
Reflll oil ond tighten plug
correctly
Remove foreign motter from
suction volve - renew suction
volve body lf volve seot
is domoged
Adiust to specificotio.ns
Removecouseof stlcklng, or
chlps- renewvolve,reflll shock
obsorberwith oll
 8et
WL selorS lo 6ulpealS puo PlnlJ alDrS 6'6
0rr e{or8 PuoH 8'6
0rt s e s o Hp u D 6 u l d ! d ' l u D l p l n l J e l o r g L'6
6tI relsooS alor€ 9'6
8tr repu!l^c leeq^ alorS luorJ 9'6
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C
r

F i g . 9 . / 1 - H y d r o u l i cB r o k e S y s t e mD i o g r o m
s
'l -
Broke f luid tonk l
2 - M o s t e rc y l i n d e r
3 - Broke booster (on SfOOn 120 LS cors) r
4 - M o s t e r c y l i n d e ns u p p l y l i n e I
5 - Moin front-brokecircuit line (
6 - Front brake distribution system \
7 - Front broke mechonism
8 - Moin reor-brokecircuit line
9 - Reor broke distribution system
10 - Reor broke mechonism
I on cors fitted
11 - Broke booster vocuum line I with broke
J booster
1 2- S u c t i o n l i n e c o n n e c t i o n

F i g . 9 . 1 / 1- R e o r B r o k e A s s e m b l Y

134
 981
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lcol puD llDtsu!
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'z
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Alquassoax
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: a p u ; 1 r i 3l e e q M u M o p 6 u ; p 1 o 1 -1 Z I L ' 6 ' 6 t J l e a q M a q l p u D a 1 o 1 c6l u 1 > 1 c Deqq l u o s l t l e u l n qo
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l l € r l r rs D y q d o r 6 o r o d a q l o ] o s l D J e l a J s a : n p e c o l c l
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'ADM slt.l] ul
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aql qllM 6utids aq1 a6o6u3 'A;loc11otuolno
- D u 1 m se q l q l l M s u l d l o q c u D e o q s o q l u o s l r o d
'su1d aql uo 6ur'rdsaq] p a l s n ! p o a J D s a l o r q J r D e JP U D l u o J l e q l q l o q
p e . r o d a l do q l l ! l p u o 'sleoqM lDal e^qluo pellrl 6trlaq
a l o o o l ' . r a 1 s n ! p o - ; 1 ae sq l ] o t - u l o6 u r 6 u l M s a q l , o ]o saoqs eql
't srun.rp gllrvr salDJq eoLls 6u;puodxa louralul
s u l d e q ] u e a M l e q i a ^ e l + t o - a c l o l3 q l l l D l s u l 'sleoqM
' 6 u 1 r d se L l ] q c l e J l s o l r e ^ t r P luoJ, aql uo PaPl^old eto saloJq 3s!C
'edAt 6 u ! t c D l c e r ! p eql s1uelsAs alDrq aql
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 Broke Shoes ond Broke Drums T h e l o w e s t l i m i t o f t h i c k n e s so f o s t i l l u s o b l e
b r o k ed i s k i s 6 . 5 m m . T h e m o x i m u mp e r m i s s i b l e
W h e n r e f i t t i n g o b r o k es h o e w i t h o p o r t i o l l y r u n - o u to f t h e f r i c t i o n s u r f o c ei s 0 . 1 5m m .
worn lining moke surethot it hos o thickness 1. After hoving lifted owoy the broke os-
sufficientto lost till the periodic inspection s e m b l y ,r e m o v e t h e w h e e l h u b o n d t h e n t h e
(ofter every 20,000kilometres).The new lining b r o k ed i s k .
is 5 mm thick. When it is worn down to 1.5 2 . R e o s s e m b l teh e b r o k e d i s k w i t h t h e w h e e l
'l
to mm (4 to 3.5 mm when meosuredwith the h u b u s i n g c o p s c r e w sw i t h s p r i n g w o s h e r s .
s h o e ) , t h e b r o k e s h o e h o s t o b e r e p l o c e dw i t h 3 . T o p r r po r c h o n g et h e l u b r i c o n ti n t h e w h e e l
o n e w . o r o r e c o n d i t i o n e ds h o e w i t h g l u e d - o n h u b b e o r i n g so n d r e i n s t o l lt h e b r o k e o s s e m b l y
n e w l i n i n g . B e s u r e t o r e p l o c et h e r e s p e c t i v e
broke shoes in both wheels to preserveo uni- ReplocingBroke Pods
form broking effect.
S p e c i o l g l u e s o r c e m e n t s o n d h o r d e n i n go t The overoll thicknessof o broke pod with
h i g h t e m p e r o t u r e so r e r e q u i r e d w h e n r e l i n i n g new lining is 15 mm.When worn down to 7 mm
t h e b r o k es h o e ss o t h o t t h i s i o b c o n b e d o n e i n (with the lining 1.5 mm thick), the pod is
s p e c i o l i z e dr e p o i r s h o p s o n l y . F o r i n f o r m o t i o n , unusoble.
opply to the broke monufocturer- Autobrzdy Alwoys reploce broke pods on both ends of
N o t . C o r p . ,J o b l o n e cn o d N i s o u . t h e o x l e o f t h e s o m et i m e s o t h o t t h e i r w e o r i s
B r o k ed r u m sa r e g r e y c o s t - i r o nc o s t i n g s .T h e i r u n i f o r m .W i t h r e g o r dt o t h e c o e f f i c i e n to f f r i c -
u n e q u o lw e o r c o n b e r e c t i f i e d b y m o c h i n i n gt o tion, they hove to be of the some type ond
o 2 3 1 m m d i o m e t e r .N o t o o l m o r k s m u s t b e l e f t rnoke.
on their surfoce which hos to be perfectly 1 . S u c k o f f t h e h y d r o u l i cf l u i d f r o m t h e t o n k
s m o o t h . T h e o l i g n m e n td e v i o t i o n o n d m o c h i n - so thot it is only holf filled.
i n g t o l e r o n c es h o u l d n o t e x c e e d 0 . 1 m m . T h e 2 . R e m o v ec o t t e r p i n s o n d l i f t o w o y t h e b r o k e
m o x i m u mp e r m i s s i b l ew e o r i s u p L o 2 3 2 m m i n lining cover.
diometer. 3 . R e m o v et h e f r i c t i o n p o d , c l e o n t h o r o u g h l y
tr
O n l y b r o k e d r u m s w i t h o n i d e n t i c o ld i o m e t e r t h e c o v i t i e so f t h e y o k e s ,p i s t o n p o r t s ,o n d d u s t
c
ore permitted to be mounted on one ond the boots.
s o m eo x l e . 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.
9.2 FRONT BRAKEASSEMBLY 5. Ploce o new friction pod into the broke
Disnrontlingond Reossembly o s s e m b l ym o k i n g s u r e t h o t t h e c l o m p o f t h e
\
thrust plote fits into the collor of the piston
1 . D e t o c ht h e b r o k e f l u i d s u p p l yp i p i n g f r o m c'
foce.
p
the broke. Absolute cleonliness is o must.
O t h e r w i s ed i r t o n d f o r e i g nm o t t e r w i l l p e n e t r o t e r€
into the piping. o
2 . R e n r o v eb o l t s l r o l d i n gd o w n t h e b r o k ey o k e 1
c r n dl i f t o w o y r l r e b r o k e o s s e m b l y . tt
pl
3. Use the MP 6-132 gouge to set correctly
t h e b r o k e ( n e w o r r e p o i r e d )o n r e i n s t o l l o t i o n . tt
4 . S e l e c t t h e s h i m s r e q u i r e dt o f i l l t h e g o p
r€
ol
between the end of the gouge ond the foce of
w
t h e f o s t e n i n g l u g . T o p o s i t i o n c o r r e c t l yt h e
b r o k e ,i n s e r t s h i m s b e t w e e nt h e f o s t e n i n gl u g s
ot
cnd yokes. You con, however, meosure direct
t h e d i s t o n c eb e t w e e nt h e f o s t e n i n gl u g o n d t h e iu
t r r o k ed i s k o n d s e t t h i s d i s t o n c ei n c o m p l i o n c e ol
dt
w i t h F i g .9 . 2 1 1b y o d d i n g p o c k i n gp i e c e st o t h e
shim pock. is
5. Using the respectivecopscrewsond spring ol
'.^roshers, sl
bolt down the yoke to the lugs.
6. Attoch the supply hoses ond bleed the Rr
broke. Fig.9.2l1-Front Wheel Broke Mechonism ot
o n d M o u n t i n g( s e t t i n g ) D i m e n s i o n s
Replocingthe Brake Disk
1 - B r o k ed i s k th
A w o r n b r o l < ed i s k c o n b e r e c o n d i t i o n e db y 2 - Broke
g r i n d i n gi t t o o t h i c k n e s so f 7 . 5 m m . l f n e c e s s - th
3 - Shims
c0
c r y , r e p l o c ei t w i t h o n e w o n e 9 m m t h i c k . A - B r o k e s e t t i n g c l i m e n s i o -n 1 8 . 7 + O . 2 c0
136
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'dnc eql 'JeAOJ
l o p u e a r l l o 1 6 u r . r6 u r u t o l a la q l u M o p
sserd puo sJnlxll eql o^ouer MoN 'sa6pa Auo a q t 6 u l 1 1 o t s u l eur€ r l M s u l d a q 1 u ! e ^ r J C ' r e ^ o c
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'uraql lano 6u1.r6ugdluo;caql
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 Reossemblethe pressure-reliefv o l v e i n t h e
f o l l o w i n g o r d e r : d u s t c u p , s p r i n g ,s p r i n g p l o t e ,
ond seol.
Fig. 9.312- SecondoryPiston Cup Mounting
F i x t u r ef o r d i o . 1 2 m m M o s t e r C y l i n d e r
( 1 - g u i d e b u s h , 2 - c l o m p i n gr i n g )
F i g . 9 . 3 / 3- S e c o n d o r yP i s t o n C u p M o u n t i n g
F i x t u r ef o r d i o . 2 2 m m M o s t e r C y l i n d e r
( 1 - g u i d e b u s h , 2 - c l o m p i n gr i n g )
9.4 REAR BRAKEWHEEL CYLINDER
'l-he
w h e e l c y l i n d e r r e q u i r e sp r o c t i c o l l y n o
s e r v i c i n gW . h e n e v e rr e m o v i n gt h e b r o k ed r u m s ,
e x o m i n et h e r u b b e rd u s t b o o t s . T h e yh o v e t o b e
p e r f e c t l yt i g h t , f l e x i b l e ,o n d u n d o m o g e dW
. hen
r e p l o c i n gt h e m , e x o m i n e t h e i n n e r s u r f o c eo f
t h e w h e e l c y l i n d e ro n d t h e s u r f o c eo f t h e p i s t o n .
F i g . 9 . 4 / 1- S e c t i o n o l V i e w o f W h e e l C y l i n d e r
138
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 permonentcontoct with the cylinder sur-
foce. A decreosedprestresssignols excessive
weor of the dust boot or its fotigue. For the
c l e o n i n g o n d l u b r i c o t i o no f w o r k i n g p o r t s , s e e
t h e i n s t r u c t i o n si n C h o p t e r 9 . 3 .
9.5 FRONT BRAKEWHEEL CYLINDERS
Wheel cylinders ore ossemblies formed by
o n e c y l i n d e r w i t ht h e y o k e o n d o n o t h e rc y l i n d e r
w i t h t h e f l o n g e o n d o c c e s s o r i e s .F i g . 9 . 5 / 1
shows the loyout. For cieoning ond lubricotion
o f t h e w o r k i n g s u r f o c e s ,s e e t h e i n f o r m o t i o n
i n C h o p t e r9 . 3 .
Dismontling
1. After hoving removed the broke pods,
d i s c o n n e c to n d l i f t o w o y t h e i n t e r c o n n e c t i n g
p i p i n g , c n d t h e n r e m o v e fo u r c o p s c r e w s t o
s e p o r o t et h e c y l i n d e r w i t h t h e y o k e f r o m t h e
f l o n g e dc y l i n d e r .
2 . P u l l o f f t h e r e t o i n i n gr i n g o f t h e d u s t b o o t
o n d l i f t o w o y t h e d u s t b o o t .C o n n e c to c o m -
p r e s s e do i r s u p p l y( o r t h e b r o k em o s t e rc y l i n d e r )
ond use it to force the piston out of the
F i g . 9 . 5 / 1- F r o n t B r o k e W h e e l C y l i n d e rc / w
BrokePods
 6et
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'lc
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 fold ot the moment of the opplicotion of the
brokes,ond led through o rubber hose (tube) to
the booster.
Removol ond Refitting
The broke booster is held down on the pedol
brocket by nuts ond spring woshers.The lug of
the control volve press button connects it with
the broke pedol, on which it is securedby o re-
toining ring. These mounting ports or the con-
nections of the vocuum supply ore to be hondl-
ed only when removing or refitting the broke
booster.
However,we odvise you to hove this iob done
in o speciolizedrepoir shop properly instructed
by the broke monufocturer.All rubber ports (in
the terms of current mointenonce, this is
procticolly the seol of the press button control-
ling the moster cylinder) must be protected
from the effects of the broke fluid or other
lubriconts. Use petrol for cleoning the rubben
ports.
Adiustment
1. Adiust the cleononcebetween the broke
booster press button ond the cylinder piston
whenever the moster cylinder or the'broke
booster ore reploced, or whenever there is ony
doubt concerning the correctness of the os-
sembly of the moster cylinder with the broke
booster. Meosure the distonce between the
cylinder bottom recess ond the cylinder flonge
nroting surfoce os well os the length of the
press button protrudingover the moting surfoce
of the booster. Compore the meosuringsond
odiust the length of the pressbutton by rototing
its threoded end to obtoin o cleoronceof 0.5 to
1 mm between the press button ond the piston.
Still better, you can use special tools Mp6.
'14'lA.
Fit it on the moster cylinder, push
i t s s p i n d l ei n t o t h e c y l i n d e rt i l l i t s r o u n d e de n d
rests ogoinst the piston, ond lock it in this po-
sitio-nwith the respectiveretoiningscrew.Apply
the fixture to the booster ond rotote the boostei
tx r5?2
Fig. 9.612- Broke Booster Press Button
Adiusting Fixture
MP6141A
140
press button so thot it iust touches the lower
flot port of the fixture spindle.
2. lf it is necessoryto level the broke pedol
with the clutch pedol, odiust the length of the
contnol volve press button lug.
Remove the broke booster from the pedol
brocket, slip off the collor (cup), connect the
booster with the pedol, ond refit it tempororily
to the brocket. Now rotote the hexogon on the
threodsof the lug till both the clutch ond broke
pedol ore level. Removeonce more the booster
from the pedol ond pedol brocket,neinstoll the
c o l l o r ( c u p ) ,o n d c o m p l e t et h e f i n o l r e o s s e m b l y .
9.7 BRAKEFLUID TANK, PIPING AND HOSES
Tonk ond Filling Hose
T h e b r o k ef l u i d t o n k i s h e l d i n p o s i t i o n i n i t s
brocket by o slip-over clomp. Speciol rubber
hoses connect it with the broke ond clutch
moster cylinders.Hose clips ore used to secure
the hoses on the tonk outlet sockets. Both the
side ond centre outlet of the tonk ore con-
nected to the bnoke moster cylinder, the third
outlet being connected to the clutch moster
cylinder (see Fig. 12.111).
PressurePiping ond Hoses
The rigid port of the hydroulic line consists
of speciol steel pipes. Their connections with I
other ports of the line ore seoled off by clomp- I
ing on the conicol surfoces- T
lf these conicol surfocesbecome domoged, !
removethem ond form new ones by floring the (
pipes.To do this, use the coulking holder, type (
M P 9 - 1 5 1C. l o m p t h e p i p e i n t h e h o l d e rs o t h o t
it is level with its upper edge ond flore the pipe t
w i t h c c o u l k i n gc h i s e l .T h e h o l d e r i s d e s i g n e d I
to be clomped in o vice. t
The holder hos two drilled holes of 5 ond t
6 mm in diometerso thot it con be used olso for t
repoirs of pipes of the clutch line. For dio. I
5 mm holes,use the MP 9-152ond for dio. 6 mm 'l
holes, the MP 9-153coulking chisel.
The flexiblepqrt of the hydroulicline consists (
of speciol hoses.When fitting them to the reor r
wheel cylinders,turn them in o position which
will prevent their contoct with ony ports of the o
cor in both extreme positions of the cor sus- c
pension. This is why the nipples ot the reor c
wheels ore inclined downword through on
ongle of 30 degreesfrom the horizontolplone.
9.8 HAND BRAKE
The hond-brokelever between the front seots
controls the tie-rod which octuotes the rocker
(see Fig.9.8/1).Cobles connectedto the rocker
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r0 . 3 - t 0 , 5
I h e p e r m i s s i b l eo u t - o f - b o l o n c m e ust not ex-
ceed 50 grommes on the rim rodius. Every new
t y r e i s p r o v i d e dw i t h o c o l o u r e dd o t o n i t s s i d e ,
i n d i c o t i n gi t s l i g h t e s t p o i n t . F i t t h e t y r e o l w o y s
with this dot focing the tube volve. ln this
p o s i t i o n t, h e v o l v e o c t s o s o n o d d i t i o n o lw e i g h t
c o m p e n s o t i n gt h e w h e e l o v e r o l l u n b o l o n c et o
o consideroble xtent.
lf dynomic boloncing of the wheel is not
p o s s i b l e ,b o l o n c et h e w h e e l s t o t i c o l l yw i t h t h e
g r e o t e s tp o s s i b l eq s s u r o c | . B o l o n c i n gw e i g h t s
of 30, 50, 75, ond 100 grommesore ovoiloble.
10.4 TUBED TYRES
F o r m o u n t i n g , d i s m o u n t i n g ,o n d r e p o i r s o f
c o n v e n t i o n o lt y r e s w i t h i n n e r t u b e s ( f o r p o r -
t i c u l o r s ,s e e t h e p r e c e d i n gC h o p t e r s ) ,t h e u s u o l
p r o c e d u r e so r e o p p l i c o b l e .T h e p e r m i s s i b l er u n -
o u t ( u n t r u er u n n i n g ) o f t h e r i m i s t h e s o m e o s
f o r t u b e l e s st y r e s ( C h o p t e r 1 0 . 5 ) .
10.5 TUBELESSTYRES
The oir-tightseolingof these tyres requires
m o r ec o r e o n d o d i f f e r e n th o n d l i n gt h o n t h o t o f
t h e t y r e sw i t h i n n e r t u b e s .
Preporotlonof Rirrr
1 3 e l o r em o u n t i n gt h e t y r e , i n s p e c tt h e r i m f o r
o n y t e c h n i c o ld e f e c t s T
. h e p o i n t st o b e c h e c k e d
ore the rim shoulder ond the moting foce for
t h e t y r e b e o d s ,i n o d d i t i o n t o t h e o v e r o l l c o n -
d i t i o n o f t h e r i m . l f o n y d e f e c t so r e f o u n d , t h e
r i m m u s t b e r e c o n d i t i o n e d .A s o t i s f o c t o r yr i m
n r u s tc o m p l y w i t h t h e f o l l o w i n g c o n d i t i o n s :
o ) T h e r i m s h o u l d e ro n d t h e t y r e v o l v e h o l e
must not be distorted; there must be no
s h c r p e d g e so r p r o t r u s i o n sl i k e l y t o d o m o g e
t h e t y r e b e o d . M i n o r u n e v e n n e s s ecso n b e
h o r n m e r e df l o t o n d s m o o t h e dw i t h o f i l e .
T h e m o x i m u m e c c e n t r i c r u n n i n go f t h e r i m
s i d e m u s t n o t e x c e e d1 . 5 m m .
b) The moting surfoces must be obsolutely
c l e o n ( f r e e f r o m s t u c k - o nr u b b e r ,r u s t , e t c . ) .
C l e o n t h e m w i t h e m e r yp o p e ro r o w i r e b r u s h
ond coot them with point.
lnstolling of Tyre Volve
C l e o n t h e r i m w i t h o d r y r o g . P u s ht h e r u b b e r
volve into the hole in the rim or pull it in by
i t s t h r e o d u s i n g , f o r e x o m p l e ,o l e v e r o s i l l u s -
troted in Fig.10.5/1.
146
F i g . 1 0 . 5 / 1- P u l l i n gT y r e V o l v e i r r t o W h e e l R i m
Mounting the Tyre
F o r m o u n t i n gt h e t y r e , u s e s p e c i o l m o c h i n e s
o n d p r o c e d u r e sd, e p e n d i n go n t h e t y p e o f t h e
n r o c h i n e l.f s u c h o m o c h i n ei s n o t o v o i l o b l e ,i n -
s t o l l t h e t y r e u s i n g s p e c i o l t y r e l e v e r s .E n s u r e
t h o t t h e b o l o n c i n gd o t i s n e x t t o t h e v o l v e .
Tyre leverrsfor fitting tubeless tyres differ in
s h o p e f r o m c o n v e n t i o n o l e v e r s .T h e y o r e t h i n -
n e r ,w i t h o u t e d g e s o , n d p o l i s h e dU
. sethem core-
f u l l y i n o r d e r n o t t o d o m o g et h e b e o d s e o l i n g
rubber bose. Insert the levers under the beod ot
short distoncesond refroin from using force. To
f o c i l i t o t es l i d i n g o f t h e t y r e c o s i n g b e o d so v e r
the rim shoulderm , o i s t e nt h e m w i t h w o t e r o n d
top them with o rubber mollet when eosing
t h e m o v e r t h e r i m s h o u l d e rI.n f l o t e t h e m o u n t e d
tyre immediotely. Check the tyre for propei'
bedding in the rim ond squoreseoting on it.
H o l d i n g t h e w h e e l p e r p e n d i c u l o r l y s, t r i k e i t
severoltimes ogoinst the f loor ot severolpoints
to force the tyre beods to bed correctly on the
bcad seots.
lnf lotion
R e m o v et h e v o l v e c o r e t o i n c r e o s et h e d i o m -
eter of the hole for oir inlet (oir should be
iniected in quick shots to force the beods on
to the beod seots) ond inflote the tyre. Use
o compressorwith oir receiver,the compressed-
.oir line of the workshop, or compressed-oirr
c y l i n d e r sT. h e r e l i e fv o l v e sh o v et o b e o d i u s t e d
to o pressureof 350 kPo (3.5 kg/cmz).
N e v e r o l l o w t h e i n f l o t i o n p r e s s u r et o r i s e
unnecessorily.As soon os the tyre hos snopped
i n t o p o s i t i o no n t h e r i m o n d i s f r e e f r o m l e o k s ,
odiust the pressureto 250 - 350 kPo (2.5- 3.5
kg/cmz). lf the tyre refusesto bed properly on
the rim, for exomple due to distorted beods or
beods compressed due to incorrect storoge,
press the tyre circumference inword to open
wide the beods which will then bed properly
on the rim. Use either o length of rope or
o speciol tightener. Slip the rope over the tyre
circumferencewith o certoin cleoronce, insert
o stick between the tyre ond the rope, ond
twist the rope.
Adiust the tyre pressureto specificotions ond
submergethe wheel in woter to check the tyre
for oir leoks.
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 Fig. 1111-Cooling ond Heotlng System
Diogrom
1 - Engine, 2- Coolont pump, 3 - Thermostot,
4 - Coolont tonk, 5 - Screw cop, 6 - Roidotor,
7 - Rodiotor fon, 8 - Fon thermoswitch, g -
Heoter, 10 - Heoter fon, 11 - Heoter reguloting
volve, 12-Woter line to rodiotor, 13-Woter
line to heoter, 14 - Filling line, 15 - Bleed
vofve, 16 - Bleed pipe, 17 - By-poss pipe, 18 -
Droin screws, 19 - Droin hose

150
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aLll utorl asoq aql lprd pr.ro l D l s o r . u J a qDl sepnlJut lolluoc alnlotadtual aq1
asoq Liurlua^ aql yo dr;c arll uirsool 'iolotpDJ ' r l s l r M S o r . u r e qD
l Aq
Pelloll
eLlt ADMo ]J!l puD sacods dtlolpoaq qloq urorl " u o i ) U D J" r o l D t p o la q l A q p u D l s D l q J l o u o - p o e q
s1;oq 6urualsol lolDtpDr oMl a^outal MoN .g oql Aq JolDrpnJ aql ul palooc azaeJftluD uD
v' vL rllrM paloor sr aur6ua ol{l 'punor roait aql llV
r a g d o q 3 e a s - ; a u o d t r u o r 1A p o q a r o l a q ] ; o l r o d ,LI6'LL
r a n n o l a q l p t r o a ; ; r 1 6 J o l D r p D ta q l a ^ o u l a u - t '6t3
a e s - e l o J D d a ss r u e l s A s 6 u r ; o o c ; 1 o a u 1 6 u e
" r o l D r [ ) DI o q 1 L i L L ' 6 1 1 u l u M o q s s r r u o : D o r ps 1 ; ' u e l s A s
a q l l 0 a p t : r ^) c D Q a q l u o l j s p o a l q o l t M s o L u J a r l l 6utloeq roo eql qllM uotlourquJoc ut 6u11o
t - { c D l a q' 1 o o q a 6 o 6 6 n 1 a q t r a ^ o a s o q a q } M o r t 1I - . r e d op u o ' ( r l u o t 6 u r z r l o n b a
le^al luDlooc) 1uo1
puD looq a6o66n1 aUt lo ecuaJalurnorJ aql luDlooc alo.rodes D puD durnd 1uo;ooc o 6ur1o
6 t t o g os d r l c u o r l a s o q 6 u r 1 u a ^ e q ] a ^ o u r a U . e - . t o d . t o c uer d A l p a a ; - e c : o ; ' a l n s s a : d : a n o ' p e s o l c
-ua eq]
'o sr uelsAs 6ur;ooc oug6ua eql
rapur sadrclurouraql ruo.usosor.r
,:?,fiJ:;:ll
f J s u u o J S t p ' r o J e r l l J e p u t lt u o l y 6 u r p a a c o ) d- Z uolldlrcsaC loc!uqcel
 11.4-11.5

on to the coolont tonk. Hose clips ore formed Removol

either by metol strips or lengths of wire. When
tightening the wire clips, toke core not to T o m o k e t h e u n d e r b o d yo c c e s s i b l ef o r h o n d -
domogethe rubber of the hoses. l i n g t h e p i p e s ,p l o c e t h e c o r o v e r o f l o o r p i t o r
o n o r o m p . T h e m i n i m u mr e q u i r e dc l e o r o n c ei s
obout 650 mnr.
To Fosten Pipes ond Hoses 1. Remo.rethe guords of the pipes ond the
f u e l t o n k , l i f t o w o y t h e s p o r ew h e e l ,o n d l o o s e n
A correct winding of the strip is importont the yokes holdingthe pipes to the floor.
t o e n s u r eo s e l f - l o c k i n gc l o m p i n g o f t h e s t r i p 2 . R e m o v ed r o i n s c r e w s t o d r o i n t h e c o o l o n t
clips - see Fig.11.411. f r o m t h e p i p e s- s e e t h e i l l u s t r o t i o n i n C h o p -
ter 15.'13.
3 . R e m o v eo n e h o s e c l i p i n t h e m i d d l e o f t h e
c o r t o d i s c o n n e c tt h e p i p e s ( o t t e n t i o n - t h e
remoining coolont will flow out), ond dis-
o s s e m b l et h e l i n e .
4. Disconnect he pipe ends from the hoses,
ond detoch the pipes from the floor or other
ports of the cor.
5 . P u l l o u t t h e r e o r p i p e s p o s s i n gt h e m c o r e -
fully oround the voriouscor ports.
6. Pull out the front pipes. Turn the front
w h e e l s i n t o t h e i r l e f t l o c k p o s i t i o n ,d i s c o n n e c t
the steering linkoge from the steering reloy
lever ond the steering knuckle orm of the right-
h o n d w h e e l , o n d p u s h t h e l i n k o g eo g o i n s t t h e
oxle body.While removingthe pipes, rotote the
l e f t - h o n dp i p e c l o c k w i s e( w h e n v i e w i n g t h e c o r
f r o n t e n d ) , o n d t h e r i g h t - h o n dp i p e o n t i c l o c k -
F i g . 1 1 . A l 1 -D i o g r o m s h o w i n g t h e t h r e o d i n go f wise.
the clip strip through the clip closp ond the
direction of rototion of the tightening cotter Reinstollotion
p i n - t h e d i o g r o m h o s g e n e r o lo p p l i c o b i l i t y
R e v e r s et h e d i s m o n t l i n gp r o c e d u r ew h e n r e -
1 - S t r i p c l i p , 2 - C l o s p ,3 - C o t t e r p i n i n s t o l l i n gt h e w o t e r l i n e . W h i l e c o n n e c t i n gt h e
s t e e r i n gl i n k o g e ,p o y o t t e n t i o nt o t h e c o n d i t i o n
o f b o l l p i n s e o l i n gc u p s ( f i t n e w c u p s i f t h e o l d
T h e m o i n p i p e l i n er o u t e d u n d e r t h e c o r f l o o r o r e d o m o g e d ) .F i l l i n t h e r e c o m m e n d e cd o o l o n t
consists of front ond reor pipes. They ore em- ond bleedthe coolingsystem.
bedded in o chonnel moulded in the floor
b o o r d so n d r e s t o n o n i n s u l o t i n g( p o l y s t e r e n e )
podding. From below, they ore protected by 11.5 COOLANT TEMPERATURECONTROL
o guord, the copscrewsof which ore locked in
p o s i t i o nb y s p r i n g w o s h e r s . Throughflow Thermostot
U s e p i p e h o l d e r s( y o k e s ) t o f o s t e n t h e p i p e -
line to the floor. In the front ond reor port of This thermostotshuts off the inlet of the
the cor, tighten the pipes over the insulotion coolont into the rodiotor during the engine
l r o d o n d i n s e r t s p r i n g o n d p l o i n w o s h e r su n d e r h e o t i n g - u pp e r i o d .l t i s m o u n t e do n t h e e n g i n e
t h e n u t s . D o n o t u s e i n s u l o t i o np o d s f o r b e n d s - see Chopter 2.3, por. 30.
forming the tronsition from the front ond reor T h e t h e r m o s t o to p e r o t e sw i t h i n t h e f o l l o w i n g
lower flot ports. Use spring woshers under the volues: I
heods of copscrews. I
i t b e g i n st o o p e n o t 80+2"C
B e f o r e i n s t o l l i n gt h e p i p e s ,p r e p o r eo u x i l i o r y it is fully open ot I
90+4oC
yokes (or use lengths of wires ottoched to the
its lift ot full opening 11 mm
provisionollyscrewed-incopscrewsof the pipe-
line guord) to liold the pipes in the moulded When closed, it is permitted to let poss
c h o n n e l i n t h e f l o o r b e f o r et h e f i n o l f o s t e n i n g o n r o x i m u mo f 0 . 5 l i t r e s o f c o o l o n t p e r m i n u t e ,
of their guord. ond it must not be closed by o bock pressure
The woter line runs under the cor together of 0.16MPo (1.6kg/cm2).
w i t h o t h e r l i n e s ,p u l l - r o d se, t c . F o r t h e i r m u t u o l W h e n r e m o v i n gt h e t h e r m o s t o tb y r o t o t i n g F
r
refotive orrongementsee Chopter 12.7. tlre rivet in the volve disk, breok owoy sedi- t'

152

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'L'LL '6lJ u! uMoqs
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leldoq3 aes lpoq rDc eql ur ualsls uollnqlrlsrp -s
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'paeds Joloul eq1 a
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u t ' s d o 1 1p u o s t c n p q l 1 n n 6 u t s o 3 e q l p u o , u o 1 u
aqt_':e6uoqoxa loeq eql - luaulala 6urloaq aql e
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00

Fig. 11.6/1- Section Through Heoter

1- Cover, 2 - Lower port of cosing (iocket) -
two-port, 3- Heot exchonger, 4- Heoter fan,
5 to 8-Control f lop volves,9-Ponel with control
levers

the bowden tubing of the bowden cobles ond
let the oil seep down olong their entire length.
Check the heoter fon for foultless running.
With the switch in position I, the fon must run
ot higher speed- for its wiring refer to Chopter
11.7- Electric Control. Fill the cooling system
with coolont ond bleed the system.
Fit the grips (buttons) on the levers observ-
ing the symbolson the grips:
left-hond lever- white orrows upword ond
downword,
centre lever - orrow downword,
right-hond lever- red orrow upword, blud orrow
downword.
To open the flow through the lower inlet
socket, turn the lever in this socket so thot it
coincides with its centre line. The socket
should be closed with the flop only when
testing the heoter, etc.
Heoter Disossembly ond Reossembly
o) Heot exchonger, volve, flops, ond levers
with links.
1. Disconnect the control bowden cobles
from the levers, remove the gosket from the
heoter beoring surfoce,loosen the locks of the
broces,ond lift owoy the broces together with
the cover ond fon.
2. Unscrew the liquid flow control volve ond
detoch the hose from the second inlet of the
heot exchongerond the bleed hose ofter hoving
removedthe hose clips. Do not detoch the link
from the volve lever - it will sove you odiust' c
ment on reossembly. I'
3. Detoch the link of the flops from the reor b
side of the heoter cosing ond unlock the flops o
in the cosing by removing lock rings, woshers, ir
ond levers.

154
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sd
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6u!t eqt
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s ! r e t D a qe q l 3 p ! s u ! M o l l r l o l o u o l l c a J ! Pe q l uo.r; 6u1.tdspuD JeqsDr*'6u;.r>1co1 aql e^ourau
r.ttJ'lt
11 . 8 - 1 1 . 1 0
11.8 HEATER CONNECTING LINE
T h e l i n e i s o c o m b i n o t i o no f s t e e l p i p e s o n d
. l l c o n n e c t i o n sm u s t b e t i g h t e n e d
r u b b e rh o s e s A
with clips of the strip type (see Fig. 11.411)or
the wire type (bleed hose). Toke core not to
overtightenthe clips of the lotter type os there
i s o r i s k o f d o m o g i n gt h e r u b b e r .
The hose from the pipe of the thermostot
body on the engine is routed to the heoter
through the f loor tunnel, the return bronch
p o s s i n go g o i n t h r o u g ht h e t u n n e l t o t h e p i p e o f
the pump.Arrongethe hoses olong the sides of
the floor tunnel so thot they do not touch other
portsin the tunnel.
For detoiled informotion obout the routing of
the hoses refer to Chopter 12.7.
11.9 otl COOLER
The oil cooler is stondordequipmentof Skodo
120 LS models. lts constructionresemblesthot
of the rodiotor.lt is instolled in the engine
comportment (boy) ond ottoched to the right-
-hond engine guord. Speciol pressurehoses
connect it with the engine. lts connecting
diogrom is shown in Fig. 11.911.
As regords oil coolers for subtropicol ond
'16.2.
tropicol regions,refer to Chopters 16.1ond
DX tfSJ
F i 9 . 1 1 . 9 / 1- O i l C o o l e r - t o - e n g i nCeo n n e c t i n g
Diogrom
1 - Outlet from engine-right-hond cooler socket,
2 - O i l c o o l e r , 3 - I n l e t i n t o e n g i n e- l e f t - h o n d
cooler socket
156
Removol ond Refitting
D i s c o n n e c tt h e h o s e s f r o n r t h e e n g i n e o n d ,
occording to circumstoncesond the purposeof
the removol, detoch the oil cooler from the
engine guord or remove the engine guord
togetherwith the cooler ond brocket.Empty the
o i l c o n t o i n e di n t h e h o s e s o n d t h e o i l c o o l e r
i n t o o s u i t o b l ev e s s e l .
When refitting the oil cooler into the cor,
proceed in occordoncewith the circumstonces
o f t h e r e m o v o l .S e c u r et h e b o l t s c o n e c t i n gt h e
o i l c o o l e rw i t h t h e e n g i n eg u o r d o n d t h e b r o c k e t
(the brocket being locoted between the cooler
o n d t h e g u o r d ) w i t h s p r i n gw o s h e r s .B o l t d o w n
the guord over ploin woshers ond use o spring
wosher for the bolted connectionof the brocket
with the bodywork.
Use seoling woshers when connecting hoses
to the engine ond the oil cooler, ond put
o s e o l i n gw o s h e ro l s o u n d e rt h e b o l t . C l o s e t h e
bolt of the engineport ot the flonge with the
pressureswitch. Fosten the hoses so thot they
ore not stressed in their bends. The hose from
the timing geor cover should be routed horizon-
tolly ond the hose ot the engine inlet so thot
it includes o downword ongle of obout 15 de-
g r e e s w i t h t h e h o r i z o n t o lp l o n e . T o p u p o i l i n
the engine.
11.10 COOLING SYSTEM DEFECTS,
T E S T I N G ,R E P A I R S ,A N D C L E A N I N G
Defects ond Testing
o ) l f t h e r e i s o m a r k e d l o s s o f c o o l o n t ,c h e c k
oll connectionsfor leokoge.The loss of coolont
con olso be cousedby o leokogeof the rodiotor
( o r h e o t e r ) . l f t h e l e o k o g ep o i n t i s n o t v i s i b l e ,
pressure-testthe system without removing it
from the cor.
Admit seoled-offoir ot o pressureof 0.12 MPo
(1.2 kglcmz) into the filler neck ond look for
ploces where the coolont is seepingor dripping
out. Inspect not only the rodiotor but olso the
lreoter.
An excessiveloss of the coolont con be olso
coused by engine overheoting. In thot cose,
look for the couse of engine overheoting.
b) P o i n t st o c h e c k i f t h e e n g i n e i s o v e r h e o t i n g
- coolont level
- operotion of thermostots ond rodiotor fon
- condition of rodiotor (whether clogged out-
side with dirt, or whether cooted inside with
scole)
c ) P o i n t st o c h e c k i f t h e e n g i n ed o e s n o t w o r m
up properly:
- operotionof thermostots
 L9l
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 691
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v9t rDc or{1Jepun selqDc
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r2.1-t2.3
Dissssemblyond Reossemblyof Pedols
T h i s i s u s u o l l yn o t n e c e s s o r yT. h e p e d o l sc o n
b e d i s o s s e m b l eo d f t e r r e m o v i n gt h e o x i o l s c r e w
in the pedol pin ond slipping off the return
spring. Do not remove the switches if it is not
obsolutely necessory- see odiustment. On re-
o s s e m b l y ,l u b r i c o t et h e p e d o l b u s h w i t h l u b r i -
coting greoseof the some brond os used for the
s t e e r i n gl i n k o g e - s e e C h o p t e r 7 . 5 , p o r . 3 .
Pedol Free Trovel Adiustment
Adjust the free trovel of pedols ossembled
w i t h m o s t e rc y l i n d e r ss o t h o t t h e p e d o l p i s t o n
r o d h o s o c l e o r o n c eo f 0 . 5 t o 1 m m w h e n b e o r i n g
o g o i n s t t h e p i s t o n h e o d s o f t h e m o s t e rc y l i n -
ders. The free trovel of the pedol pod should be
from 3 to 5 mm. lt con be odiusted by rototing
the eccentric pin on the pedol brocket - see
Fi9.12.111.
F o r t h e o d j u s t m e n to f t h e b r o k e p e d o l w i t h
broke booster ond/or levelling of the broke
p e d o l w i t h t h e c l u t c h p e d o l ,s e e C h o p t e r 9 . 6 -
A dj u s t m e n t .
Adiustmentof Switches
T h e s w i t c h e sc o n b e m o v e d i n t h e e l l i p t i c o l
holes of the brocket ofter looseningthe fosten-
i n g c o p s c r e w sw i t h p l o i n w o s h e r s u n d e r t h e i r
h e o d s .A p o c k i n gp i e c e s h o u l db e s l i p p e du n d e r
the switch of the broke pedol trovel worning
l i g h t o n d t h e p o w l o f t h e s w i t c h p i n s h o u l db e
held down under the fostening copscrew.
Ad just the stop-light switch so thot it
switches on the stop lights ot o pedol trovel
of 10 to 15 mm meosuredon the centre of the
pedol pod.
Adiust the pedol trovel signolling switch so
t h o t t h e p u s h e d - i n s i d e p u s h - b u t t o np i n i s
re,ecsed ot o pedol trovel of 100 to 110 mm
mecsuredon the centre of the pedol pod. Press
the push button into the switch ofter hoving
c o m p l e t e dt h e o d i u s t m e n t .
12.2 ACCELERATORPEDAL AND CABLE
T h e o c c e l e r o t o rp e d o l f o r m s o u n i t w i t h i t s
s e l f - l u b r i c o t i n gb e o r i n g o n d t h e l e v e r . l t i s
bolted to the floor tunnel. A coble possing
through the tunnel is ottoched to the pedol
lever ond the reloy lever on the engine by
meons of clomps- The coble is protected by
o B o w d e nt u b i n g .
Pedol Removing ond Refitting
1 . L o o s e nt h e c l o m p h o l d i n g t h e c o b l e o n t h e
e n g i n e - m o u n t erde l o y l e v e r .
162
2. Removethe copscrews holding down the
b e c r r i n gw i t h t h e p e d o l , d e p r e s s l i g h t l y t h e
pedol,ond lift it out of the f loor tunnel together
with the beoring.
3. Disconnectthe pedol from the coble ofter
i o o s e n i n gt h e c l o m p .
Removol ond Refitting of Bowden Tubing
ond Cqble
The Bowden tubing is fostenedto the brocket
irr the floor tunnel by meons of circlips. After
t h e i r r e m o v o l ,p u l l t h e B o w d e n t u b i n g i n s i d e
the cor.
O n r e fi t t i n g t h e t u b i n g , l u b r i c o t e i t w i t h
o low-viscosito y il (of the SAE20 closs).lt hos
been lubricotedwith greose in the foctory. Fit
the clonrpsso thot their longer ports (from the
screw to their end) ore on the side of the
Ie v e r s .
AccelerotorCoble Adiustment
Adjustthe cobleso thot it is not excessively
tensioned or too slock. Loosen the clomps on
t h e e n g i n es i d e o f t h e c o b l e , m o v e s l i g h t l y t h e
clomp toword the reloy lever, ond tighten the
screws of the clomp.
I
12.3 GEAR SHIFT LEVER AND LINKAGE I
I
I
T h e g e o r s h i f t m e c h o n i s mc o n s i s t s o f t w o
units: the geor lever with its housingond oc-
cessories, ond the geor shifter rod ond the
shifter lirrk with joint (ot the georbox) for
domping the vibrotion of the power pock
tronsnrittedto the geor lever.
RemovingGeor Lever Housing ond Link
1. Lift owoy the mot from the floor tunnel in
the front ond reor comportment. lf seporote,
remove the individuol floor mots ofter hoving
prised out their clips with o screwdriver or
o similor tool. lf o one-piecefloor covering is
used, remove the door sill strips on one side,
tip the seot, ond bend over the floor covering.
2. Removethe geor lever housing copscrews
o n d p r i s eo u t t h e l i d ( n e x t t o t h e c l i p ) b e t w e e n
the seots. Proceedthrough the opertureto dls-
connect the bolted connection of the link with
t h e h o u s i n gs h i f t e r r o d .
3. Lift owoy the housing with the lever
through the operture.Swivel the lever so thot
the shifter rod does not protrude over the
housing beoring thus obstructiongthe removol.
4. Usuolly it is not necessoryto remove the
geor shift link from the cor. lf obsolutelynecess-
ory, the link con be disconnected only ofter
 89r
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12.6-12.f
2. Proceeding fronr below, rernove the fuel
t o n k s h e e t g u o r d o n d t h e g u o r do f t h e c o o l i n g
woter pipes.
3 . D i s c o n n e c t h e p i p e o f t h e c l u t c l rh y d r o u l i c
l i n e f r o m t h e c l u t c h r e l e o s eh o s e b r o c k e t .
4. Screw out droin plugs to droin fuel from
the fuel tonk ond ot the sometime disconnect
the fuel hose from the fuel pump. After com-
p l e t i n g t h e d r o i n i n g ,r e i n s t o l l t h e d r o i n p l u g s
( s c r e w s ) w i t h t h e i r s e o l i n gr i n g s .
D i s c o n n e c tt h e t r o n s v e r s eh o s e c o n n e c t i n g
both sectionsof the fuel tonk ond stop the open
p i p e sw i t h r r u b b epr l u g s ( t o p r e v e n tt h e r e m o i n -
ing fuel spilling over your honds ond clothes
when lifting the tonk owoy).
5 . D i s c o n n e c tt h e g e o r s h i f t l i n k o n d t h e
speedometerdrive from the georbox- see Chop-
t e r 4 . 1 ,p o r . 9 .
6. Detoch cobles from the hond broke rocker
ond pull them out from under the cor - see
Chopter 9.8.
7. Droin the cooling system- see Chopter
-15.13.
D i s c o n n e c tt h e m o i n w o t e r l i n e i n t h e
r n i d d l eo f t h e c o r . D i s c o n n e c t t h e p i p e s f r o m
the engine (from the hose of the thermostot
o n d t h e p u m p c o n n e c t i n gh o s e )o n d r e m o v et h e
pipes- see Chopter 11.4.
8. Disconnectthe hose of the fuel tonk from
t h e f u e l f i l l i n g p i p e , o n d , i n t h e u p p e rp o r t , t h e
h o s eo f t h e f u e l f i l l i n g l i n e v e n t p i p e .
9. Sever the electric connection of the fuel
level gougefloot systemunder tlre right-hond
I eor seot.
10. Use o iock to support tl're georbox ond
loosen tlre connection of the georbox cross
beorer with the bodywork.
11. Loosen the copscrewsfostening the fuel
tonk to the bodywork ond lower the iock to tip
the power pock. Retoin the fuel tonk while ne-
n r o v i n g t h e c o p s c r e w s ,m o v e t h e t o n k b o c k -
words ond down, tip it down ond forword, ond
r e m o v ei t i n t h i s d i r e c t i o n .
F i g . 1 2 . 6 1 1 -F u e l T o n k D r o i n P l u g s
164
1 2 . S h o u l dt h e p i p e s o f t h e b r o k e s y s t e mo b -
s t r u c t t l r e r e m o v o lo f t h e t o n k , d i s c o n n e tt h e m
from the finol drive ond from broke hose brock-
ets.
Refitting Fuel Tqnk in Cor
Reverse the procedureof the tonk removol.
F i l l t h e c o o l i n g s y s t e mw i t h t h e r e c o m m e n d e d
c o o l o n t o n d b l e e d i t , o d j u s t t h e h o n d - b r o k eo n d
the occelerotorcobles. Bleed the clutch hy-
droulic line ond olso the reor wheel brokesif
t h e h y d r o u l i cb r o k e l i n e h o s b e e n d i s c o n n e c t e d .
T i g h t e n p r o p e r l yo l l j o i n t s o n d c o n n e c t i o n s ,
f o s t e n t h e c o b l e s ,l i n k s , o n d p i p e s o b s e n v i n g
their correct orrongement- see Chapter 12.7.
Fuel Line ond lts Accessories
F i l l i n g p i p e . T h i s i s q s h e e t- m e t o l t u b e o t -
toclred to the hose on the fuel tonk by meons
o f o c l i p , o n d t o t h e b o d y w o r kb y t w o h o l d e r s
w i t h o c o p s c r e wo n d b o t h o s p r i n g o n d o p l o i n
w o s h e r .l t p o s s e st h r o u g l ro b u s h i n gi n t h e s i d e
of the bodywork.
Venting line. The hose is ottoched to the fuel
tonk filler neck in the upper port of the tonk
ond to the filling pipe by meonsof clips. For
its possoge through the bodywork stiffener,
see Fig. 12.714.
F o r c l i p s o n d t h e i r t i g h t e n i n gs e e F i g . 1 1 . 4 / 1 .
T h e o i r - f e e dh o s e i s s l i p p e d o n t h e f i l l i n g
pipe outlet ot the fuel tonk neck; its loop is
i n s e r t e du n d e r t h e d o m p i n g l i n i n g o f t h e b o d y -
work, ond its other end is insertedinto the hole
o f t h e f i l l i n g p i p e s o c k e tb u s h i n g .
Filler neck cop - see Chopter 1.5.
Fuel gouge - see fuel reserve signolling
switch, Chopter 13.17.
12.7 ARRANGEMENTOF PIPELINES,LINKS,
AND CABLES UNDER THE CAR
The routing, fostening, etc., of pipelines,
l i n k s , o n d c o b l e s i s d e s c r i b e di n c h o p t e r sd e o l -
ing with these ports. They oll leove the floor
tunnel under tlre fuel tonk to be covered by
o g u o l d h e l d i n p o s i t i o n b y s e l f - l o c k i n gn u t s
w i t h p l o i n w o s h e r s .T h e f o l l o w i n g i l l u s t r o t i o n s
show their correct orrongementwhich hos to
be mointoined if incorrect function or domoge
is to be prevented. lt is imperotive to ensure
free movement ond swing of the geor shift
link.
Securethe correct position of oll ports under
the fuel tonk by clips which hove to be pro-
vided with sleevespreventing domoge to Bow-
den tubings, etc. The overoll orrongement is
shown in Fig. 12.712ond 12.713.
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nolly emerges into spoce under the floor toword
the georbox. lt is ottoched to the speedometer
by meons of o union nut ond to the georbox by
o sleeve ond o screw.
It is lubricoted with oil from the georbox
which creeps olong it due to copillory elev-
otion" Lubricote it with engine oil of o lower
viscosity dripped into its sheoth only if the
lubricotion by creeping is inodequote.
166
When refitting it in position, put it into the
cor from the front, connect its both ends, ond
then orronge it so thot it does not form ony
shorp bends ond is not too tout. The speedo-
meter con be disconnectedofter removing the
i n s t r u m e n tp o n e l ,o n d r e m o v e db y p u l l i n g i t i n
forword direction.
For the speedometer drive shoft possoge
under the ffoor refer to Chopter 12.7.
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F i g . 1 3 . 1 1-1 W i r i n g D i o g r o m
100- Storoge botteny 1 0 8- l g n i t i o n h o r n e s so n d s p o r k i n gp l u g
1 0 1- Switch box interferencesuppressingresistors
102- Alternotor 109- Fuses
'110-
103- Voltoge regulotor Instrumentponel
104- Storter motor 111- Instrrument ponel terminol boord
1 0 5- lgnitioncoil 1 - H i g h - b e o mw o r n i n g l o m p , 2 - L u b r i -
1 0 6- lgnitioncoble cotion worning lomp,3 - Telethermometer,
107- Distributor 4 Alternotor (chorging) worning lomp,

169
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W I R I N GD I A G R A M

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 14.Fuse box y e l l o w-
Centrol connection of conductors- do not femole connector5.5 telethermometer
seporotethem from the bunch! primory element
green-
15.Direction indicotor switches, dip switch, femole connector7. corburettor
and horn switch
iet seporotor
eight-pole terminol boord
six-pole terminol boord 27. lgnition coil, voltoge regulotor, olternotor,
tochometer
16.Porking light switch ond high beom feeder conductor with femole connector ond
four-pole terminol boord b r o n c h i n gl u g
femole connector-regulotorterminol 15/54
17. Switch box l u g- i g n i t i o n c o i l t e r m i n o l 1 5
f e m o l e c o n n e c t o r s5 . 5 w i t h s y m b o l s " 1 5 " , blue - femole connector 5.5,
"30", ond '50" to be connected to symbols
"15u, "30', ond '50" on the switch symbol "R" . regulotor terminol "R"
box yellow - femole connector 5.5,
18.Instrumentponel s y m b o l" M " r e g u l o t o rt e r m i n o l " M "
blue -
ten-pole terminol boord
six-pole terminol boord connector "R" . olternotor terminol "R"
e o r t h i n gc o b l e w i t h l u g y e l l o w-
c o n n e c t o r" M " . o l t e r n o t o rt e r m i n o l " M "
'19.
Heoter switch lug terminol "+B"
four-poleterminol boord conductor with
lug i g n i t i o nc o i l t e r m i n o "l 1 "
20. Switch of disobility lights (tochometeroperotion)
s i x - p o l et e r m i n o l b o o r d
28.Toil lomp cluster, right.hond
21. Door switch, right-hond y e l l o w-
green - femole connector 5.5 femole connector5.5 toil light
b l o c k-
22. Dome light, right-hond femole connector5.5 direction indicotors
green - femole connector 5.5 red -
- femole connector 5.5
'i red femole connector5.5
green-
stop light
23. Stop switches
iii forked (yellow) -
femole connector5.5 reversinglomp
I femole connectors5.5 . upper ond lower 29. Licence plote light
switch conductorswith femole connectors5.5
red -
femole connector5.5 upper switch 30. Toil lomp cluster, left.hond
white - se point 28.
femole connector5.5 lower switch
24.Fuel gouge b) Connection of free conductors
block - femole connector 5.5
yellow - femole connector 5.5 1. Storoge bottery
blue - femole connector 5.5 bottery coble positive (*) terminol -
to be connectedto the respectivepins storter motor
(blodes) of the some colourof the fuel gouge botteryeorthing strip negotive(-) terminal-
25. Storter motor, reversing lomp switch bodywork
conductorswith lugs stater motor moin (eorthing conductor)
terminol boord 2.Engine
c y l i n d r i c o l( p i n ) e n g i n ee o r t h i n gs t r i p ( f o s t e n i n gl u g ) -
connector storter motor engine cross beorer
control switch (eorthing conductor)
green-
femole connectors5.5 heodlompswitch 3. Distributor
speciol coble from distributor to ignition
26. Oil pressuregouge,thermometer,corburettor coil; end with interference suppressing
iet seporotor terminol to distributor
green- coble from distributor to ignition coil
femole connector5.5 pressuregouge t e r m i n o l" 1 "

172
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 r3.2-t3.3

Observe strictly the following instructions: At o 20 per cent chorging, the bottery is
consideredprocticolly dischorged.
1. Mointoin the electrolyte level ot the level
of the perforotedinserts between the plotes or Toble of Chorging ond Dischorging Values
so thot the inserts ore coveredwith the electro-
lyte to o moximum height of 4 mm. The bottom Roted voltoge 12 volts
l i m i t o f t h e e l e c t r o l y t el e v e l i s 3 m m b e l o w t h e
perforotedinserts. Use only distilled woter for Roted copocity C 20 ot o
topping up the electrolyte.Add electrolyteonly 20-hourdischorgingto 1.75
if it hos been obviously spilt from the bottery. volts per cell 37 omperehours tu
In such cose, its density must correspond to Normoldischorgingcurrent J
t h e d e n s i t y o f t h e e l e c t r o l y t eE e m o i n i n gi n t h e for 20-hourdischorging to
bottery. 1.75 volts per cell 1.75 omperehours
2. Keep the bottery terminols cleon, remove
o x i d e s o c c o s i o n o l l y ,o n d c o o t t h e t e r m i n o l s Normol uniform chorging 3.7 omperes
w i t h m i n e r o li e l l y .
3. Wipe off the electrolytespilt over the bot- Two-stogechorging:
tery surfoce since it is conductlve ond couses stoge I up to 2.4volts per
dischorgingof the bottery. cell; gossing beginning 4.4 omperes
4. Check the chorging of the bottery occord-
ing to the electrolyte density or check the s t o g el l u p t o f i n o l m o r k s
voltoge drop using o voltmeter with o looding of fuffychorgedcondition 2.2 omperes
resistor ond comporing the obtoined reoding
with on evaluotion toble or scole. Diffenentinstructions,determinedspecificolly
5. When chorging the bottery outsidethe cor, by bottery monufocturers,opply to moking o
use chorging current volues occording to the new ond empty bottery reody for operotion or
t o b l e .T h e v o l t o g es h o u l db e c o n t r o l l o b l ei n t h e t o s o - c o l l e dq u i c k c h o r g i n g .
ronge from 12.6 to 16.8 volts. The fully dis-
chorged bottery is fully chorged in obout 13 to Sofety Precoutions ond Other Meosures t(A
20 hours when 4
During chorging, the electrolyte temperoture
o) the electrolyte ottoins o density of 1.28 in must not exceed +40oC. As soon os this tem'
l
o l l c e l l s o n d d o e s n o t c h o n g e i n o p e r i o do f peroture is reoched, interrupt the chorging or 3t
i
two hours; lower the chorging current (this opplies es-
i b ) t h e c e l l v o l t o g e( m e o s u r e d
w i t h o p p l i e dc u r - p e c i o l l yt o s o - c o l l e dq u i c k c h o r g i n g ) .
2t
ii rent) ottoins o volue of 2.6 to 21 volts ond
does not chonge within two hours of con-
During chorging, on explosive mixture of hy-
drogen with oxygen is liberoted from the elec-
tinuedchorging; trrolyte.Therefore,the oreo where the bottery is ,t
c) oll cells ore lively gossing. chorged must be ventiloted, ond it is forbidden
to opproochwith o noked flome (or spork) the
6. An olreody used bottery must not be left cell filling holes (even ofter o consideroble
without electrolyteor dischorgedos it is opt to (
period of time ofter the chorging hos been
suffer from such o condition.
completed).
7. The bottery in on unused cor must be W h e n c h o r g i n g t h e b o t t e r y ,o p e n t h e f i l l i n g
removed ond chorged outside the cor within
holes of its cells to enhonce degossing.
three months ot th-e lotest. lf the cor is under The electrolyteis on ocid hormful to the skin
repoir for o prolonged period, toke oll necessory
ond clothes os well os to ports of the cor fin-
steps to keep the bottery in good condition.
i s h e d i n e n o m e l .R i n s e w i t h w o t e r i m m e d i o t e l y Pe
ony contominotedspots. lp
Bottery Chorging versus Electrolyte Density
5
13.3 ALTERNATOR
Specificgrovityl i Electrolyte 4
(density) iChorgingl freezing The olternotor is o three-phosegenerotorwith
g/cms I I temperoture o built-in semiconductorrectifier for feeding 3
electricol devices ond the bottery with direct
1.28 1ooo/o -60 0c current. 2
1.24 Toolo -50 0c
1.22 s0% -35 0C Alternotor lnstollotion ond Generol lnstructions I
1.15 2oolo -17 "C
1.12 0 -120C They opply to both olternotor models. The
following principles should be observed:
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 g) Excitotion of the olternotor by o current
supply outside the cor is not permitted.
sould suffer.
A g o i n t h e s e m i c o n d u c t o rw
h) A blown chorging worning lomp must be
r e p l o c e di m m e d i o t e l yw i t h o n e w o n e .O t h e r -
wise correct excitotion of the olternotor is
n o t e n s u r e d .U s e o n e w l o m p o f t h e s o m e
r o t i n g ( o r i n p u t ) , i . e . , 1 . 5t o 2 W .
i) Be sure thot there is o perfect electricol
c o n n e c t i o no n t h e c o n n e c t i n gt e r m i n o l so n d
thot the olternotorond regulotorore properly
eorthed.
i) The olternotor is oeroted, open. Therefore
toke core when woshing the cor thot woter
or cleoning ogents do not get into it through
t h e v e n t i n gh o l e s .
Removing the Alternqtor
1. Disconnecthe bottery.
2 . D i s c o n n e c t h e o l t e r n o t o rl e o d s .l t w i l l b e
h e l p f u lt o r e m e m b e tr h e c o l o u ro f o n e c o n d u c t o r
o n d i t s c o n n e c t i o nf o r r e i n s t o l l o t i o n .
3 . R e m o v eo l l p o r t s h o l d i n gt h e o l t e r n o t o ro n
t h e e n g i n e ,o n d l i f t o w o y t h e o l t e r n o t o r .
L
Reinstolling the Alternotor
1 . C l e o n o l l m o u n t i n gs u r f o c e s F . or the olter-
notor mounting,see Chopter 2.3, por.42.
i
2. With the bottery disconnected,insert the
conductorsinto the respectiveconnectors "M,,
o n d " R " ( t h e c o n d u c t o r sb e o r t h e s o m e s y m -
b o l s ) , o n d f o s t e nt h e r e m o i n i n gl e o d w i t h o n u t .
3. Reconnectthe botterv.
F i g . 1 3 3 l a- A l t e r n o t o r- S e c t i o n o lV i e w
176
Alternotor Disossembly- Repoirs
1. Screwoff the belt pulley nut ond remove
t h e b e l t p u l l e yo n d f o n .
2. Lift the brushes with o hook proceeding
t h r o u g ht h e h o l e s i n t h e c o m m u t o t o re n d s h i e l d
ond hold them in the lifted position by wires
i n s e r t e di n t o t h e s h i e l d t h r o u g hd i o . 3 m m h o l e s
u n d e rt h e t e r m i n o l su M ' o n d " R u .
3 . M o r k t h e m u t u o l ( r e l o t i v e ) p o s i t i o no f t h e
c o m m u t o t o ro n d d r i v e e n d s h i e l d so n d s e p o r o t e
t h e q l t e r n o t oo r f t e rh o v i n g r e m o v e di t s c l o m p i n g
b o l t s . T h e d r i v e e n d s h i e l d r e m o i n sc o n n e c t e d
with the stotor.
T h i s d i s o s s e m b l yw i l l g i v e o c c e s s t o t h e
b r u s h e so n d s o m e o f t h e d i o d e s .A l l o t h e r i o b s ,
with the exception of the renewol of the beor-
ing, shouldbe done by expertsin speciolized
r e p c i r s h o p s - s e e t h e n o t e s u p p l e m e n t i n gt h e
f o l l o w i n gp o r o g r o p h s .
Alternotor Reossembly
1 . I n s e r tt h e c i r c l i p i n t o t h e b e c r i n g b o r e i n
t h e c o m m u t o t o re n d s h i e l d .
2. Fit the drive end shield with beoringon
the rotor shoft.
3. Assemblethe stotor with the rotor ond the
c o m m u t o t o re n d s h i e l d .
4 " T i g h t e nt h e o l t e r n o i o rw i t h c l o m p i n g b o l t s
ond check the rotor for free rototion while
t i g h t e n i n gt h e b o l t s .
5 . S l i p t h e s p o c e ro n t o t l r e s h o f t , t o p t h e
k e y i n p o s i t i o n ,f i t t h e f o n o n d b e l t p u l l e y ,o n d
t i g h t e n t h e e n t i r e o s s e m b l yu s i n g t h e n u t w i t h
s p r i n gw o s h e r .
6 . P u l l o u t w i r e s f r o m t h e c o m m u t o t o re n d
shieldwhich hove been used to hold brushes
in their lifted position.
Replocementof Beorings
T h e u s e d b e o r i n g so r e f u l l y c l o s e do n d s e o l e d ,
ond they hove been filled in the foctorywith
l u b r i c o n t o l o s t t h r o u g ht h e i r e n t i r es e r v i c el i f e .
1 . P u l l t h e b e o r i n go f f t h e r o t o r u s i n g o s u i t -
o b l e p u l l e r .W h e n r e fi t t i n g t h e b e o r i n g ,p r e s s i t
o n t o b e o ro n t h e s h o f t c o l l o r -
2 . B e f o r er e m o v i n gt h e d r i v e e n d s h i e l d b e o r -
i n g , f i r s t d r i l l o f f t h e h e o d so f t h e f l o n g e r i v e t s
ond then drive the beoring out from the outer
side of the drive end shieldusing o suitoble
m o n d r e l( d r i f t ) .
O n r e o s s e m b l y c, l o s e t h e b e o r i n g w i t h t h e
f l o n g eo n d r i v e t t h e f l o n g e t o t h e s h i e l d .
Replocementof Diodes
T h e u s e o f t h e r e m o v o b l ed i o d e b l o c k w i t h
the individuol corriersof the so-colledpositive,
n e g o t i v e ,o n d o u x i l i o r yd i o d e s ,f o c i l i t o t e s c o n -
siderobly the replccement of ony defective
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j u n c t i o nw i t h t h e o l t e r n o t o ,or c c o r d i n gt o C h o p - i n g . l f t h e w s r n i n g l o m p d o e s n o t g o o . u tw h e n
ier 13.3 ond mointoining o constont voltoge of d r i v i n g , i . e . , i f i t g l o w s o t i n c r e o s e de n g i n e
tlre power supply set within the entire ronge of speed brightly or dimly, or if it does not stort
service speeds. glowing ofter stopping the engine ond o new
Tlre voltoge regulotoris instolledorr the body iurning of the ignition key in the switch box,
c r o s s b e o r e r ,t o t h e r i g h t o f t h e e n g i n e o n d the voitoge regulotoris proboblyfoulty.Another
b e s i d et h e i g n i t i o nc o i l . symptom of o regulotorfoilure is o poor chorg-
T o f o c i l i t o t e h o n d l i n go f i t s l e o d s 'e s p e c i o l l y irrg of tlre bottery or its overchorging..lf there
the occess to their connections,it is recom- i s n o t h i n g w r o n g w i t h t h e r e g u l o t o r c, h e c k t h e
rrrended to remove the regulotor fostening reguloted voltoge over the regulotor which
screws. For disconnecting procedures, see slrould reod 13.2volts ot the minimum ond 14.8
"Alternotor lnstollotion ond Gen- v o l t s o t t h e m o x i m u n r .T h i s c h e c k i n t h e c o r
Chopter 13.3
erol lnstructions". i s o n l y t e n t o t i v eo n d o n l y o c h e c k o n t h e t e s t
b e n c h ' c o nb e c o n s i d e r e do s d e f i n i t e o n d b i n d '
in g .

Electricol Adiustment

The voltoge regulotot-should be tested ond

o d j u s t e do n l y o n o t e s t b e n c h i n o c o n n e c t i o n
slrown in Fig. 13.412.
At o lood of some 2 onrperes,the checked
voltoge should correspondto volues specified
i n t h e c o l u m n " C h e c k i n g " .l f t h e c h e c k e dv o l t -
oge is within the specified ronge,do not odiust
the regulotor.Othenwiseodiust it to the volues
" A d i u s t m e n t " .l f w o t e r
DK1565 s p e c i f i e di n t h e c o l u m n
evoporotesobnormollyfrom the bottery, odiust
F i g . 1 3 . 4 1 1 I-n t e r n o lW i r i n g D i o g r o mo f the voltoge regulotor to the bosic volues of
" A d i u s t m e n t "u t i l i z i n gt h e l o w e r s e c t i o no f t h e
Alternotol with Voltoge Regulotor ond Outer
Connections t o l e r o n c ez o n e .

Altenrotor:
B, R, M - olternotoroutlets
f - olternotorphose windings
m - o l t e r n o t o rf i e l d w i n d i n g
D1,2,3,4, 5, 6 - moindiodes
D 7 , 8 , 9 - o l t e r n o t o ro u x i l i o r yd i o d e s
D 1 0- o l t e r n o t o rc h o k i n g d i o d e

Voltoge regulotor:
R, M, 15/54- regulotoroutlets
reg - regulotor tension winding
Rk - boloncing resistor
Ro - protective resistor
Rr - odiustobleresistor DK1566
Kr - regulotorcontocts
Fig.13.al2- Wiring Diogrom of Voltoge
Outer connections: RegulotorTested ond Adiustedon o Test Bench
K - worninglomp (1.5W)
G - olternotor
S - switch (switch box)
REG- voltoge regulotor
B - bottery
A - ommeter
V - voltmeter
Checking Voltoge Regulotoron Cor
S - switch
The regulotor operotion con be offected by R - lood resistor
loosenedconnections ond on imperfect eorth- B - bottery

178
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r o l e l n b e gl e c l u e q c a n O Z O ' L L n- 9 L L ' e n n
q'€l-t't t
 6 . S c r e w o f f t h e r e t o i n i n gs p r i n g s .
7. Lilt owoy the vocuum chomber (do 19t
o p e n i t , o c h o n g eo f t h e c u r v e i s o n . i m p r o b o b l e
d'efect;do not chonge the screw-indepth of the
p
' ull-rod).
tN' 8. Lift owoy the contoct breoker bose plote
w i t h p o c k i n gp i e c e f r o m t h e h o u s i n g .
g. Litt owoy the shoft with the centrifugol
> governor.
-
1 0 . l f n e c e s s o r yd, i s o s s e m b l ef u r t h e rt h e s u b '
t
ossembly of the shoft with the centrifugol
\' 5 g o v e r n o r( o d v o n c em e c h o n i s m )o n d c o m .
J I

(Il 2tD zsa !l! ReossemblY

qt3 F llti rc l?;h.',0,
Fig. 13.5i3- VocuumControl Course-
opplicoble to both regulotor models
copscrew fostening the distributor brocket to
t h e s u p p o r to n t h e e n g i n e ( d o n o t l o o s e nt h e
b r o c k e tc l o m p i n g b o l t ) .
Refit the distributor on the engine by re-
versing this procedure.The coupling on tlre
shoft is osymmetricolond it hos to engoge into
the heod of the drive shoft in the engine. To
seot properlyo new distributoror o distributor,
the brocket of which hos been loosened,refer
to Chopter 2.3, por.25 to 27.
Distributor Disossemblyond Reossembly
T h i s s h o u l db e d o n e i n s p e c i o l i z e d w o r k s h o p s , " i f . ' S t i p w o s h e r so n t h e s h o f t i n t h e o r i g i n o l
e s p e c i o l l yw i t h r e g o r d t o t h e c h e c k i n g o f t h e
m e c h o n i c o lc o n d i t i o n o r o r e p o i r o f t h e d i s -
tributor. lt is recommendedto use o suitoble
holder for doing the moiority of the required
i o b s i n o v e r t i c o l p o s i t i o n .W h e n r e o s s e m b l i n g
t h e d i s t r i b u t o r ,l u b r i c o t et h e s l i d i n g p o i n t s o c -
cording to Chopter 15.3 but bewore of over-
lubricotion.
Removeolso the copscrew on the bottom of
t h e d i s t r i b u t o rh o u s i n go n d d r i p s o m e l o w - p o u r
p o i n t o i l i n t o t h e h o l e t o i n c r e o s et h e o i l r e s e r v e
o f t h e s h o f t s e l - l u b r i c o t i n gb e o r i n g- s e e C h o p -
" S p e c i o l
ter 15.2 Oils".
Disossembly
1 . R e m o v et h e d i s t r i b u t o rc o p o n d t h e b r e o k e r
orm.
2. Removethe coupling from the shoft (note
t h e r e l o t i v e p o s i t i o n o f t h e e c c e n t r i cd o g s o n d
1. Reossemblethe centrifugol governor (the
weightsmust be freeto rototeon the pins).
2 . l n s t o l lt h e r e o s s e m b l e d shoft with the res'
pective woshers into the distributor housing.
3. Fit the contoct breokerbose plote with the
f i x e d c o n t o c t h o l d e ro n d p o c k i n gp i e c e i n t o t h e
housing.
4 . F i t t h e p u l l - r o do n t h e p i n o n d l o c k i t i n
position,screw down the vocuumchiomberwith
t h e c o p o c i t o r .C h e c k t h e i g n i t i o n o d v o n c e p o -
sition for the first cYlinder.
5. Screw down the retoining springs with
s h i m s ( t h e s p r i n gw i t h t h e d o g o p p o s i t et o t h e
t e r m i n o l" 1 " i ; t h e b o s e p l o t e m u s t r o t o t e f r e e l y
i n t h e d i s t r i b u t o rh o u s i n g . " 1 " .
6 . R e o s e m b l et h e t e r m i n o l
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'
s e q u e n c e s, l i p o n t h e c o u p l i n g o n d l o c k i t i n
position^
9 . F i t t h e l u b r i c o t i n gf e l t i n t o t h e h o l e o f t h e
c o m o n d i n s t o l l t h e b r e o k e ro r m .
1 0 . F i t t h e d i s t r i b u t o rc o p i n p o s i t i o n .
1 1 . C h e c k t h e d i s t r i b u t o ro p e r o t i o n .
Checking
A d e fi n i t e i n d i c o t i o no f t h e c o n d i t i o n o f t h e
d i s t r i b u t o r( d u r i n go n o p e r o t i o n ocl h e c k o s w e l l I
os ofter o repoir) con be obtoined by testing
t h e d i s t r i b u t o ro n o t e s t s t o n d w i t h o c i r c u l o r I
s p o r kg o p .A f t e r o p r e l i m i n o r yo d i u s t m e n o t f the
contoc-tbreokerpoint gop, the stond is used for
c h e c ki n g : t
1. The contoctpoint contoctongle. b
c
2. The spork - + 4 5 ongulor distribution (with o tol-
e r o n c eo f o n g l e m i n u t e sw i t h i n t h e e n t i r e ll

t h e b r e o k e ro r m ) . o p e r o t i o n o rl o n g e ) .
e
3 . R e m o v et h e c i r c l i p f r o m t h e p i v o t o n d l i t t 3 . T h e r o n g J o n d c o u r s eo f t h e c e n t r i f u g o l
owoy the breokerorm. ond vocuumcontrol. c
tl
4 . R e m o v et h e s u b o s s e m b l yo f t h e t e r m i n o l 4. The operotion ot moximum speed (length
"1" (current d
s u p p l yt o d i s t r i b u t o r ) . of spork on spork goP - 4 mm) for o brief period
n
5 . S c r e wo f f t h e c o p o c i t o r . ( o b o u t2 m i n u t e s ) .

180
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8'Sti'€t
orotely ( screen the other one). With left
directionol heodlomps,the borderline deviotes
towords the other side.
lf the heodlompsore neorerto the woll thon
the soid 5 metres, decreosethe meosureindi-
coting the deviotion of the light ond dorkness
bordeiline from the height of the heodlomps
obovethe ground in the direct proportionto the
decreose of tfre distonce, for exomple when
plocing the cor 2.5 metres from the woll, de-
creosethe deviotion bY holf. "B"
"A" ond correspondto
Light proiections
the spocing of heodlomPson the cor ond they
hovethe followingdimensions:
Heodlomps,dio. 160 mm
Duol heodlompsd , io. 130 mm
Auxiliory heodlomps,dio. 130 mm
W h e n o d j u s t i n gt h e h e o d l o m p st,h e c o r m u s t
be empty ond the tyres must be correctly in-
floted. Hologen heodlompsshould not be left
switched on for too long o period os they build
up heot if not cooled by heod-onoir blost when
driving.
For lhe odiustmentof heodlomPsore intended
screws in their fromes.The screws ore occess'
ible ofter the removol of the side ports of the
grille. Remove the copscrews of the corners
o n d p u s ht h e g r i l l e o s i d e .
Heodlomp Assembly
o) The fundomentolfostening Port of circulor
heodlompsis the so-colledsupport plote (rec-
tongulor plote) ottoched to the bodywork by
copscrews with lock woshers. The heodlomp
housing is bolted to this suPPortplote by bolts
with nuts ond lock woshers. One of the bolts
holds down olso the lug of the eorthing coble-
The inner frome, forming the odiusting element
of the heodlompinsert, is ottoched to the hous'
ing by two speciol odiusting screws ond two
tension springs. The heodlomp insert is ot'
toched to the bezel by three copscrews.
There is one left-hond ond one right-hond
supportplote. Both should be mountedwith the
"TOP" upwords.With the
oriow ond the word
exceptionof the ouxiliory heodlomps,the heod'
lomp inserts ore different for the left-hondond
the right-hondtroffic. The leods enter the hous-
ing through o rubber grommet.
When r-eplocingthe insert, remove the bezel
copscrews.After hoving fitted o new insert, it
1,030mm is necessoryto reodiustthe heodlomps.
1 , 1 1 4m m
790 mm
Front Direction Indicotors
T h e r i g h t - h o n do n d l e f t - h o n dd i r e c t i o n i n d i -
c o t o r s o r e u n d i s o s s e m b l o b lu en i t s ( t h e l o m p
fostening sockets (locks) ore mounted in the
direction towords the cor longitudinol centre
l i n e ) .T h e y o r e f o s t e n e dt o t h e i r b r o c k e t si n t h e
bumperwith o nut ond o ploin ond o lock
wosher.
I
Toil Lomp Cluster I
I
T h e l o m p c l u s t e ri s o n u n d i s o s s e m b l o b luen i t s
fostened to the bodywork by nuts with ploin
I
woshers ond the respective bolts. Scrope off
the enomel ot the top bolt used for holding
d o w n t h e e o r t h i n gc o b l e . I
F o r t h e s e q u e n c eo f t h e i n d i v i d u o ll o m p s o n d I
their bulbs see Fig. 13.111ond the respective
t
p o r o g r o p ho n b u l b s .

(
(

t
l

,
t
T
c
R
L
D
- Adiusting ond Fastening Screws of Right-hondHeodlomps- their locotion on
Fig. 13.812
v
Ir
is their mirror reflection
left-hondhe-odlomps
1
1 - Sidewoys odiusting screw 2
2 - H e i g h t o d i u s t i n gs c r e w 3
3 - F o s t e n i n gs c r e w s

182
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'lalcos sll -|
1 ! u n e l q D l q r u d s s D s l p u nu D s t d u o ; s ! L l l _
q l l / v \ r e q l a o o]lq 6 l | ( e p t s ) s c u o r o e l ca q l l o q l n q
1 q 6 ; 1 e 1 o 1 6e c u e c ! - l
e q l M D r p t { } l M' q l n q e q } e ^ o u s r p u D ' e s l M l c o l s 'qollMs
-lluD ll peurnl puo posseJdap6urnoq JaUDlcol 1 e ; o de n l l c 6 s u e ^ ! l D s ! l l
q l n q e q l l o r v r o1 1 1'1I u o 1 1' l c o l a L l l J o l D e se q l sql ol ellsoddo ellul eql lceuuoc ]ou oc 'el!u)
e l o u r e r ' ( u 6 ; s e p d r u o l p o a qa q l u o 6 u r p u a d a p ) siluec eql ol (uaer6) qctr!Ms roop eql uro4
l!
sstqoc ro pr'oq tou!urra]eql ilo O,'" p o o l o t l l p u o 6 u r . r d se p l s l D l l e q l l D J o l c e u u o o
.!inH", a , t u l e q l o t p o e l ( p a r ) e n l l q s o da q t l o a u u o C
l
eseql ;o sPoeq aql JeAo uaql s^ouraJ puo p u e r e q l o e q l u ! s s e . r du a q l -
s d t u o g p o eaqq 1 A g l q 6 r l se l o l o J ' s m e J c 6 su1ua1so; puo qcl/v\s eql qll/t,[pua eql lsrll ernuedo eql p
d u r o ; p o e qe q l u e s o o l ' l u e r u 1 s n ! p o d u . r o g p o a q o l u ! l r e s u ! ' 1 ; 6 u g ; ; o l s u l e Ju a r 1 M ' q c l l M s e q l o l .
uo qdo.rDorod eqt u! peqlJcsepsD re^oc rolDrpor a l r s o d d o p u e e q l u o ' ' e ' ! ' M o J J Du o q l l M p a l r D r ! e
aql to s1.rodrelno eql a^oueX - sdruolpoag ro^oc eql lo pue eql pulqeq pallddo loot rol e
'loqoclDqllM 'i(;luelJe^poul - l u r ! s D J o J e n l r p M e J c so q l l r " r 1 n o 6 u 1 s ; . r dI n l e J D O
l! qsor* A q p e n o u e r o q u D c d u o l e q 1 ' 1 u 1 o dl o s e r , o q
's.re6u1;palDu gltrvr
ll peqcnol e^oq nol ;;
durol uaboloq eql lo qlnq eq] qcnol lou 06l l s n u ' 6 u g . r d s6 u r q l r o e l D l l e p l s e q l q l l r r t l c D l u o c -
'ueql ulnl u ! a q l l l r t t rr l c ! q M ' e 6 p a s 1 ; ' 1 : o r u A p o q e q l u ! e r n l
PUD - l a d o a n l l c e d s a r a q 1 o l u t I 1 r u . t ; 1p e s s a : d s ! ' l ! u n
s s e : d e p I ; d L u r s ' s q l n q e s a q l 6 u 1 c o 1 d au. re q 1 1 -
's1col o l q o l q u e s s D s ! p u nu o 6 u 1 l u . r o';1 q 6 ; qa u o p a q 1
lauoloq pallDc-os eqt Aq uMop plsq ll
t
a J Ds q l n q l l D ' s r e p l o ql c D l u o c o l u ! s e s D qr a q l 1q6;1 (Ase1rno3) euro6
13 . 9 - 13 . 1 0

13.9 HORN heor the ormoturebeing ottrocted (o cleor ond

l o u d c l i c k ) . N o w c o n t i n u et o s w i t c h t h e b o t t e r y
I t i s s i t u o t e db e h i n d t h e l e f t ' h o n dp o r t o f t h e on ond off while rototing corefully ond sloryly
"1" onticlockwGetill the horn sounds'
front bumper. To remove it, disconnect the the screw
leods ond remove the fostening screw. iune it by rototing the odiusting.:cr9ryslightly
clockwiseor bock.-Afterhoving odiusted(tuned)
Operoting voltoge 12 volts ih" honn,secureoll odiusting ports with o dob
M o x i m u mc u r r e n td e m o n d 4 omperes of point.

Horn Adiustment
B e f o r eo d i u s t i n g ( t u n i n g ) t h e h o r n , c l o m p i t
firmly by th'e brocket ond tighten thoroughly
-@
"4"
oll screws ioiningthe horn cover with the
h o u s i n go n d t h e d i o P h r o g m .
1. The horn is
"hoorse"- Using o screwdriver
"1" clockwise to odiust
c
rotote slowly the screw
t h e c u r r e n td e m o n dt i l l t h e t o n e i s c l e o r . @
2. The horn sounds weokly - Using o screw-
driver,rotote the screw
"1" slowly onticlockwise
to decreosethe current demond till the tone is
c
loud ond cleor.
3. The horn does not sound ot oll-Proceeding
through the operture in the front cover, loosen
the nut "2" using o socket sPonner.Then insert F i g . 1 3 . 9 / 1- S e c t i o n o lV i e w o f H o r n o n d o V i e w
o screwdriverond rotote the odiusting screw of Reor Adiusting Screw
c l o c k w i s et i l l i t b e o r s l i g h t l y o n t h e c o r e .T h e n
bock off the screw by 1lz or moximolly 3/a of
o turn to odiust the distonce of the ormoture 13.10 STARTER MOTOR
from the core. Hold the screw in this position
with the screwdriverond tighten firmly the nut This is o series motor for intermittent oper-
by rototing it clockwise.After hoving connected o t i o n w i t h o n e l e c t r o m o g n e t i c o l l ye n g o g e d
t h e b o t t e r y ( o f t h e s p e c i f i e dv o l t o g e ) ,y o u w i l l pinion.

Specificotions
TyPe PAL-Mogneton 12 V/0.8 h. p. - 443'115'142'070
Roted output 0.66 kw (0.e h. P.)
Storting torque 1 2 . 2 5N m ( 1 . 2 5 k g m )
'1,000r. p. m. moximum
Speed for roted output
"30" of roted output 9 . 5V m o x i m u m
Voltoge ocross terminol
No-lood storting current 65 A moximum
Direction of rototion o n t i c l o c k w i s e( l e f t ' h o n d )
N u m b e ro f p i n i o n t e e t h / m o d u l u s. 912.5
Contoct spring pressure e.3 N (0.ss0 ks) +100/6

Mointenonce The brushes must be sufficiently long ond

they must slide freely in their-cells,their press-
The mointenonce consists of periodicol in' ure springs must hove o sufficient thrust, the
spections ond repoirs or replocementof foulty commutotormust not show ony domoge,ond it
ports: must be free of dust ond dirt. Cleon the commu-
totor with olcohol, petrol or trichloroethylene,
o) brushes ond let it dry before closing it ond switching
b) b r u s hs p r i n g s on the storter motor. A burnt or mechonicolly
c) commutotor domoged commutotor must be repoired or re'
d) s t o r t e rp i n i o n o n d i d l e r ploceJ immediotely.A commutotorin good con'
e) s e l f - l u b r i c o t i nbge o r i n g s d i t i o n h o s o b r o w n i s hr e d h u e .

184
 981
' ( e c u a n b a sr e q l p u r t x u ; d e a l
) u o l u e u u D d r . u o cs 6 o 6 6 n 1' ( 1 1 l n q - u 1. r) o e .ar q t J o
'l rooll aql JePunPellDlsu!s! rolotu reuDls eq1
l r o d a n g i p l r D q s e q l l o s r e q s o Mt l o d l l s
'ple!qs
Puee^lrpaql 6u;g;1eX puD lDAouraUrolo!\l reuDls
uro.r;uolu;d eql qllM eJnJDurro oql e^oueu '9
' p l e ! q sp u e 'Jolout JauDls orll
]o
e ^ l J pa q l l o l n o u r d e q l a ^ ! r p p u o u ; d : a n e ; 6 u 1 Ilqtuassosgpeqt q11m 6u11oapqdo.r6orodaql
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'q31!,!\S 'lelp! eql qllM elalduoc euo Meu o q1;m (q1ae1
e q l r l n D J P q ] ! Mp u D ' u o l s u e d s n s l l o l e q l u o r l paDouop rll!t*) uo!u1dpe6oruopeql acoldex
ernlouro r]c]!Ms eql aerl 'plelqs pue e^!rp aql
u o r 1 c l l M s a q 1 6 u 1 p 1 o q s r r , r a r c s d o ce l o r r l a g " t
'{1rodo a^rnC tndtno
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' ( s . r a q s o ms q ]
]o
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deel) a)Drq aql lo sraqsDM eql qllM .raq1a6ol
plelqs pue rolDlntuuo" aq] Iorrto 'Z
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,t;qtuassoss!O Jolol l rauols
'roloru JeilDls aq1 6u1111;eJueqrurernpaco.rd s1q1
e s J e A e U ' l o r v r ol ! 1 1 l p u o 6 u l s n o q x o q . r o a 6e q ] o l
Jolotrl JelJDls aq1 6ugua1sol slrra:csdDc enoueu
'Jolou Jauols aql uoJ+ fue11oq eql uoJl pDal
orll puD qo]lMs eql ol pDel eql ]ceuuocslc
' ( ; o ur u r
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'pJDoqJooll
lueul:oduoc e6o66n1aql u! srenoc
qloq enorreJ PUD'lDLu eql u!l 'uo!qsnc lDas
r o e r e q l d 1 1 ' x o q : o a 6 a q 1 1 o e p l s p u D q - q 6 ! ra q l
rolonl reUDtrSjo Metn lDuollcos- L/01'eL'6!J
LgL ilt}
W
0t'€t
 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.Thesome oppllesto the end shieldswith
beorings. By dipping them in o degreosing DK1575
ogent, the beorings become procticolly worth- Fig. 13.10/3- Storter Motor Testlng Connection
less"
Storter Motor Reossembly minols u30" ond "50" with switched on
1. Lubricote the hellx of the ormoture shoft ignition), stort looking for o foilure of the
with greose - see Chopter 15.2 'Lubriconts of storter motor switch. Even in this instonce,
foreing mokeu ond fit the pinion with the idler the cousecon be o fully dischorgedor foulty
o n d t h e s l i p - o v e r i n g i n p o s l t i o n .F i t t h e c i r c l i p bottery.
into the groove in the shoft, ond drive the slip- b) lf the storter motor continues running even
on ring over it. The pinion with the idler must ofter the ignition key hos beenswitchedin
"START",
move freely olong the shoft. the switch box from the position
2. Slip the respectivewosherson the shoft in it hos to be stopped without ony deloy by
their originol sequence (corrier ring, distonce disconnectingthe bottery (using its eorthed
ring, fibre ring, distoncering) ond insert the pole).
ormoturewith the engoging lever into the drive c) lf the storter motor hos no power to cronk
end shield. the engine, stort with switched-on heod-
3. Suspend the switch ormoture into the lights. A morked dimming indicotesc poorly
pre-engoginglever ond bolt down the switch chorged bottery.
lightly. Fit the lever pin into the drive end
shield ond lock it in position with the retoiner. Tentotive Checking of Storter Motor
4. Tighten the copscrewsof the switch ond Outside Cor
f i t t h e s t o t o ro n t h e d r i v e e n d s h i e l d . "30'of the storter
Connect the terminol
5. Instoll the respective woshers into the motor to o properly chorged bottery ond incor'
c o m m u t o t o re n d s h i e l d i n t h e i r o r i g i n o l s e - poroteon ommeterwith o wide meosuringronge
quence (the dished wosher with its centre into the circuit - see Fig. 13.10/3.Stort the
f o c i n g t h e s h i e l d , t h e n t h e p l o i n w o s h e r ,t h e "50"). The
engine (feed current to the terminol
toothed wosher, ond the drive wosher). volue of the current ot idling speed must not
6. Fit the commutotorend shield with lifted exceed65 omperes(not consideringthe peok ot
brusheson the shoft (in the position occording the first momentousdeflection).
to the recess for the excitotion outlet ond the The storter motor must run noiselessly,
notch) ond screw in the clomping bolts. smoothly, ond the pinion must move smoothly
7. Instoll the brush interconnectingstrip ond into ond out of the rest position (engoge ond
bolt it down together with the field winding d i e s e n g o g e )T. h e e n g o g e dp i n i o n m u s t n o t r o -
outlets to the positive brush holders,lower the tote direct on the foce of the slip-on ring. The
brushes. run-out of the storter motor must not lost longer
8. Fit the Insulotingstrip in position ond bolt thon 8 seconds ofter the disconnectionof the
down the cover. switch from the current supply.
9. Test the storter mottr. Inspect the brush pressure springs. The
brushes must beor on the commutotor by ot
Diognosing Storter Motor Defects in Cor leost two thirds of their surfoceond they must
o) lf the storter motor refuses to operote, look move freely in their cells.
first for on interruptedconnection between The ormotureshould hove o noticeoble oxiol
the bottery ond the storter motor,the engine cleoronce (ploy) not exceeding 0.7 mm. At
eorthing ond the storter motor,or the engine o s l i g h t r o t o t i o no f t h e p i n i o n i n t h e d i r e c t i o n
eorthing ond the bottery. lf these connec- of the storter motor rototion,the idlor must slip (
tions ore in order (current flows to the ter' freely.
1
z
186
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6ur6e6ue ualorg
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uo paqclr/ns 6u;eq rege Eulurnl lou Joloru reyels (e
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13.11 WINDSCREENWIPER
Technicol Description
The rotory windscreen wiper consists of the
wiper motor with o geor cosing, o lever system
driving the wiper orms, ond two wiper orms
with wiper blodes.
The two-pole wiper motor with permonent
I mognets is o two-speed unit with self'lubri'
coting beorings.The geor cosing compriseson
i
Windscreenwiper tyPe - for left-hondsteering .
- for right-hond steering
Roted voltoge
Roted current
Wiping cyclesper minute
Differenceof cycles between speeds
f1 Direction of rototion when viewing the output
shoft
Removol ond Refitting
According to the noture of the required re-
poir, removeeither only the motor with the geor
cosing after hoving disconnected the pullrod
from the cronk,the cronk from the geor cosing,
ond the geor cosing from the brocket,or remove
the completeunit ofter removingthe wiper orm
beorings- see wiper orm drive.
When refitting the windscreen wiper unit,
observe the ossembly position of "Motor
cronk - see the following porogroph
Geor Cosing". For position of the wiper orms
'Wiper Arms". ln-
( b l o d e s ) ,s e e t h e p o r o g r o p h
stoll the brocket into the body bulkheod ond
fosten it in position with the nut, using o rub-
llr ber ond o flot wosher.
fi.,
Cleoning ond Repoirs
When disossemblingthe windscreen wiper
motor, do the following jobs:
1. Reploceworn brushes ond use petrol to
il cleon motor ports ofter blowing the dust out of
the brushes;moke sure thot the brushesmove
freelyin their cells.
2. lf the commutotor is dirty, cleon it with
petrol, if it is domoged,re-turnond polish it.
3 . D u r i n g c l e o n i n g ,t h e s e l f - l u b r i c o t i n bgeor-
ings must not come into contoct with the
c l e o n i n g( d e g r e o s i n g )o g e n t ( p e t r o l e, t c . ) .T h e y
s h o u l db e l u b r i c o t e do n l y w i t h o l o w - p o u r - p o i n t
o i l d r i p p e di n t o t h e c u t - o u t so f t h e c u p r e t o i n i n g
lr
l
13.10-t3.11
epicyclic geor ond on outomotic self-porking
device. The shoft runs in self'lubricotingbeor'
ings, the geors being lubricoted with greose
pocked into the geor cosing. The lever system
(leveroge) includes self-lubricotingioints ond
beorings.
PAL 443.122- 081.071
PAL 443.122- 076.071
-12
volts
4 omperesot high speed,
2.5 omperes ot low speed
6 0 o t h i g h s p e e d( m i n i m u m )
2 0 ( m i n i m u m )t o 5 0 ( m o x i m u m )o t l o w s p e e d
1 5 c y c l e sp e r m i n u t e ( m i n i m u m )
onticlockwise- for left-hond steering
clockwise- for right-hond steering
t h e b o l l b e o r i n go n d t h e f e l t . U s e o n l y o s m u c h
oil os the felt con hold.
4. For the epicyclic geor in the geor cosing
use greoses specified in Chopter 15.3- either
of foreign moke or of Czechoslovokmoke- re-
commendedspecificollyfor windscreenwipers.
MOTOR AND GEAR CASING
the wiper Ports of the motor with the geor cosing (or
ond geored motor) is the wiper brocket, the pro.
tective housing, ond the driving cronk. When
i n s t o l l i n gt h e w i p e r , p u t t h e h o u s i n g o n t h e
motor with the geor cosing ond clomp it from
below. Bolt down the brocket using ploin
woshers under the bolts. Fosten the motor
e o r t h i n gc o b l e u n d e r o n e o f t h e b o l t s .
F o s t e nt h e c r o n k i n p o s i t i o nu s i n g o n u t o n d
o s p r i n g w o s h e r w h i l e o b s e r v i n gi t s o s s e m b l y
position:
o) with wipers for left-hondsteering-toword
the right-hond side of the motor ond deflected
13odownword from the oxis porollel with the
centre line of the motor;
b) with wipers for right-hond steering
toword the left-hondside of the motor ond de-
f lected17"downword from the oxis porollelwith
the centre line of the motor.
Dismontlingthe Geor Cosing
1. Remove three screws ond lift owoy the
cover.
188
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epld lueulnqD sl! puo 6u1.rdseqt uesul .g pollDlsu!eq plnoqs reqsDM
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eql lo su;d eql uo sleeqM lauo;d eLll llJ 'l
aq] lo llo uaql lnc 'peJaplos lou eJo seqsntq
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rlaqt Jeplosun 'uroM erD seqsnrq eql I 'Z
'seel6ap gg; q6norq] rolDls oql 'UDqs 6ugsoc.roe6eq1 6u;dd;rb Iq 'paso;c
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luoJl Jolor aql 6ulrrrra;^ueqM os!M)colc alolol UDqs eql 6u1dd1r6 {q uorl;sod u! l! ploq 'rolDts
lsnur Jolotu aq1 '6uguunl rcdold Jol l! ),lcoqc oql qtlM .raq1e6olpe^oueJ 6u1equorl rolor aql
'JoloJ aql AorvrD 'rolols
puo l.relpq oq] ol roJoru eql ]csuuoC .g lueneld of llll ueql puo
's6u;.roeq sl! u! Jolor oql oliles aql PUD plelqs pue JolDlnultuoc eql a^ouor
ol 's1;oq Duldtuolceql 'L
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I
'lnu eql 6u;ue1q6;1{q uo;1rsod
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lo anlDl o o1 Aold lDlxD rolor eql 1snlpy .g
'plalqs pue rolDlnuuoc eq] ur*op 6u;ploq slnu 'sloeqm
lauogd
aql ue1q611puD slloq uo sreqsom 6ug.rdsdgls eql e^ousr puD Uoqs eql ;;o .toe6 elqnop eql
'Je^ocJoeJeql 'Jaqlo qcoa elgsoddoe.roseu11
lll eq1 dgls 'l.rosseceu;; 'ugo.r1loe6 eql lno qsnd
xepu! otrAl eql loql os rolDls eql llolsul 'g ol UDqs (en;rp) I.rotul.rdeql lsulo6o sserd 'Z
 t 3.tr*r 3.12

1. lf the wiper moves with the switch in the the wipers. lf necessory,turn the wiper cms
OFF position ofter its connectionto the electric on the pins. The wipers must wipe the lorgest
power supply,tighten (screw down) the screw possible oreo of the windscreen without, how'
till it begins to be litfed by the geor com ond ever, touching the windscreen glozing mould-
till the wiper begins to be switched off ond in g .
broked. Screw down the screw from this po'
s i t i o n b y o n o t h e rh o l f t u r n .
2. Press the lid into the cover ond seol it 13.12 RADIATOR FAN
with point.
Technicol Description
WIPER ARM DRIVE The fon is on ossemblyof the fon motor ond
impeller. The impeller is pressed on to the
T h i s d r i v e c o n s i s t so f t h e w i p e r b e o r i n g s w i t h motor shoft.
cronks,the tie-rod of the cronks, ond the driv- The motor hos permonent mognets ond
i n g t i e - r o d .T h e d r i v e i s i n s t o l l e di n t h e c o r o s o rotor running in self-lubricotingbeorlngs.The
o unit. impelleris mode of plostic.
Tie-rods Motor type PAL 443.132- O97.O45
Roted voltoge 12 volts
The tie-rods should be slipepd on the cronk
p i n s i n t h e f o l l o w i n gs e q u e n c eo: s p r i n g w o s h e r Roted current 7.5 omperes
with its centre comber focing outword (owoy Roted output 55 wotts
from the pin), o flot wosher, the tie-rod, o flot Direction
wosher, ond o lock ring. of rototion c l o c k w i s e ( r i g h t - h o n d )w h e n
lf necessory,lubricotethe ioints with greose viewing the front end of the
- see the following section deoling with beor- shoft
ings. Fill the cover at the point of the tie-rod Coble poles coble with lug (blue)-
motor cronk connection with greose (of ony negotive pole
brond) ond slip it on the tie-rod. coble with femole connector
(red) - positive pole
Beorings
On one side, the beoring is inserted into the Removol ond Refitting
wiper brocket from inside the body, on the
other side, it is fitted into o speciol wosher in- The fon is occessible ofter removing the
serted with its nose foremost into the re- rodiotor to which it is fostened by meons of
spective hole in the body. Locote o seoling o rim held down by copscrews ond sprlng
wosher with corefully smoothed-outedges ond woshers.The motor rests on resilient bushes in
o flot wosher from outside, ond secure the the rim. When refitting the fon moke sure thot
entire unit with the respectivenut. The unit is there is o spocer tube in the bush, locote the
seoled off by o rubber pocking. Fill the unit flot ond the spring woshers, ond tighten the
with greose(see Chopter 15.3for recommended nut.
foreign bronds or CzechoslovokLrrondsSP 4 or
A 4) ond press it down into the neck of the Cleoning ond Repoirs
bush.
lf it is necessoryto remove or disossemble Refer to porogrophs 1 to 3 deoling with
the beoring, prise the lock ring out of the pin cleoning ond repoirs in Chopter 13.11.
grooveunderthe rubberpocking.On reossembly,
insert o spring wosher under the bush with its Dismontling Motor ond lmpeller
combered centre toword the bush. Lubricote
with the specified greose. The motor con be removed (ond dismontled)
only ofter removingthe impeller.Use the puller
Wiper Arms MP 8-102to pull off the fon or support the fon
hub in three points on its circumferenceond
The wiper orms fitted with o rubber blode press out the motor by opplying Pressure on
con be swung owoy from the windscreen.They the motor shoft. No topping or blows on the
ore held down by nuts on the groovedtopers of shoft ore permitted.
t h e b e o r i n gp i n s . 1. Remove the nuts of the clomping bolts,
After hoving fitted the wiper orms, sproy hold the shoft by its grooved end, ond lift
woter on the windscreen ond test the run of owoy the commutotorend shield ond stotor.

190
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lo
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aq lsnur Uoqs eql 'Uoqs eql llo repledul eql uo;1d;rcse6 lDc!uqcal
'6ug.reql 'lool elqDllnsreqlouD
11ndpuo 11odgls
.ro s6u1.r.ra6eag.ro1s.re1;d6u1sn leg;edurgeql NVr Ufrv3H et'et
uo palll+ 6u;r 1co; aql lo spue aql poetdg '1
'sse:d aql
.re;1edur1
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r.lllM llorls Jolour aqr lo lcoluoc lcaJlP luena:d
o1 6u1.ro .ro edld 1o q16ua1o asn '(pa111r-u.red
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aql qllrrt tlsnll llDqs eql uo ra;gadu; aql ssa.rd
puD rolour eql lo plalqs pue aql yoddnS 'g
.ogg; q6norql plotr{s
pue Jololnuuoc eql alDloJ 'uo11ca:gpallsoddo
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prDMol lols eql Llll/t^rolDls eql llolsu! 'ltoqs
eql to puo pe^oor6 aql lg rolor eql ploH 't
'6u111nc:1c-poqs
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'lelcDlq eql uoll
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pe^otloJ ueqM Pelocllqnl aq uoc JoloLu eql
'LL'01 leldoqC u! o1 sqdor6o.todot relau s!qt ul uaql lsulD6o 1sa: s6ug:dsuogsse:dtuoc
t L aql lel 'apn.r1o.rd A11o11rod uaql 6u!uel sat{snrq
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'2'g.;raldoq3 'lsr!l pallDlsu!eq plnoqs reqsoM (tuu
S'O)
u! paqllcsep e.tD Aaql '.toc eql uloJl pe^oruel u!ql oql 'sraqsDM pezlreqqnj oMl eLll uee'\^
relDeq oql qtlM Iluo auop eq UDOsqo! aseql -1eq aco;d sl! sDq reqsDMflel eqf - epls reqlla
uo sJoqsoM eeJql llolsu! PUD loloJ JolDlnu
6u;gg1eg puD lDAoueU uoJ -uroc oql uo 6ug.rrorttolql-llo eql alDool '!
llDqs re;;edur1puo lolo4 6u;;qutessoag
lndlno eql 6u;r*e!AuoqM
(puoq-1;ep
) aslntlco;cg1uo uollDloj lo
uo!lcoJ!c Jolol l UDJ
'61)
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Prooq lou!ulel |o ePDlq
puorl-Uolo1 a;od en;11sod
-lolceuuoc elouel qll/v\ alqoc
PrDoqloululrel lo opDlq puDtl
-1q6r.raqt o1 egod err11o6eu
- (antq) 6n1 qltrt alqoc slDultursl puD
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'seqsnJq
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uo sunr JoloJ sl! puo 'slau6Dtu luouDtu.redsoq eql Japlosun 'l.tossoceu 1 'JoloJ et{t Aorvro
'uteql 1su1o6o s6u1.rdsuolssa:duoc
eqI'lloqs Jolout aql uo pesse.rd
rolou,ra;od-orrr1 ull puo 'saqsnlq
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t 1'81-?l't l
 t3.tt-l 3,I 5

2. Removethe clomping bolt from the brocket

ond lift owoy the motor.
3. Removethe other clomping bolt from the
motor, lift owoy the stotor ond the brush
springs, ond push out the brushes. The other
motor ports connot be dissosembled.
Reossemblyof Motor ond lmpeller
1. lnstollthe stotor with the slot focing the
b o s s e so n t h e f r o m e o n d w i t h i t s i n d e x l i n e
focing the line on the frome,ond fosten the
ports with screws ond woshers.
2. Instoll the brushes ond brush springs,
suitobly orch the brush cobles so thot they do
not obstruct the movementof the brushesond
so thot they connot couse o short-circuit.
3. Top the stotor lightly with o soft mollet Fig. 13.1a11-Windscreen Wosher
to settle it in the beorings, ond lubricote the -
1 R e s e r v o i r2
, - S p r o y i n gn o z z l e s ,3 - M o t o r
beorings. with pump
4. Connect the motor to the power supply
ond test briefly its running ond direction of
rototion. lf it rototes in the opposite direction, b r o n c h r e i n f o r c e dw i t h o c o l l o r ; t h e p o s i t i v e
rotote the frome ossemblythrough 180'. pole is connectedto the suction side, the
5. Removethe clomping bolt of the motor on negotive pole to the dischorge side (when
the terminolboord side, instoll the motor in viewing the cor from the front, suction is on
the brocket, ond lock it in position with the t h e r i g h t - h o n ds i d e , t h e d i s c h o r g eo n t h e l e f t "
bolt ond wosher. h o n ds i d e ) .
6. Fit the spring on the motor shoft, support The distributor volve is fostened by o cop-
t h e s h o f t t o o v o i d d o m o g i n gt h e b e o r i n g s o , nd s c r e w , t h e d i s t r i b u t i o np i p e l i n e b e i n g s i m p l y
press-onthe impeller. The cleoronce between fitted on it.
the impeller circumference ond the brocket The nozzles (heods with nozzles) ore se-
must be smoll, obout 1.5to 2 mm. Lock the im- cured in position by pressing them down from
p e l l e r i n p o s i t i o nb y p r e s s i n g- o n t h e l o c k r i n g obove into bushings inserted into the cor body
I - ogoin the motor shoft must be supported. by their necks.To odjust the requireddirection
7. Close the motor beoring from obove by of the woter streom, turn the nozzles to the
fitting the cover. respective ongle using o needle inserted into
the nozzle hole.

13.14 WINDSCREEN WASHER Fil!ing the Reservoir

Open the reservoir by turning its cop onti-
Technicol Description clockwise.In summer,fill it with woter or o mix-
ture of woter ond one of the odditives for wind-
T h e w i n d s c r e e nw o s h e r i s o u n i t c o m p r i s i n g screenwoshersovoiloble on the morket,ond in
o reservoir,o pump with motor, o distributor winter exclusivelywith on ontifreezeof o brond
v o l v e , t w o n o z z l e so, n d t h e c o n n e c t i n gp i p e l i n e . intended speciolly for windscreen woshers -
never use on ontifreeze intended for motor
Windscreenwosher type MEZ MM 2004 vehiclecooling systems.
Roted voltoge . 12 volts Be coreful if the body finish is touched up
Roted input . . 50 wotts with other thon boking enomel. Additives in
P u m pd i s c h o r g e , t h e w o t e r o n d o t h e r l i q u i d s ,u s u o l l yc o n t o i n i n g
minimum . 15 c. c. ot o pressure spirit, ore opt to leove unremovoblespots on
of 10 MPo the enomel. Use only woter when testing the
(1 kg/cme) windscreenwosher.
Fitting, Removol, ond Adiustment
1 3 . 1 5 I N S T R U M E N TP A N E L
The reservoiris held in its ploce by o cover
bond secured by copscrewswith flot woshers. Technicol Description
The motor with pump is bolted down, using
flot woshers under the copscrews.The suction The instrumentponel contoins oll meosuring
bronch socket is smooth,thot of the dischorge instruments ond indicotors recommended by

192
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uMoqs lauod luar,un:lsu!6ugu:acuocuo!loulJolut ' s d r u o la n l l c a d s e ra q ] lauod
o] Jalai 'salqDo]o uollcauuoc eql puo 'sdtuo; ]11 puo l o s 6 u r s n o qe q l
6 u r u : o r * p u D s l u a u n r l s u ! a q t 6 u g u e t s Drl o J 6u1nor.ua.r .re1;olauod lcoq eql ;o a6pe eql lD
sano:csdoc x!s e^ouer 'sa6no6lon] puD arnlorad
g/e't'6!J u! urnoqs leuDd luounrlsul -ual ]o asDceql ul 'lnu 6u1ua1so;:alauopaads
'a6no6 aqr Jro peMeJcs6u;noq JellD puo ]uauinJlsu!
loquAs snu!ur Jolsnlceqt lo acusJs,ulnoJ!c aql uo sd11cpenour
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]o l q p e l q u a s s D s r ep q u o c ; e u o dl u o u nrlsu!eql
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aql oultttleJ ueqM repJo osJs^eru! peacoJd
l o a p o ! q a . r l u a c ) u o ! l D u r u n l l ! l u e u r n r l s u-l L 'JDc eql uJol' eq
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'6ur1gnd i q s p r o o q 't
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-un lq a^!rp releuropaeds aq1 e6o6uesl6 'Z
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l D c l r t c e l eq l l M s 6 n l d
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rueql 6ullcouuocsrp eroleq salqDc aql lrotAl
' ( s l o q t u A s )s l o l d s r p p u o s s o ; 6 p a r n o l o c ul qllltnllDep sr UDls a^rrp raleuopaads aq1
adll alqopuadxeaql ]o arD
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slueurnrlsutllV 'glt'L ol t/t'L '6;3 eas u61sap
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spuoq .ranocAq uMop pleq ero sluauln:lsul
'se1co1decel
t/t't'6!J u! u^ oqS leuDd luoulnrlsul o1 iltce.r!p palcauuoc slalcos .to
lo urrol aqt ul pap;nords! uo!lceuuoc lDclilcal3
'6ursnoqenllcedse.t '6u;,r1rp alos lo r*ell lo 1u1odaql uorl elqo
u e a r 6s n ; d
s 1 ! L r ! d r - u o 1e q l 1 g 3 ' d u o 1 6 u r u r o n n -J!sep Jo spJDpuDlspuo suo!lD;nDe.r luau;1:ed
9!'gtJl'€l

ox 1568
- S w i t c h B o x w i t h S t e e r i n gL o c k -
Fig. 13.16/1
the orrows indicote the copscrews (M 3.5)
h o l d i n gd o w n t h e s w i t c h b o x i n t h e s t e e r i n g
lock housing
d i s e n g o g i n gt h e s h o f t f r o m t h e b o d y w o r k- s e e
Chopter 7.8, porogrophs1 to 5 - without, how-
e v e r , d i s e n g o g i n gt h e s h o f t f r o m t h e s t e e r i n g
box.
The switch box con be removedofter loosen-
ing two copscrewson the steering lock hous-
ing (seeillustrotion).
Reverse this procedure when refitting the
switch box. Turn the key ond the key hole of
the switch box into the left-hond extreme pos-
ition (STOP), instoll the switch box in the
s t e e r i n gl o c k , t i g h t e nt h e c o p s c r e w so n d s e c u r e
them with o dob of point.
13.17 SWITCHESOF LAMPS AND WARNING
SYSTEMS,DIRECTIONINDICATOR
TICKER,RECEPTACLE
For the wiring of these electricol devices
refer to Chopter 13.1 - Electricol Equipment
C o n n e c t i o n s o n d W i r i n g D i o g r o m- o n d f o r
their operotionto Chopter 1.3.
A l l t h e d e v i c e so r e e x p e n d o b l eo n d t h e y h o v e
t o b e r e p l o c e dw i t h n e w u n i t s i f d e f e c t i v e .
All the switches ore of the contoct type,
s p e c i o lt y p e s o n d e x c e p t i o n o lc o n n e c t i o n so r e
m e n t i o n e di n t h e f o l l o w i n g t e x t .
o) Switch of porking lights ond heodlights
(feeder of chonge-over switch of these
lights)
The switclr is fostened to the instrument
ponel by o nut with o wosherunderthe push
b u t t o n .W h e n i n s t o l l i n gt h e s w i t c h , t u r n i t s o
t h o t i t e n g o g e si n t h e l o c k i n g s l o t s . T h e p u s h
b u t t o n c o n b e r e m o v e db y p u l l i n g i t o f f o n d
r e f i t t e d b v p r e s s i n gi t d o w n .
b) Heoter switch
T h i s i s f o s t e n e d i n t h e s o m e m o n n e ro s t h e
s w i t c h s u b o ) . A c c e s st o t h e s w i t c h b o d y c o n
b e g o i n e d b y r e m o v i n gt h e c e n t r e p o n e l o f t h e
194
13 . 16 - t 3 . 17
focio ofter removing two copscrews ol-l the
ponel bottom. lt moy be olso necessoryto pull
off the heoter control push buttons.
c) Switch of disobility worning lights
-l
F o r f o s t e n i n g s e e i n f o r m o t i o ns u b b ) . h e
switch operotes only when connected to the
d i r e c t i o ni n d i c o t o rt i c k e r .
d) Dipswitch, direction indicotor, horn, wind-
screen wiper, ond winscreen wosher switch
This switch is instolled on the steering
c o l u m n s h o f t o n d fostened to the reduction
s l e e v e o f t h e t u b e w i t h s h o f t b e o r i n g so n d t o
t h e t o p p o r t o f t h e steeringwheel shoft shroud.
Removol:
Remove the steering wheel ond the bottom
port of the shroud - see Chopter 7.8. The switch
con be releosed from the shoft ofter loosening
the screw in the driver ond the removol of the
driver ( if the switch is equipped with such
driver), ond the loosening of the screw in the
yoke on the switch bottom right-hond side.
Loosen or remove the fostening screws of the
shroud ond lift owoy the top port of the shroud-
lf you intend to remove olso the steering
geor, do not loosen the screw on the switch
bottom right-hond side but the screw on the
left-hond side, ond lift owoy the switch
t o g e t h e r w i t h t h e r e d u c i t - t gs l e e v e o n t h e s t e e r -
ing wheel shoft tube.
Refitting ond Adiustment
Reverse the described procedure when re-
fitting the switch. lf the cor is equipped with
outomotic direction indicotor concelling
:"
F i g . 1 3 . 1 7 1 1A- d i u s t i n g E l e m e n t s o f D i r e c t i o r r
Device
l n d i c o t o rS e l f - c o n c e l l i n g
1 - Centering pin of the left-hond switch or
mork on the switch foce, 2 - Boss on the bush
foce,3 - Driver
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 13.18 FOG LAMPS AND OTHER OPTIONAL
EQUIPMENT
Fog lomps
The fog lomps ore optionol equipment.When
f itting them on the cor, refer to the wiring dio-
g r o m w h i l e o b s e r v i n gn o t i o n o l r e g u l o t i o n s( i n -
ternotionol regulotions hove not yet been uni-
fied os for os individuol requirementsore con-
cerned) ond the following informotion. In
Czechoslovokio,the Decree No.100/1975of the
Book of Stotutes, porogroph 51, is opplicoble.
Switching reloy
U s e o s w i t c h i n gr e l o y o f t h e s o m e d e s i g n o s
f o r t h e o u x i l i o r yh e o d l o m p s( o n c o r s w i t h t w i n
heodlomps) or onother reloy operoting in the
some woy. Any ploce con be chosen for its in-
corporotion into the circuit.
Cobles
For worning lomps ond the reloyswitching
circuit use cobles with o section of 0.75 mm2,
for the remoining electricol equipment 1.5 mm2
section cobles.

R,ELAYSWITCHING OF HEADLAMPS
Optionol equipment moy include on incorpor-
c r t e dr e l o y f o r s w i t c h i n g i n t h e h e o d l o m p s .I n
;;---A.i' some countries (for exomple Sweden), this
reloy is required by regulotions. For the re-
s p e c t i v ec o n n e c t i o n ss e e t h e f o l l o w i n g w i r i n g
t..[9-+'--'o diogrom.

A
5-l l

Y r369 1L7 1L7a DK 1582

F i g . 1 3 . 1 81i - W i r i n g D i o g r o mo f F o g L o n t p s
Fig. 13.1812 - Wiring Diogrom of Heodlomps
1 - S w i t c h , 2 - F o g l o m p s ,3 - W o r n i n g l o m p , U s i n g S w i t c h i n g R e l o y- o d d i t i o n o l i n c o r p o r -
4 - Switching reloy (A - reloy closing circuit, o t i o n i n t o t h e b o s i c e l e c t r i c o le q u i p m e n t
B - f o g l o m p sf e e d i n gc i r c u i t ) , 5 - F u s e N o . 1 o f (Fi9. 13.1/1)
cor electricol equipment,6 - Fuse No. 4 of cor
electricol equipment, 7 - Fuse No. 7 of cor 147 - Reloy of moin heodlomps
electricol equipment, 8 - Fog toil light, I - 1 4 7 o - R e l o y o f o u x i l i o r yh e o d l o m p s
Switch of fog toil light, 10 - Wcrning lomp

I
Switches
I
I
I n s t o l lt h e m o n t h e o u x i l i o r yp o n e l ( s t o n d o r d Heated Rear Window (1979 on)
l';
port of the cor) under the focio. Use the switch
w i t h t h e b u i l t - i nw o r n i n g l o m p f o r t h e t o i l l i g h t . Circuit

Worning lomps Divide into two sections.

1. Heaterswitch with five positionsfrom left
Use the unconnectedgreen wo,rninglomp in to right.a) Heatedscreen b) off c) High speed
the instrumentponel for fog lomps;the worning fan d) Slow speed fan e) Slow speed and
l o m p o p p e r t o i n i n gt o t h e t o i l l i g h t i s b u i l t - i n heated screen.
in the switch. 2. Power supply.

196
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A\ntu USIV]H
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1t . 1- 1 4 . 3
surfoces ore sproyed with o Protective com'
p o u n d .T h e f l o o r b o o r d s i n c l u d i n gt h e f l o o r o f
the boot ore coveredwith textile corpets while
r u b b e rm o t s o r e u s e d i n S k o d o 1 0 5 S . T h e i n -
t e r i o r l u g g o g ec o m p o r t m e n ti s l i n e d w i t h i n s u -
lotingfelt sheet.
f n e b o d y f i n i s h c o n s i s t so f s e v e r o ll o y e r so f
speciol onti-corrosivecootings, o primer coot,
ond o synthetic boking enomel top coot in
c o l o u r sc o m p l y i n gw i t h o s p e c i o ls p e c i f i c o t i o n .
14.1 BUMPERS
To Remove Front BumPer
D i s c o n n e c tt h e l e o d s o f t h e h o r n o n d f r o n t
direction indicotors. Remove bolts connecting
t h e s i d e s e c t i o n so f t h e b u m p e rw i t h t h e w i n g s
ond bolts of the bumper brockets,connecting
them to the wheel splosh guords.Now the
e n t i r e b u m p e ri s f r e e o n d i t c o n b e r e m o v e d .
Te Remove Reor BumPer
Proceedin the some woy with the exception
t h o t t h e r e o r e n o l e o d st o b e d i s c o n n e c t e d .
To Remove Overriders
Screw off the nut M 10 ond lift owoy the
overrider.
14.2 WTNGS
To Remove Front Wing
First remove the front bumper (see Chop-
t e r 1 4 . 1 ) ,t h e f r o n t d o o r ( s e eC h o p t e r1 4 . 5 ) ,o n d ,
i n t h e c o s e o f t h e l e f t - h o n dw i n g , t h e b o o t l i d
Fig. 14.211R - e m o v i n gF r o n t W i n g - o r r o w s
i n d i c o t ef o s t e n i n gp o i n t s
202
(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
t h e b o d y w o r ku n d e rt h e s i l l ( f r o m u n d e r n e o t h ) ,
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 Portof the wing
i s d o m o g e d ,r e p l o c e i t w i t h o n e w o n e , o n d
stick it on if it hos got unstuck. Pock olwoys
o new seoling strip between the wing edge ond
t h e b o d y f r o m e w o r k .T h e n i n s t o l l t h e w i n g i n
p o s i t i o no n d l o c o t e i t b y t i g h t e n i n gs l i g h t l y t h e
c o n n e c t i n g( f o s t e n i n g ) b o l t s . D o n o t t i g h t e n
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
t h e c o m p l e t el i d .
Removing Engine Bonnet
Slip the bonnet strut out of its guide, screw
o f f t h e n u t s o f t h e h i n g e f o s t e n i n gb o l t s , o n d
lift owoy the bonnet.
Reinstollotion ond Adiustment of Boot Lid
ond Engine Bonnet
Instollthe lid (or bonnet) over the luggoge
( o r e n g i n e ) c o m p o r t m e n to n d t i g h t e n l i g h t l y
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-
Assemblethe strut of the boot lid.
Boot Lid Releose Rod ond Engine Bonnet
ReleoseCoble
The releose rod of the boot lid (Fig. 1.3113)
is connected with the reloy link by meons of
o p i n o n d f o r m s o n o s s e m b l yu n i t w i t h t h e l i d c
locks. The hondle of the releose rod con be o
removed ofter pushing out the pin. The entire o
ossemblycon be lifted owoy ofter removingthe o
lid locks. ir
Reverse this procedure to reinstoll the os' e
s e m b l y .T i g h t e n t h e b o l t s o f t h e l o c k s l i g h t l y tt
ond fit the lid properly in positlon. Now odiust d
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 l o c k a r e w o r k i n g a n d e n s u r i n gd o o r i s n o t
being stressed by excessivetension up or
down, in or out.
A d j u s tt h e d o o r c a t c ht o e n s u r ew h e n t h e d o o r
i s c l o s e d ,i t w i l l n o t r i d e u p o r d o w n '
E n s u r et h e d o o r d o e s n o t c a t c ht h e d o o r p i l l a r ,
w i n g , o t h e r d o o r e t c . ,w h e n b o t h a r e o p e n o r
closed.
Door top half
lf you-havecorrectlyadjustedthe bottom half
of thb dooryou mayfind that the window frame
t o p h a l f s t i l l n e e d sa n a d j u s t m e n t .
Here it will be necessaryto lower the moving
w i n d o w a n d c a r e f u l l yb e n d t h e f r a m e o f t h e
window to match the frame of the door'
F i g . M 5 1 1 - P r i s i n go f f D o o r P o n e l

W h e n i t i s r o i n i n g o r w h e n w o s h i n gt h e c o r ,
woter runs down the gloss ond penetrotes
i n t o t h e i n n e r s p o c e o f t h e d o o r .T h e f o i l i s
supposedto prevent the forming of under-
pressurein the cor interior ond to prevent
the woter from sookingthe interior trims ond
r u n n i n gd o w n i n t o t h e c o r . T h e r e f o r ei,t h o s
to be stuck on by rubber cement os shown
i n F i g s .1 4 . 5 1 2o n d 1 4 . 5 / 3( c r o s s h o t c h i n g ) .
First slip the lower port of the insulotion
( f o i l ) , t h e i n n e r e n d , i n s i d et h e d o o r ,o n d
t h e n o p p l y o s e o l i n g c o m p o u n do n t o t h e
d o o r i n n e r m e t o l - s h e ep t onel ond the insu-
l o t i o n o s i n d i c o t e di n t h e i l l u s t r o t i o n( b l o c k
dots) .
C l o s eb o t h d o o r s o n t h e s i d e t o b e a d j u s t e d
a n d v i s u a l l ya s s e s sw h i c h a r e a so f e a c h d o o r Fig. 14.4/14
r e q u i r e r e - p o s i t i o n i n gt o p r o d u c e a n e v e n
c o n t o u rj o i n i n g t h e f r o n t a n d r e a rw i n g b o d y Common Areas the Door Touches
l i n e s i n r e l a t i o nt o t h e d o o r h e i g h t s .
With carefuladjustmentof hinges,satisfactory
body linescan be obtained.
H i n g e sc a n b e m o v e do n t h e d o o rp i l l a ri n t h e
following ways.
1 . U p a n d d o w n a f t e rs l a c k e n i n gb o l t s .R e s u l t :
height of door in relationto door ap_erture.
2 . I n a n d o u t a f t e r s l a c k e n i n gb o l t s . R e s u l t :
Position of the door leading edge in
relationto bodY aPerture'
3 . S h i m s P t . N o . 11 3 - 9 8 B 9 O O b e t w e e n
h i n g e sa n d p i l l a r
a ) S h i m su n d e rb o t h h r n g e sm o v e st h e d o o r
rearwardsand increases the gap between
the door leading edge and the wing
( F r o n td o o r ) .
b ) S h i m su n d e rt h e b o t t o m h i n g eo n l y ,w i l l
lift the lower edge of the door.
c) Shims underthe top hinge only, will
have the reverseeffect.
I t i s s o m e t i m e sp r e f e r a b l teo r e m o v et h e d o o r Fig. 14.512- Front Door lnsulotion- ":t;
catch(On pillar)to removemisleadingstresses h o t c h i n g i n d i c o t e sw h e r e r u b b e rc e m e n th o s t o
b e i n g p l a c e do n t h e d o o r .T h i s p a r t b e i n g r e - b e o p p l i e d ,b l o c k d o t s i n d i c o t e s e o l i n g c o m '
fitted and adjustedso that both stagesof the poundopplicotion

204
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eql q]!M laqleDol elPuDqaql Molaq MeJcsJeqlo
sql umop MeJcS '/neJcs aq1 ua1q61] lou oc
 Door Cotch Retoiner rubber moulding using o suitoble tool. Now
press corefully ogoinst the gloss from inside
The position of the door cotch retoiner on the cor ond slip the liP of the glozingrubber
the door pillor ond/or the reor wing foce con moulding step by step over the edge of the
be odiusted within certoin limits ofter loosen- windscreenor window frome olong its entire
ing its fostening screws. Adiust the retoiner circumference,ond finolly lift owoy the gloss
in the requiredposition,check the door for cor- together with the glozing rubber moulding.
rect closing ond fitting with the other ports of
the bodywork, ond then retighten the screws. To Refit Windscreen ond Reor Window
The door cotch must slide on to the leodlng
surfoceof the retoiner so thot it rests ogoinst F i r s t c l e o n t h o r o u g h l yt h e e d g e s o f t h e g l o s s
it. ond of the window opening (frome). Slip the
Sometimes, it moy be necessory to ploce g l o z i n g r u b b e r m o u l d i n go v e r t h e e d g e s o f t h e
o pocking piece under the retoiner (to prevent gloss.
the fouling of the door cotch pin). ln such lnsert o twine with o smooth surfoceor, pre'
o cose, mork the position of the cotch on the ferobly,o rubber insulotedcoble of 2.5 to 3 mm
bodywork, slocken the screws, ond instoll o in diometer into the inner groove of the glozing
pocking piece under the retoiner slipping it r u b b e rm o u l d i n g .
over the lower screws ond tipping it into po-
sition on the upper screws.
It is importont to observe the correct ongle
of the inclinotion of the retoiner leoding sur-
foce, which hos to correspondwith the incli.
notion of the beoring surfoceof the door cotch
(outer door lock). Therefore,fosten the bose
plote of the retoinerso thot its upright stiffener
is porollel with the edge of the mouldedrecess
for the retoiner on the door pillor ond the reor
wing.
The leoding surfoceof the retoineris provided
with o friction plote. In the cose of domoge
(excessiveweor, impoct of on incorrectly od-
iusted door, etc.), prise off the originol friction
plote ond fit o new one. lf the frictionplote is
l o c k i n go r i f i t i s e x c e s s i v e l yw o r n , t h e d o o r i s
opt to rottle.

F i g . M . 6 l 1 - F i t t i n g G l o z i n gR u b b e rM o u l d i n g
on o GlossPone

- Door Cotch Retoiner

Fi1.14.514

14.6 WINDSCREEN,REAR WINDOW,

S I D EW I N D O W S
To Remove Windscreen ond Reor Window
Rernovethe connection of the spocing Insert Fig.14.612 - Insertingo Twine into the Groove
o n d l i f t o w o y t h e s p o c i n gi n s e r t o f t h e g l o z i n g o f t h e G l o z i n g R u b b e rM o u l d i n g
206
 LOe
(lsod erluec 1o lrod .reddnu! Mercs prlql) a c ! ^ a c l u ! - > l c D dL 9 L - 8 d 1 ^]l o p r v e L l l
lsod elluac r l l l n l r+ r a s u l 6 u l c o d g 6 u 1 1 . r a s u- ; g i t l t L ' 6 l J
e q l l o s l n u p u D s M a : c s 6 u r 1 s n l p o 7 6 u ! u e l s-otJ
p o . r1 1 n de l p u o q r o u t r l- Z
( p o : 1 1 n d )l u r l l o r l u o c q c l D l r e u u l - I ,
s M e r c s 6 u r l s n l p y T 6 u l u e l s opJu D
e 6 o 1 u 1 1l o r l u o C r o o C l] u o l l - g / g ' t L ' 6 l l
dun4 ;91-g 66;
t i L r 1 s 1( f"s1! u r D nl t O , o u o 1 l o c 1 1 d d- yV l g ' V L ' b l J
s l n u u M o p - p 1 o qs 1 1 6 u r
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eqf 'aurDJl Joop eqt q6no.rql leuuDqc 6u11.rod
-dns s11 qllrvr ssol6 eql MDrpqll4,q 'lsod orluao
e q l o n o t u e J p u D l n o 6 u r r v r su a q l p u D ' l s o d s . r l u a c
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'o6
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6urzo16 aql olu! lresur 6ulcods eql ]rasul
'dund
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a L l ] r e ^ o d e l s A q d a l s 6 u l p 1 n o u rr e q q n r a L 1 1 1o dtg
a q 1 d 1 1 sp u o J o c a q ] o l u t l e e ' a P t s l n o t u o l ; i p o q
a q l l o 6 u g u e d o e n g l c e d s a . er L l l o l u o 6 u 1 p ; n o u rsr y0
r e q q n r 6 u 1 z o 1 6a q l q l l r * s s o 1 6e q l s s e r d r u o 1 1
 Reversethe dismontling procedure to rein'
stoll tl-rewindow ond its winder. The loterol
ploy con be odiustedby odiusting (swinging
out) the centre post ofter hoving loosened
'14.6/6
the
respectivebolts ond nuts - see Fig. ond/
or 14.617.
Use this occosion to lubricote inner door
mechonisms- see Chopter 15.12.

Fig.14.617 - Reor Door Control Linkoge

ond Fostening/AdiustingScrews L
5 4 1 7- S
- l !

1- Innerlotch control link (short) 3 . W h e n b o l t i n gt o g e t h e rt h e r e g u l a t o rd r i v i n g

2- Reloy lever
3- lnnerlotch controllink (long)
4- I n n e r h o n d l ep u l l r o d
5- Fostening/odiustingscrews ond nuts of the
centre post
(third screw in upper port of centre post)
Repair of Window Regulator Defects
l f t h e w i n d o w s a r e d i f f i c u l tt o w i n d u p a n d
down (the maximum torque applied on the
s p i n d l e o f t h e w i n d o w r e g u l a t o rw i t h t h e g l a s s
i n s t a l l e di n t h e d o o r s e x c e e d s2 . 5 N m ) ( 1 . 7 7 t t
l b s ) ,i t i s r e c o m m e n d e dt h a t t h e f o l l o w i n gs t e p s
aretaken as regardsboth the front and reardoors:
1 . D i s c o n n e c t h e r e g u l a t o rd r i v i n gp l a t ef r o m
t h e w i n d o w g l a s sc h a n n e l .P u s ht h e g l a s su p w a r d
and try the relieved regulator by turning the
regulatorcrank. lf the regulatordoes not work
s m o o t h l y( j a m m i n g ,r a t t l i n g )o r i f a t o r q u eh i g h e r
t h a n O . 7 N m / ( O . 4 9 5f t l b s ) i n f r o n t a n d 1 . 1
Nm/(0.78 ft lbs) in the rear is required for its
operation,replacethe whole regulatorwith a new
one working satisfactorily.
2 . A d j u s tt h e c e n t r ep i l l a rp o s i t i o ni n t h e d o o r
u s i n g t h e j i g a s p e r d r a w i n gN o . A 1 - 15 4 1 7 - S .
Loosen the top screw of the centre pillar and
retighten it while pressing the centre pillar
a g a i n s t h e w i n d o w g l a s sw o u n d u p t o i t s u p p e r -
most position. Loosen the bottom screw of the
c e n t r ep i l l a r a n d r e t i g h t e ni t w h i l e p r e s s i n gt h e
c e n t r ep i l l a ra g a i n s tt h e w i n d o w g l a s s .
p l a t ew i t h t h e w i n d o w g l a s sc h a n n e lm a k e s u r e
t h a t t h e h o l e s i n t h e s e t w o p a r t sc o i n c i d ea l o n g
t h e w h o l e l e n g t h o f t h e c h a n n e l .l f i t i s n o t s o ,
move the channel into a satisfactoryposition.
4. lf the regulatoris not lubricated,lubricatethe
r e g u l a t o rc a b l e i n t h e t u b i n g w i t h g r e a s e a n d
a p p l y o i l t o t h e r e g u l a t o rc r a n k s p i n d l e .
To Removeond Reinstoll Reor Door Fixed
Window
Agoin remove first the door trimming. The
gloss is only inserted into the door frome ond
supportedby o bolted-down holder with o rub-
ber pocking piece. The gloss con be moved in
the door covity ond withdrown through the
door frome.
14.7 TRIMMING UPHOLSTERY
AND WEATHERSTRIPS
Ponel-typeTrimming
This type of trimming is used for the doors -
see Chopter 14.5,Fig.14.511-ond for the front
ond reor window posts. Ponel-type trimming
f o s t e n e db y c l i p s ( f l e x i b l es p o c i n gp i n s ) c o v e r s
olso the porcel troy below the reor window, the
outer guideroils of the front seots, the front
wheel orches, ond the focia. On centre posts,
the trimming is fostened by screws.

208
 602
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sepls Jlaql sse:dtuoc's6ugplnou sseq_lualsDl lauod pauollusut aql lo uolldacxa aqr qrlrv\
oI 'ernlcnJls loels lDuralu! uD qtlM s6ulplnou
golcadsAq u1 plaq sloes adAl-asoqlolceds ql!r* 6u;tuur;r1 uo-penlg
6',il-l'tl
 the ploces from which you hove removed the
sticking dirt ogoin, ond wipe the entire body-
work diy, including chromium'plotedports,with
chomois leother. Wosh ond wlpe dry the vor'
nished surfoces with uniform strokes in one
direction, i. e. not by circulor movements.
After hoving wiped oll vornishedports of the
b o d y w o r kd r y , p o l i s ht h e m w i t h o s o f t ( f l o n n e l )
d u s t e r .D o n o t u s e p o l i s h o f o n y k i n d .
lf the bodywork is so dirty thot it connot be
woshed cleon with woter, use cor shompoo.
lf it is necessoryto refreshenthe gloss of the
finish, use o cor polish occordingto instructions
of its monufocturer.
To wosh the underbody, use o hose ond
running woter, worm or cold; never use petrol,
kerosene,diesel oil, etc.
Remove greose spots with o cloth, dry or
sooked in petrol if necessory. To removetor, dip
the cloth in keroseneor o speciol tor removing
preporotion,ond rub the spots.Then immediotely
wosh owoy oll troces of kerosene or the tor
r e m o v i n gs o l u t i o n ,o n d r e p o l i s ht h e s p o t s w i t h
o cor polish.
TOUCHING.UPVARNISH
Preporotion:
Removol of Polishes etc.
I
When touching up o repoiredbodywork (dom-
x oged surfoce finish), it is importont to olso
li
I cleon the surroundingvornish to prevent the
I.t t o u c h i n g - u pp o i n t f r o m f l o k i n g o f f l o t e r o n i n
ploces of overlopping.
R e m o v ec o r p o l i s h e sw i t h o s h o m p o oS . ilicone
o i l , c o n t o i n e di n s o m e b r o n d s o f p o l i s h e so n d
preventing the odhesion of the touching-up
point, con be woshed owoy only with o speciol
preporotion. !n Czechoslovokio, this is for
e x o m p l eV E N E D I N .R u b w i t h t h i s p r e p o r o t i o n
olso vornished oreos which will be roughened
by grinding where the bore ploces poss into
ground ond cemented oreos.
Removol of Rust
R e m o v e r u s t m e c h o n i c o l l yb y g r i n d i n g o r
rubbing with emery poper ond woshing with
c derusting ogent (for exomple SK 2, which is
bosicolly o 300/s phosphoricocid).
Procedure:f irst cleon the rusty spot with
e m e r yp o p e r N o . 8 0 o n d 1 0 0 o r u s i n g o g r i n d e r .
Then rub the spot with o 150/6 solution of
phosphoricocid (SK 2 deruSter) heoted up to
4 0 o C .W h e n u s i n g o c o l d s o l u t i o n ,i t s c o n c e n -
trotion must be obout 300/e (undiluted SK 2
deruster).Work in rubbergloves.
After hoving removedthe rust, wosh the spot
twice. First with tepid or cold woter, soft or
210
softened by odding 2 to 2.501sof sodo, then
with o solution of chromium trioxide (1 gr. to
1 litre of soft woter) heoted up to 80oC (thls is
the so-colled possivoting rinse). Now let the
spot dry.
Degreosing
Degreose the spot to be touched up by rub-
bing it down with trichloroethyleneor technicol
petrol.
1. Touching-up with low-boking points -
the most perfect procedure
o) Cleon the touched-up spot, derust ond
degreoseit (see the previousporogrophson
preporotion)
b) Sproy over with priming point
c) Let the priming point dry ot 80oC to 110oC
for o period of 50 or 15 minutes (50 minutes
o t 8 5 o C ,1 5 m i n u t e so t 1 1 0 o C )
d) Coot over with synthetic cement or poly-
ester cement
e) Let the cement dry ot 85oC or 110oC for
o period of 50 or 15 minutes respectively;
when using polyester cement, the drying
period con be shortened- this cement dries
of normol temperoture
f ) Grind under woter with emery poper No.280
to320till the spot is perfectly flot ond even,
ond let it dry
g ) S p r o y w i t h t o p - c o o tv o r n i s h
h) Let it dry ot 80oC to 110oC for o period of
15 or 50 minutes respectively;ofter boking,
the vornishhos o high gloss ond it is not
necessoryto polish it
i) Use o polish to remove ony visible troces of
tronsition between the originol ond the new
vornish.
2. Touching-up with nitro-combinotion vornish
o) Cleon, grind, derust, ond degreosethe spot
to be touched up
b) Apply priming point with o brush or o
sproy-gun
c) Level up, if necessory, with on oil-bose
cement (once or twice)
d) Let it dry lor 24 hours ond then grind with
emery poper No.220
e) Sproy the entire touched-up oreo with
sproyingcement ond let it dry for 24 hours
f) Grind with emery poper No. 280 ond 320
under woter till the oreo is perfectly smooth
ond flot, ond let it dry
g) Sproy the touched-upspot with o vornish
prepored by mixing low-boking ,vornish
(Toolol ond touching-upvornish (300/e);use
exclusively o nitro-thinner for diluting the
vornish
 ttz
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 l4.ll-14.12

has two anchoring points. The seat belts have

anchoringbolts on the size 7/16-20 UNF-2A'
In front, the anchoringthreads are easily
accessible being provided on the door posts
(removeonly one of the pair of pins coveringthe
thread),on sills below the posts,and on the sides
o f t h e ' f l o o rt u n n e l b e h i n d t h e f r o n t s e a t s '
Anchoringpoints for rearseat belts are shown
in the illustation.For the seat belt of the person
s i t t i n g i n t h e m i d d l e ,t h e t h r e a d sa r e u n d e r t h e
seatcushionsand ratherremovedfrom eachother
(A3). For the seat belts of personsoccupyingthe
butsideplacesthe threadsare also under the
cushions,nearerto the centre (A2), in the body
s i d e s c l o s e t o t h e c u s i o n s( 8 2 ) , a n d i n w i n d o w
pillars(C2).These latterthreadscan be found by
touch in the point of intersectionof the plane F i g . M . 1 1 l 2- L o w e r A n c h o r i n gP o i n t s
p a s s i n ga b o u t 1 6 5 m m a b o v e t h e r e a r w i n d o w
parceltray and in parallelwith the door frame at a
distanceof about85 mm. To gain accessto them, 14-12 FACIA
it is necessaryto cut through the trimming.
We must stressthat for the fitting of points A2 l - h e f o c i o c c t l b e r e n t o v e do t t e r u n s c t - e w l l l g
and A3, the bolts should not protrudebeyondthe the nuts of its peripherob l o l t s o n d o f t e r l '13'15'
ifting
owoy the instrument ponel - see Chopter
It is olso necessory to remove the steering
wheel with the shroud of the steering wheel
shoft (see Chopters7.7 ond 7.8), ond the heoter
c o n t r o l p o n e l ( s e e C h o P t e r1 1 . 0 ) .
The bolts holding down the focio ore occess-
i b l e o f t e r r e m o v i n ! t h e i n s t r u m e n tp o n e l o n d
the heoter control ponel, ond ofter swinging.out
the glove box. To swing out the glove box,
o p e n i t s l i d o n d l o o s e nt l r e s c r e w so f i t s s t o p s '

- Upper Anchoring Point

Fig. 14.1111 F i g . 1 4 . 1 2 1-1F o c i o M o u n t i n gP o i n t s

captive not more than 1lz mm or there is every

l i k e l i h o o do f d a m a g i n gt h e f u e l t a n k .
The depth of the nut from the mountingface is 14.13 WATER LEAKS
15 mm.
To determine the source of a water leak
Child seat fixing proceed in a progressivemanner.
1 . D e t e r m i n ea r e a w a t e r f i n a l l y r e s t s '
Followthe seat belt manufacturers instructions 2. lf possiblefollow water trace to source'
as to the spacing of the belt straps. 3. lf hot, remove carpets and clutter'
The straps can be mounted to the rear parcel 4. Dry car inside and out'
s h e l fi f t h e m o u n t i n gh o l e sa r ed r i l l e d3 0 m m f r o m 5. Us'ea sprinkler ratherthan a hose jet'
t h e f r o n t e n g i n eb u l k h e a dT . h e s o u n dd e a d e n i n g 6. Start on the underside of the vehicle and
t r i m i n t h e e n g i n ec o m p a r t m e nw t ill needto be work up. Do not do any adjustments or
lowered to fit the spreadingplate and nut. sealing until after the first test.
Be careful when drilling the shelf, not to 7. When"you have finished adjustments and
scratchthe rear screen. s e a l i n gR E T E S T .

212
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 14.13,2 WATER LEAKS INTO THE 2. WINDSCREENS
P A S S E N G E RC O M P A R T M E N T W i n d s c r e e ns e a l i n gi s i n f a c t s e a l i n gt w o j o i n t s
a n d t h e y s h o u l d b e t r e a t e di n d r f f e r e nw t aysand
1 . I N G R E S SO F W A T E R F R O M T H E F R E S H as separatejoints.
AIR BOX
1 . G l a s st o G a s k e t
2. Gasketto body.

'^'i-T
/c^sKEr
{af
Fit expanding cable here

(b)

Fis. 14/13.5

a) Box drain tubes (One eitherside of car) Pt No. Fig. 14.13/8

11 3 - 7 9 0 9 7 0 i f p e r i s h e d r e p l a c e , s e a l i n g
r u b b e rt o m e t a l w i t h c l e a r m a s t i c .
b) Heater bleed tube/speedometer cable
grommets. lt is suggested that the original
g r o m m e t sa r e r e p l a c e dw i t h d o m e d g r o m m e t
PtNo.113-793801.
EXISTING
GROMMET U S EO F P T N O 1 1 3 - 7 9 3 8 0 1
Fig. 14.13/6
T h e d o r n e s h o u l d s t a n d u p i n t h e a i r b o xa n d
s h o u l db e p a r t i a l l yf i l l e d f r o m i n s i d ew i t h D u m
Dum.
T h e g r o m m e t s h o u l d b e s e a l e dt o t h e b o d y
u s i n gc l e a rm a s t i c .
d i J a c k s o c k e t .S e a lt h e t e r m i n a b l a s eu s i n gD u m
D u m .T h e b a s e s o c k e t ss h o u l db e s e a l e dw i t h
c l e a rm a s t i c .
d) Water entering through Centre of heater. The
cover plate over heater, motor fan if it is not
" : I
f u l l y b u t t e d a g a i n s tt h e s h u t t l e( i e . a g a p ) s e a l
II
with
I
i e) Bodyjoints insideairboxto innerwing. Ensure
s e a l a n tc o v e r sa l l j o i n t s u p t o t h e u n d e rs i d e o f
i t h e s c u t t l ep a n e l .
1 . T h e j o i n t b e t w e e nt h e s c r e e na n d t h e r u b b e r
i s s o m e t i m e sf a c t o r ys e a l e dw i t h a s e a l a n vt a r n i s h
w h i c h h a r d e n sa n d w h e n d i s t u r b e ds h a t t e r s a; n d
t h i s i n t u r na l l o w sp a s s a g e fso r w a t e r f r o mo u t s i d e
t o t h e i n t e r i o rA . p p l i c a t i o no f g l a s sm a s t i cs e a l e r
will drive out the water and seal the joint' lf,
however,this is not achievedit will be necessary
t o r e m o v et h e r u b b e ra n d c l e a nt h e s e a lf a c e sa n d
t h e g l a s s i n o r d e rt o e n s u r et h a t t h e j o i n t c a n b e
made.
T h e e x p a n d e ro f t h e 1 0 5 / 12 0 r a n g es h o u l d b e
fitted to the rubber after fitting the glass and
r u b b e rt o t h e b o d y u s i n g s p e c i a lt o o l M P 8 - 1 6 1 .
Carefullyfit the rubberto the glass,stretching it
e v e n l ya r o u n dt h e w h o l e g l a s sa n d n o t s t r e t c h e d
over the last side/cornerto be fitted.
After f itting the screen/rubber assembly,
e n s u r e t h a t t h e g l a s s i s c e n t r a l i s e di n t h e
aperture.
T h e e x p a n d e rc a n n o w b e f i t t e d u s i n g M P 8 -
1 6 1 e x p a n d e rf i t t i n g t o o l .
2 . T h e s e c o n dj o i n t i s b e t w e e nt h e r u b b e ra n d
the body.We must stressthat there are two areas
o f t h i s j o i n t , o n e ( a ) i s a w a t e r d r a i nc h a n n e la n d
the second (b) servestwo duties of holding the
glass in the apertureand stopping the ingressof
water into the passengercompartments.
T h e w a t e rd r a i nc h a n n e lm u s t n o t b e f i l l e dw i t h
a n y s e a l a n ta n d t h e d r a i nh o l e sa t t h e b a s eo f t h e
apertureshould be free of obstruction.
T h e w a t e rs e a l i n gp r o p e r t i e so f t h e j o i n t c a n b e
re-inforcedby the applicationof mastic sealant
into the joint (b) shown in the diagram.

Test for water leaks

Spray water onto and around screen being
t e s t e d ,l i n g e r i n ga l o n g t i m e i n a l l p o s i t i o n s ,t o
ascertain the point of entry. Determine it is
c o m i n g f r o m t h e g l a s s r u b b e rs e a l o r t h e r u b b e r
F i g .1 4 . 1 3 / 7 body seal then correct the leakage.

214
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oLuer'roop aql lceqo A;;n;eteco1fuessecaust 11
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'lelaur ssocxo e^oulal ot al4 e asn eql eltnbe.t / IV
' l e a sa q llou o d e 6 e s o s n e c t
l l r Ml r s a s e oa u o s u l
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;o sace;d >;le6;
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q O n o q r greu a ; q o r de q l s a l e t ^ a l l el a q s e m0 u l . t d s oql olut ssalOut Jalem ;o su6ts lol qcleM
a q l 6 u r n o u a u' p e q s e n b sa q o 1l e a se q l 6 u t s n e c ' o l c l q e ^ D u t A e . r d su o s - r a da u g
os lno puels ol spual leas eql ol lxau lloq ' e l c l q o n a p l s u l u o s . r e da u g
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Front Door Components Fig' 14.13/10

216
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r a 1 ; o r u a l s l s e s D e l e Jq c l n l c p u o u e l s A s e l D J q aql qllM JDc eql lo :aAnq aql ol Je^o papuDq
c l 1 n o : p l q e q l ' o s 1 . r o d. r e q q n r l l D ] o a 6 u o q 3
' s . r o a Ae o r q l o l o M l J a l l o l o o g J e q c n o ne c ! ^ r e s e q l u ! l l l o n p ; n 1 p u lP e ! ]
;o luolooc a6uoq3 - q c e d se r o ' s q o ! e c u D u a l u l o t ul D n P ! ^ ! P uel q t
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cf]lfnvul s3u+ll loll) Jo u38wnN
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puD sgor ecuDuelulDlNpepueuuoceu teqlo
. t L . 9 Lo r q D n o r q l
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luauecoldeJ lsDl eql uoJl sAorvrlopelunoc aql 6ugu.lacuoc suollonJlsu!ecuDueluloutJoJ
aq plnoqs (OOO'02ol 000'gL) serlaruoll;
s6nld 6u;1rod5 'L 'lvu3Nfe t'91
Notrvl tuolNl
z ' 9t - t ' 9 t
tificotion number, or in words. For exomple Czechoslovokoils
Mobiloil 30 is on oil in the SAE 30 viscosity PP 90 (SAE 90) geor oil; PP 80 (SAE 80)
closs, Mobiloil Speciol belongs to the SAE geor oil
10W/30 closs. We quote the viscosity closs
s y m b o lo f o i l s i d e n t i f i e di n t h i s w o y i n b r o c k e t s Foreign oils
f o l l o w i n gt h e o i l b r o n d ( t r o d e n o m e ) . Agip: F. 1 Rotro 140; 85/90; 75Wl8O
Oils designotedby o doubled viscosity closs BP: Geor Oil 140 EP; 90 EP; 80 EP
symbol ore the so-colledmultigrode oils. Their Costrol: Hypoy B 140; B 90; B 80
c o m p l i o n c ew i t h v i s c o s i t yc l o s s i f i c o t i o ni s e x - Mobil: MobilubeGX 140; GX 90; GX 80
pressedby the symbol before the froction line Shell: Spirox E. P. 140; E. P. 90; E. P. 80 W
progressivelyto the clossificotionexpressedby Other geor oils of foreign moke con be used
the symbolbehind the froction line. Thus,for if equivolent o the listedoils.
instonce,the SAE 10W/30oil hos the properties
of the sAE 10w, sAE 20w120, ond sAE 30
SPECIALOILS
closs.
Czechoslovokoils Distributor beorings (service inspection)
Motor oil M6 AD (SAE 30), M4AD (SAE 20W/ Czechoslovokmoke - ON 1 low'pour-pointoil
20), Mogul Super SAE 20W50, Mogul Speciol Foreign moke - for exomple, Shell Clovus 17
SAE 2OW/30 o n d s i m i l o ro i l s
Modit Oil SAE30 (M6 AD), Modit Oil SAE
2 O W l 2 O( M 4 A D ) , M o d i t O i l S p e c i o lS A E 1 0 W /
GREASES- use throughoutthe yeor
30, Modit Super SAE 10W/40
Foreignoils Woter pump
Agip: Agip F. 1 Motor Oil HD SAE 10W/20, Czechoslovokmoke - SP 4 sooP greose,NH 2
2OWl30, 4Ol5O;Agip F. 1 Super Motoroil or A4 motor greose
10w/40,20wl50
BP: Energol HD SAE 40, 30, 2OW (2OW|?O), Front wheel beorings, geor lever brocket
10W; Super Visco-Stotic 10Wi30, 10W/40, Czechoslovokmoke - SP 4 or NH 2 soop greose
20wt20
'10 King pins
Costrof: Costrol 40,30, 20Wl2O, W; Costrolite
(SAE 10W/30), XL (SAE 20W/50); GTX Czechoslovokmoke - A 00 motor greose
(SAE 10w/50)
Mobil: Mobiloil 40, 30, 2OWl2O,10W; Speciol Inner door mechonisms,locking mechonisms
(SAE 10W/30); Speciol 20W/50;Super (SAE Czechoslovokmoke - SP 2-3 soop greose*)
10w/so) Clutch releosebeoring
Shefl; X-10040, 30, 2OWl20,10W; Super (SAE
10w/so) Czechoslovokmoke - SP 4 or NH 2 soop
O t h e r o i l s o f f o r e i g nm o k ec o n b e u s e d i f e q u i - greose*)
v o l e n t t o t h e l i s t e d b r o n d s ,f o r e x o m p l e ,A v i o ,
E s s o ,H e n o ( O p t i m o l L D ) , I N A ( D e l t o T L X ) , Steering tinkoge boll ioints, cronkshoft beoring
N o f t o g o s( G o l o x G T X , O m n i o ) e t c . Greoses listed in the porogrophon greosesof
foreign moke
GEAR OILS - type E. P. (high-pressure) Greosesof foreign moke:
Agip: F.1 Greose30; BP: EnergreoseL2; Costrol:
I Viscosity j Ambient Costroleose l. M.; INA: Automost Speciol;
L u b r i c o t i n gn o i n t
I c l o s s ! t e mperoture M o b i l : M o b i l g r e o s eM P ; S h e l l : R e t i m o x A ,
o n d o t h e r g r e o s e se q u i v o l e n tt o t h e l i s t e d
sAE 140*) -r50to +15 oC ones.

Georbox/finol BRAKE FLUID

drive SAE 90 *35 to -15 oC
To SAE J 1703C Specificotion
SAE 80 * 5 to -30oC ln Czechoslovokio- SYNTOL HD 190 broke fluid
Abrood - SYNTOL HD 190,PentosinSuperFluid,
throughout M o b i l H y d r o u l i cB r o k e F l u i d , A T E B l o u , B P
teering box SAE 90 B r o k e F l u i d ,S T O PS P 1 9
the yeor
*) Not used in Czechoslovokio r) Greosesof foreign moke should be preferred.

220
 lzz
'(g'; .raldoqC oes enbrol 6u!uelq6!t sl!
eslo+ ol doc eql uMop MaJcsPuo esDeJoqllM
ll IcDd
'doc .to1ocl.tqnl
iellnDts eql llo /v\ercs .ro1) u1 li 6ulrvre.rcs uaqrrr6n1d aq1 6u1ua1q611
-.ranor(q pDolr{} eql dlJls o} ou In}aJDceB 'euo
s6ultDog dun4 rolDn1 lo uollDcllqnl r.lrouD qtlMl! eco;dal'e6o1oe;u! llnseJo1 i;e111
s! qc!qM e6outop;o su61sAuo srvroqs6n1du1o.tp
'PaDDruDP
ll d u n s ; g o a q l l o 6 u 1 . r6 u ; 1 o e se q l l l : e 1 o N
'ez!llqDls
'l! MoueJpuo pDeq lloq eq] rapun 6u1.r6u1;oes 'l!
Iceqcar puo la^al l!o oql
aql oslD eulrrDx3 '6u1.r 6u;1oas Meu D esn 'slorvrlloer{t
1a; IID o}u! se}Dr}euad11oeql_ll!r
'pe6otuop es!lvrraqlolo pelrols!p s! 1! 'uo!lcos
,l (a1nu1uD ,lorl lnoqo) stull lroqs o .ro1eu16ua
'rell!l
rDlncr!clo s! lMoq aql roPun 6u;.r6u11oes eql eql unu 'llo qserl qurlt eu!6ua aql ll!l
'uo!lDz!l!qDlssl! reuo
la^el llo eql Iceqcer l ! o a q l p u o 6 n p du g o l pd r u n sl l o e q l p e l l D l s u l e r
p u o e u 1 6 u aa q 1d o l s u a q l ' e 6 o 1 o a ;l o l 6 u ; 1 u n o u 6u;noq JaUV '(pa11anor1 sarleruol!l Jo Jeqrrnu
r e t l ! l l ! o e q l 6 u ! l c e q 3 e l ! q / v \u n : e u 1 6 u ae q l eql uo Dulpuedep) ouo /l^ou D qllM lueuele
' l l o q e q t u e l q 6 l t p u o a u 1 6 u aa q l u o J D l l o c Joll!l aql ecolda: rolpuD lmoq sl! uDelc PUD
lol
rill 6uglunotuaql uo lMoq palquassD eql acDld roll!l llo eql oslD a^ouleu 'lno /v\oll llo eql lel
, i l i
I 6u1.rds q11melogdlsnrqt eq] puo duns l!o oql uo.r16n1du!Dip eql e^oueu
prDMol spls s!ql qllM luausle eql u.rn1'(e1ou
e6uoq9 119
u61aro1to slueuele Jotlll euos lo osDc aql s!
qc!qlvr)e1o1deql u! lDas uouoq lDuotltppDuD
q l l M p s p ! ^ o . r ds 1l u e u a l a r e l l l l a q l l l : e t o N 6nta
' D u 1 u a 1 s or e; l l l l a l o g 6 u 1 1 1 1t J! O p u o > 1 c 1 1 s d l!tCO - L / 0 ' 9 1' 6 l J
I!o aq16u;rnp
roam a^lsDrqDo1 lcelqns s1 6u1.r6u;1oes,{rp V
' l l o q o q r 6 u r 1 1 o 1 s u 1ear.or l o q
l!o u! pDeq 1oq
eql ropun 6ug.r6ulgoeseq1 d;p o1 1a6ro;lou oC
'luaulple retl!l Mou aq] puD prDMlno6ugco;e1old
lsnJgl-eql q11r*6u1.rds aql l! uo peddd;gs6u1noq
rauD ' lloq
eLll llDlsuler puD lMoq eql uDelc
'lmoq oql ulorl 6ugrdssl! tlllM .req1e6o1
uMDlpqllM eq uDc l! puD pesDelels! lueuele
roll!, eql 'pe^ouer lloq aql qllnn 'l/v\oq eqr
Ioano ryrg puD lloq e:luec eq] a^oueg 'eu16
-ua e q l l o a p l s p u o q - 1 q 6 1orq l u o l M o q l D c l r p
- u g 1 AD c u l p a l l D l s u !s ! l u e u o l a r e l l ! + l ! o a q l
lueualS jall!J l!o lo lD/t^euau
'lro eql e1
1o i(1tp1ng c u o q u ao 1 d n
l! rrlJoMo] aui!] Uoqs D rol unJ eu16uaoql ]al
'au16ueploc D urorl po aq] 6u1u1orperole€l
'punolD
'le^al
l o ^ a l u o p e c o l do q p l n o q sl D c a q l llo aql
6 n 1 6u 1 o . 1 61 0 - Z / C ' S L' 6 1 3 6 u r l c e q c u e q 6 ' s l l D M a u g 6 u eo q l u o r l u M o p
M o l +o ] a u l l l ! o o q l e ^ t g r' 6 u t l l l l J a U DJ o u n r D
te1lo Alalogpauu! le^el t!o eql lceqc lou oC
'asl'vtlcolclluD
11 6u11o1o.r Aq 6n1d eql pa^oure: 6u1noqlal1o
ro^oc poeq lepu1;[c eq] ul aloq aql q6notql
'lq6leq ulnulxDtx puD unullu!tu
l!o oqt dn do1
s116u1>1.rotu seu!l eql ueomleq 1sn! eq Plnoqs
q c ! q M l e ^ e l l t o e q l l c s q c o 1 4 c ; 1 s d ; pe q l a s n
le^o't l!O 6u;1ceqg PuD ll9 dn'6u;ddo1
sfluossSccv sll cNv lNleN3 8'9t
leqsDM usorcspu!/v\eql olu! ISolcvle
rolDlporeql olu! ouolodg X3ClUl
' 6 ' a ' ( o 1 > 1 o ^ o l s o q c a zu C
!) SfZSSUJIINV
 p r e s s u r eo i r . W h e n d r i v i n g o f t e n o n d u s t y r o o d s ,
i h e c l e o n i n g i n t e r v o l ss h o u l d b e s h o r t e n e db y
holf.
F o r o i r c l e o n e r m o i n t e n o n c ei n t r o p i c o l r e '
gions refer to ChoPter 16.2.

Air Cleoner- winter oPerotion

Removethe rubber cop from the cover exten-

sion orm ond use it to stop the mouth of the
o r m . F i t o g u i d e e x t e n s i o ni n t o t h e c l e o r e dh o l e
in the ornr ond insert the corrugotedpoper hose
(includedin the cor equipment) into the ex-
iension ond the holderon the intoke ond ex-
houst monifold.
G i v e t h e h o s e t h e r e q u i r e ds h o p e b y b e n d i n g
i t s l o w l y o n d c o r e f u l l y .A b o v e o l l , p l o c e i t i n t o
t h e h o l c i e rs o t h o t t h e r e i s o s u f fi c i e n t d i s t o n c e
F i g . 1 5 . 3 / 3- O i l F i l t e r (wide enoughto insert o finger) between it
I - oil filter bowl witlr filter element c r n dt h e e x h o t - t sm t onifold.
centre-boll
.'t o i l p r e s s u r es w i t c l r Tightening of cYlinder heod bolts

T h e c y l i n d e rh e o d b o l t s s h o u l d b e t i g h t e n e d
i n t h e r u n n i n g - i np e r i o d b e f o r et h e g o s k e t g e t s
settled ond then ofter every replocementof the
gosket, i.e., ofter obout 1,000 kilometres' For
itre tightening procedure, s9e Chopter -2'16'
Check'ilg of vilve cleoronce ofter every tighten'
ing of tlie cylinder heod is o routine procedure
which must not be omitted.

Volve Cleoronce

s n d o d i u s t i n gv o l u e s ,
F o r c h e c k i n gp r o c e d u r e o
refer to ChoPter2.13.

Alternotor V'belt Tensioning

Loosenthe nuts of the bolts in the olternotor

F i q . 1 5 3 1 4- L u b r i c o t o ro f W o t e r P u m p B e o r i n g s
oll the greose into the beorings. Tighten the
cop thoioughly so thot it connot be worked
loose by vibrotion.
Air Cleoner - cleoning ond replocing of filter
element
f l o n g e( f o s t e n i n gi t t o t h e e n g i n e o n d t h e s t r u t )
ond'of itre bottJ holding down the strut on the
olternotor,ond swing oside (tip) the olternotor'
Adiust the belt so thot it gives woy 10-to
15 mm midwoy between the belt pulleys when
d e p r e s s e dl i g h t l y ( o t i f o - w e i g h t o f o b o u t
2 k g w e r e o p p l i e a l w i t h t h e f i n g e ro t t h i s p o i n t '
LoCkthe olternotor in this position by tighten-
i n g p r o p e r l Yo l l t h e n u t s .
B e l t d i m e n s i o n s9: x 9 . 5 x 1 , 0 O 0m m .

Unclosp the cover fostening clips and lift
owoy the lid. Depress the cross broce in the
it, ond
1ock6t,rotote it slightly to disengoge
withdrow the filter e l e m e n t . W i p e c l e on the
inside of the iocket, cleon the filter element or
reploce it with o new one, ond reclose the oir
c l e o n e r p r o c e e d i n g i n r e v e r s eo r d e r .
Shoke ond top the filtet element to rid it of
clirt porticles, oncl blow it off ond through with
To Cleon the Distributor
The contoct breoker points, the cover, ond
the rotor orm of the distributor must never be
greosy or dirty. Scrope off ony burns on the
distributor cover.
lf you hove cleoned the distributor with
oetrol, do not refit the cover till ofter the petrol
h o s c o m P l e t e l Ye v o P o r o t e d .

222
 ezz
'lloq Aellnd
lleq uoqs{uDr3 eql }o Poaq aq} ol slulod 6ug1oc1.rqn1
rolnqtrlsrC- llt'gL '6tJ
pe!lddDJeuuDdsD esn 'au!6ue eql 6u;urn1.ro1
'11oq6uldruopc
otll 6u1ua1q6g1 Iq uo;11sodslql u! rolnqlrl
:slp aql ajncss 'eu16ueeql ol elqDc oq] uorl
leno-1rodseql Aq pelllruapl s! ocuD^poles eLll
o1 6ulpuodsorroclolnqlrls!p aqt lo uotltsod aq1
'l1mo1s urnler puD as!rvrlcolclotnqllls!p aql
]!
alDlou 'Icolq aql qllm l;enllcnpuoc pelceuuoc
pod au16ueJaqlouo ro lcolq :epu11{ceq} uor}
uut g ol t to acuDlslPD ]D elqoc eql lo pue eql
plorl puo (11ocuo11;u6;tuo.r;pDel 't'g) re,roc
rolnqlrls!p oql 'o lno alqDc erluec eql llnd 't
'uo!l!u
-6! otll uo qcllMs puD lelcoiq sl! u! rolnqlrlslp
er{l 6u1p1oqlloq 6uldtuolc agt uesoo-l 'z
'ecuDApD par;nbal aql lo enlDnoql ol le^oc
roe6 6u;tu1laql uo >1.rou 6u1u1lsq] ol e1;soddo
los s! Ae11nd lleq UoqsluDrc aql uo )rDr! Dultull
eql loql os (11oqs1uo.rc) eu;6ua eqt urni '!
:sp!o tnorlllM ernpaco.rd6u;lsnlpy (o
'6ll
sllog uMop-ploHrolourollv - 9i0'SL
oZToS sl ozl puo 1 ozl vclo)$
oZTot 1 901 PUD S 901 VAO)S
(1loqs1uorcuo parnsoeu) senlon Eulues clsDg
ecuDApVuog11u61 clsDg ;o lueulsnlpy
'slcoluoc eql
lo Duluedoeql ]o lceLlc rDl
-n6uo :o1 g'g; .raldoqCeas 'rvra:csdocuMop-plotl
aq1 BuluesoolJelrD Japloq ]cDluoc aq1 6u1nor-u
Aq do6 oql lsnlpD puo 's1u1odralDarq lcDtuoc
aql ueeMleq do6 lcerloo eql ro' g'g1-.to1doq3
ol Jelou 'ruDc llot{s lo}nqlr}slp eq} }o }l!l lln}
eql o] eu16uaeql urnl pLrD'turD .ro1oleq1 'Iro
- s s e c a ul ! ' p u D i a ^ o s J o l n q l l l s l pe q l e ^ o u o u
dogr 1u;o6 ra{Dorg lcoluoC Du;lsnlPY
'(sttO g o l c e d g- Z ' 9 L . r a 1 d o qo
31 r e l e r )
6u;loeq 6u11oc;.rqn1-114s oql ol uo 11o 1u1od-
-rnod rvrog1o;cedso d1.rppuo 6ulsnoLllolnq!rl
-s!p aql to tuolloq eql uorl lloq aql e^otuer
'uollcedsug ec!^Jas o .to tlode.r o 6u1rvto1;o3 u o l l o l e d g J a l u l l " ^ .l o ] e s o H P U D
'(tuo11oqrolnqlrls!p eq] u! oloq orlt '6ll
sd;13 6uluetsDJ ra^oC rauDelCrlv - 9/0'91
q6no.rq1 tno ivrol,lllrvrl!o snld.rns)ap;d :e1oa:q
tcDtuoc eql ut eloq eql q6no.rqlpallddo l!o lo
sdo.rpengl ol rnol qllr* 6u!snoq rolnq!rls!p oql
u! loJluoc 6u1tu11;o6n;;lluac eq] elDc!rqn-l
'esoal6
LgZ tu!]D!C
qllm ro ('cte 'V xDulleu lleqS) alo141u61ero11o
sesoare - z'gL.re1doq3ees - esDor6qrtr* Petac
- l r q n l o q o s l D u o c ' u o c e q l ' 6 u o 1 o 6 u g p ; 1 sr 1 a 1
eq1 6u1pn1cug 's1u1odasoqf '1u!l
loJluoc ulnncon
aql lo u1d eq1 puo alpulds rolor aql (dorp
'Plotl
euo) 11oq11r*A16u;.tods loog lllM ]lal aql
so 'ruDcaq] aplsu! llsl aql Puo tuDc aq1 6uo1o
6u;p;1sllel er{l uo llo qcnu os dgtp puo 'r.u.ro
JoloJ eql PUD Je^oc Jolnqlllslp eq] a^oueu
rouqlrlslo oql elDclrqn'l ol

F i g . 1 5 . 3 / 8- D i s t r i b u t o rA d i u s t i n g E l e m e n t s
1 - c o n t o c t h o l d e r ,2 - r o t o r o r m , 3 - c o m ,
4 - distributor brocket,5 - distributor brocket
c l o m p i n gb o l t
A l w o y s t u r n t h e e n g i n e c l o c k w i s et o e l i m i n o t e
o n y p l o y i n t h e d i s t r i b u t o rd r i v e g e o r o n d t o
o v o i d l o o s e n i n go f t h e b o l t . T o r e l i e v et h e c o m -
p r e s s i o nr e s i s t o n c e i,t i s r e c o m m e n d e d to bock
o f f t h e s p o r k i n gp l u g s .
b) Stroboscopicmethod:
W h e n u s i n g t h i s m e t h o d ,t h e v o l u e s o f t h e
bosic ignition timing ond the odvonce con-
t r o l l e d b y t h e c e n t r i f u g o tl i m i n g c o n t r o l ( f o r i t s
diogrom refer to Chopter 13.5) should be odded
u p w h i l e m u l t i p l y i n gb y t w o t h e o d d e du p v o l u e s
o c c o r d i n gt o t h e d i o g r o m .A n y e f f e c t o f t h e
v o c u u mc o n t r o l m u s t b e e l i m i n o t e db y d i s c o r r -
n e c t i n g t h e r e s p e c t i v eh o s e ( c o n n e c t i n gt h e
d i s t r i b u t o rv o c u u m u n i t w i t h t h e c o r b u r e t t o r ) .
T h e m e o s u r i n gp r o c e d u r ei s i n d i c o t e d b y t h e
d i o g n o s t i ce q u i p m e n ti t s e l f .
To Adiust ldling Speed
Use the oir-correction screw (speed cor-
rection screw). The speed decreoseswhen ro-
t o t i n g t h e s c r e w c l o c k w i s eo n d i n c r e o s e sw h e n
rototing it onticlockwise.
A d i u s t t h e i d l i n g s p e e d i n o c c o r d o n c ew i t h
t h e t o c h o m e t e ro n d w i t h i n t h e l i m i t s s p e c i f i e d
in the following porogroph "To Adiust ldle
R u n " . T h e e n g i n e m u s t b e w o r m e d - u pb e f o r e
s t o r t i n g t h e o d j u s t i n gp r o c e d u r e( s e e o l s o t h e
f o l l o w i n g p o r o g r o p h s )o n d i t s i g n i t i o n m u s t b e
in perfect condition (distributor contoct-breoker
p o i n t s , s p o r k i n gp l u g e l e c t r o d e s o
, nd ignition
odvonce).
N o t e : F o r t h e b o s i c p o s i t i o no f t h e o d i u s t i n g
screw refer to Chopter 2.19- "Mointenonceond
Adiusting".
224
F i g . 1 5 . 3 / 9- A i r - c o r r e c t i o nS c r e w- i d l i n g s p e e d
correction screw
To Adiust ldle Run
Acljustthe contoct-breokerpoint gop,the gop
o f t h e s p o r k i n g p l u g e l e c t r o d e s ,o n d t h e i g -
n i t i o n o d v o n c eT. h e n c h e c k t h e v o l v e c l e o r o n c e
( i f t h e r e i s n o c l e o r o n c e ,o d i u s t t h e v o l v e s ) ,
c l e o n t h e o i r i n t o k e f i l t e r e l e m e n t ,o n d m o k e
s u r et h o t t h e o c c e l e r o t o p r edol link hos the re'
quired free trovel - see Chopter 12.2-
Use o needle to remove the plug covering
t h e f o s t - i d l i n gs c r e w o n d l e t t h e e n g i n e r u n o t
obout 2,000r. 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-
m e t e r ) o n d t h e o n o l y z e ro f c o r b o n . m o n o x i d e
( c o n t o i n e di n e x h o u s tf u m e s ) . U s e t h e o i r ' c o r -
iection screw (Fig. 15.3/9) to set the speed
-r-?n
at 800 l;; t. p. ni. cnd the fost-idling screw
( F i q . 1 5 . 3 / 1 0 )t o o d i u s t t h e c o n t e n t o f c o r b o n
moioxide to 2*0.50/sor the oir-fuel proportion-
b y - w e i g h tm i x i n g r o t i o , c o m p o r o b l ew i t h t h e
+$.t.
specified corbon monoxidecontent,to 1+.2
A f t e r a b o u t o n e m i n u t e o f t h e c o n t i n u e di d l e
r u n n i n gr e c h e c kt h e o d i u s t m e n to n d c o r r e c t i t ,
. l o s et h e h o l e w i t h t h e f o s t - i d l i n g
i f n e c e l s o r yC
s c r e wb y d r i v i n g i n o n e w p l u g w i t h i t s b o t t o m
outword.
of odiusting
N o t e : F o r t h e b o s i c p o s i t i o "nM
ointenonce
s c r e w s r e f e r t o C h o p t e r 2 . 1 9-
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 corburettorpull-rod
itself with obout one drop of oil. Then depress
 9ZZ
a q t l o l D e M o q l q l l / v \ A l l D n P D l Ds e s o s J c e Pt t l s l u D d L u n 61 1 1 1l o n J - L L l t ' g t ' 6 t J
- q c e u l n o m o r q ] e q l t o l o ; d A . r o s s a c e ue q l
luarulsn!PY
'llaM
l!o e^eols
'6u1
aql ul lle' eql uo ]carlp lro eql .rnod-to
-.roaq (1nomo:ql) esoalar qclnlc eql lo e^eels
osDeler eql ]o lle/v\ l!o eqt olu! uMoP Moll lilM
ilo eql qc!qM uoJl re^el esDslal qclnlc eql +o
ssecer eJluec eql olul po 1 o sdorp ZL ol OL Jnod
' , r a p u 1 l A ce s D o l a r L l o l n l c e q l
]o Ja^oc el!lolDq
a q l l o r * o U ! l p u D 6 u 1 . r d se q 1 l o m o 6 u 1 r * s u a q l
'sloes rDor eql pulqeq
l u a u l r o d u r o c a 6 o 6 6 n 1e q t
ur pJDoqJoolt eql ,o Ja^oc sJluec eq] a^oujeu
uollDc!rqnl
' uo
HCrnlC t'S! !l!
-sod pelcol sl! ul aulotl slcrl3 ]l lirl sprorvrdtt
r a ^ a l a q l 1 1 n du a q l ' . r a r r a61u t t u u d a q 1 6 u t l o n l c o
'6!l I q l e n l g l l r r r d u n d e q 1 e r , u 1 . r'dA r o s s e c a u ; ;
reurDrls rolleinqrDC - 0L/t'gl
'a>;ol aqt
+o tnu aql 6u1ualq6r1
{q uorllsod ut lMoq aq} arnoes 'lMoq eql otru!
zrsLyo l D a s e q l L l l l M ] l l l D l s L r e Jp u o 1 o . r 1 a du! uearos
e q l q s D M ' l D e s p u D u e e r c s a q l 6 u 1 p n 1 c u !l M o q
aql ADMD1l!l puD lMoq aql to Luolloq aql ]D
( p u o q l a n o c ) a > 1 o Aa q t l o 1 n u e q l ' r o { c D B
lmog a6pnlg dun4 lanl uDelC ol
'sseceJ anllcadsa.r
aqt olu! ig6nus s1l l! loql os Mercs 6n1d eq1
] o p l o a q ] q l l M l ! l l D l s u l e r p u D l o a s u o - p a d'dl ltol s
a q l q l l M M a r c s 6 n 1 d a q l u o 1 1a c u ; d u a q l
' t a u 1 o l 1 sa q 1 { o m o
ll Molq puo ;ol1edu! ll llrMS
'lalur
llll l a n l e L l l l D / v \ a r c s6 n 1 d a q r e ^ o u e u
,teulorls ,ollernqloc uoalc ol
u a a r c s q l l M l M o q a 6 p n p s- 7 ' 6 u g q n 1u e p M o q
. r a n a ;6 u 1 t u 1 . r d u n d - ; e q ] o l u ! r e q u n ' l r o a q l A r . r o c p o . r - ; 1 n da q 1 1 a 1
u l st u D q c o l A 01 soru!1 lDle^os ;opad lolo.relacsD aql AlMols
rotoreleocv ,o uorlDclrqnl - 6/t'gL '6!l
6n1dctlsold D ql!M Pasolc
'6!l
s l 1 l o l s s e c c o - r n r r a r c s6 u r 1 p ; - 1 s o 1- 0 l l t ' 9 1
f r i c t i o n f o c i n g . l n o d e q u o t ep l o y r e s u l t si r r o t o o 15.5 GEARBOX AND FINAL DRIVE UNIT
short free trovel of the clutch pedol ond on
o l m o s ti m m e d i o t ec l u t c hd i s e n g o g e m e nAt .c c e s s Checking Oil Level ond Topping'up Oil
t o t h e r e l e o s ec y l i n d e r c o n b e g o i n e d o s d e -
scribed in the previous porogroph on clutch Renrovethe centre cover ol the f loor boord in
lubricotion. Hold the rod protruding from the the luggogecomportmentbehind the reor seots.
r e l o s e c y l i n d e r o n d f o r c e f r o m i t c o r e f u l l yt h e Pull off the filler neckcop ond usethe dipstick
r e l e o s el e v e r , o g o i n s t w h i c h i t i s r e s t i n g i t h e t o c h e c kt h e o i l l e v e l .W i t h t h e d i P s t i c ki n s e r t e d
l e v e r c o n b e r e l i e v e d b y d i s e n g o g i n gt h e t e n - i n t o t h e n e c k u p t o i t s s e o l i n gr i n g , t h e o i l l e v e l
s i o n ( p u l l - o f)f s p r i n g s . should be obout 8 mm obove the upper line'
ln service, the forcing-off must be ot leost For this check, the cor should be ploced on
2 m m . A d i u s t i t t o 4 t o 5 m m b y o d i u s t i n gt h e level ground. After hoving topped up the oil,
length of the rod. After hoving loosenedthe nut w o i t o b o u t 2 m i n u t e s( w h i l e o i l f l o w s f r o m t h e
on the rod of the releose cylinder, rotote the g e o r b o xp r o p e ri n t o t h e f i n o l d r i v e o n d i t s l e v e l
releosefinger to obtoin the correct rod length. i s s t o b i l i z e d ) ,o n d t h e n r e c h e c ki t s l e v e l -
Then retighten the nut, thus locking the releose
f i n g e r i n i t s p o s i t i o no n t h e r o d .
lf the ploy is correctly odjusted, the f ree
trovel of the clutch pedol pod should ronge
from 40 to 50 mm. lt should not be ollowed to
'!0
drop below to 15 mm. lf the described od-
j u s t i n g p r o c e d u r ef o i l s t o b r i n g t h e r e q u i r e d
r e s u l t ,i t i s n e c e s s o r yt o o d j u s tt h e c l u t c h m e c h -
o n i s m i n o c c o r d o n c ew i t h i n f o r m o t i o n c o n
t o i n e di n C h o p t e r3 . 2 .

Bleeding the Glutch Hydroulic System

The movement of the clutch pedol is trons-

m i t t e d h y d r o u l i c o l l yt o t h e c l u t c h r e l e o s ec y l i n -
der. The couses ond symptoms of penetrotion
o f o i r i n t o t h e h y d r o u l i cs y s t e m ( s i m i l o r t o t h e
broke hydroulic system) ore describedin detoil
- T r o n s m i s s i oU
Fig.15.5/1 n n i t F i l l e rN e c k
i n t h e s e c t i o n d e o l i n g w i t h b r o k e s .T h e p r o -
c e d u r eo f b l e e d i n g t h e c l u t c h i s t h e s o m e o s
w h e r r b l e e d i n gt h e b r o k e s - s e e C h o p t e r 1 5 . 8 .

;rt'i,*
tiiffi
ii.! i;
br'ill
ffi

F i g . 1 5 . 4 1 1A
- d i u s t i n gE l e m e n t so f C l u t c h Fig. 15.512 - TronsmissionUnit Droin Plugs
Control Mechonism o n d I n s p e c t i o nP l u g
I - r e l e o s ec y l i n d e r r o d , 2 - r e l e o s ec y l i n d e r , 1 g e o r b o xd r o i n p l u g ,2 - f i n o l d r i v e d r o i n p l u g ,
-
3 - releose lever, 4 - bleed screw 3 - inspectionplug,4 - switch of reversinglcmps
(except SKoDA 105 S)

226
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'6lJ a l o g 6 u 1 1 1 1xJo g 6 u t : a e l g - L / g ' g L ' 6 ! J
u!d 6u!) rol sslddtN osDere - LILgL
e 1 9 ty o
'g'7 raldoqc oql u! peu!oluoc suo!]cnrlsu!
a q l l o e J D s 6 u r r D e qa q l e c u ! s u o ! l D s t r q n l o u
s r o s D e r 6l o u o l l D c ! l d d oe q l ; o a s o d : n de q 1 ql!ivr ecuoproccD ut es!rrtsl!l Aold Iuo eloultu!l:l
'(g'l lat
' e p r sr e q l ! e u o e 1 d d 1 au s o e : 6e u o s r e r a t r D : ) r : o l 1 g s o du ! l c o l p u D r u a q l l c e u u o J a r
l-
aql repun lrroJ]olq!ssoccDeJDselddruilsno.rt) d o q C a e s ) a s o a . r t ri l l ! M s l u t o ! 6 u 1 . r a a l so l o o ! J q n l
'J)oJ
IoDJI eql uor1 spo-r6ultaels lceuuocs!(l
su16 6u1; lo uollDcllqn'l
An14 a6o4u;1 6u;ree1g lo uollDultullf
'paltnbel se dn do1 '/l^oleq umoqs
'ecuDJoalc6u1:oaqeql
lo truaulsnlpo se pojnlcelnueuJ lclls dlp qrlinr,la^al llo lceqS
p u o a s o e r 6l o l u n o r u Dp a l l n b e ;e q l J o l ' L V p u o g Z ' 6 n 1 da q 1 l n o M e l o s l ( o q o u t l a e l s e q l
lo 6n;d nne:cs
o1 77 sqdolBorod'g'g reldoqc ol puD qnq leoqM a q l o l l s o c c e u t e b o l l e e u / v le l e d s e q ] a ^ o t u o u
eql lo lD^oruer rol t'g .raldoqc eqt ol Jeleu t ' l - -T--
'asoar6plo eql po^ouar
9t xog 6upealg ur
6u1noq rouo osoe.r6qsa.r1qlll s6ulrDeq eq]
1codey
'elxDeql urorl sqnq
leaqMaql enouau
+
J_
llO dn butddol
I
s6ulroeg leeq/v\ to uollDclrqn'l 9NrU33rS 9'9t
t-J
t
I e ! l
'gZ ol g7 sqdorDorod 'g'g .ra1doq3 ees
.MoJcs uollcadsul aq]
's6u1loeq p u D s 6 n 1 d u l o r p i o 6 u 1 u a 1 q 6 l l p u D 6 u 1 1 o e sa q 1
leeqrl'rtoeouoloelcaql 6u;lsnJpo.ro3
luals!xe- ro] 6n1dugorpdr.uns;go uo elou aql ol raleu
-uou I;locglcord aq plnoqs luaus^our eer] V l!
' I 1 e 1 o u r e 1d; on ' e l oIceqc
q aqt
1 r ; 1 n dp u o u M o p 1 gq s n dr o u M o p p u D e z ! l t q D l sl e ^ 3 1l r o e L l l 1 4 1u 1 o 6 y
puo dn leeqM eq1 6ulrvrspuD loc eql dn >1co1- d o t s I l a l o ! p e u u . r !p u D e l o q u o g l c a d s uel q t o l u !
i t t c a l u ! n o A 1 o q 1u ! M o l a q u o r l o s l D l l o q l l M
e c u D J D e l C6 u ; r o e g l a a q 1 pell!i oq uoc llun uolss!ulsuD.r1 .rervrod eq1
'pez!llqDls
'(suol1cnr1s
sor{ 1! JaIJD le^el lro eql )caqc
31XV INOUJ I'91 - u ! d n - 6 u g d d o pl u o 6 u ; 1 c a q o e ^ o q D a q l e e s )
ll!l
l c e u r e l l ! l a q l q 6 n o r q ll ! o q s e r l ' o s a r l ! l z u !'lno
'JAID/!|\put) puo s6n1dpeuDelclllca;led u! Mercs ueql
Moll l!o llo lol puo s6nldulorp eq] Marcsun
frlp Aq palralto AlasranpoerD slulol 6u1rae1g
'g'l puD g'2 sleldoqC oss - asoar6 e6uoqS 1;9
qsorl q]!M s6ug.roaq eq1 lcod puo l;a1o1pauru1
ueql Meuar 'pe6ouop a:o iaql ,l 'uo!l!puoc 'ajnPasolcl Du!)caqc
:o; sdnc 6ug;oasJeqqnl eq] eu!uJDxe'uosDes puo dn-do1 aql loeda:
'aloq eql
,o lno seuoc
ploc eql lo lesuoeql lD l1;orcedsa'i11ouo1soccg 'larennoq ';; 'lno Moll 11osnldlns 1a-1
'uo!lDc!rqnl i1o ou
'selnulu 'eloq
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'dn 6ulddol puD
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sluloft 6u;raa15 Jol pesn oslD aq uoc eloq uo;lcadsu; eq1
I EtJ St
I 5 . 7 *15 . 8
s e l l - l u b r i c o t i n gt y p e b u t t h e g r e o s e i s i n t e n d e d
t o r i d t h e b e o r i n g so f o n y m o i s t u r ew h i c h m o y
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
F o r m e o s u r i n go n d o d i u s t i n g t h e t o e - i n , s e e
Chopter 6.1.
Fliminqtionof King Pin PloY
Removethe 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, porogroph21. Lock
t h e n u t i n t h e f i r r o lp o s i t i o n w i t h t h e c o t t e r p i n
F i g . 1 5 . 7 1 2- K i n g P i n H o l d - d o w n
cnd Adjusting Ntit
Note:
irr the list of servicing (mointenonce) iobs,
I,he porogroph on "Checking Front ond Reor
Wlreel Brokes" includes
o ) i n s p e c t i o no f t h e b r o k e - s h o e l i n i n g o n d i t s
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
B r o k e F l u i d T o n l k- f i l l i n g
The brake fluid tonk is instolled in the boot
{ i n o i n l u g g c r g ec o m p o r t m e n t ) c n d c l o s e d w i t h
228
- Broke FluidTonk
Fig. 15.8/1
o screw cop. lt servesolso the r:lutclrlryrlrotrlic
control systenr.
Keep the brqke fluid level withirr tlre ronge
of the moximum filling, i. e., not lower thon
"MAX"
10 mm below the mork or so high thot
it j u s t covers the pcrtition woll of the tonk
which con be seen on looking inside the tonk.
O b s e r v e o b s o l u t e c l e o n l i n e s sw h e n f i l l i n g i n
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
T h e b r o k e f l u i d o b s o r b so t m o s p h e r i ch u m i d i t y
ond the chcnge of its propertiesis opt to offect
broking ond even bring obout corrosion of some
ports of the broke system.
T h e t i m e p e r i o d ,i n w h i c h t h e s e c h o n g e s c o n
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
y e o r s) .
Suck out the old fluid 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
"spongy" ond the
system,the pedol broke feels
broke efficiency decreoses. Ingress of o lorge
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erll ueyor.ls ol A.rossecausr 11 '6ugsoercep
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-eq eql 'salqDc elDrq aql 6u1qc1er1s
le^Drl ll lo ETDJB
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f u o s s e c e u s l 1 l ' e u l l e q l l l o p r n l l a > l o r qe q ] u !
p e 6 . r e r , u q nasq n l o q ] l o p u s a q l q l l M e ; q g s s o d s o
'dnc q 6 r q s o . r o l a q l p l o q o l a J o oa l o l ' . r o l s s o ; 6 e q l
lsnp eql puD repulllc
u1 paD.reuqnseqn] oql lo pue eqt uo.rl 6u1doc
l e e q M e q l u o u o g l l s o d s l l o l u l a u o q 6 u 1 . re q l -sa dols selqqnq rlo llll e:npecord stql loedag
acJol otr lene1 6ulpuodxa aq1 u1o6o asn puo 6u1.r 'uosrad JeqlouD jo acuols!ssD eql peeu
eq] ol uo t/8'91 '69 ut uMoqs 6tl aqr ilddy ll!M
'6ug: 6 u l u a l s D l e q l e r l u e c p u D n o l ' p a u e 1 q 6 1 1{ 1 1 n ; u a e q s o q M e r c s 6 u ; p e e l q
llDlsu! puD eql raUD A;uo pasoalereq plnoqs lopad aql sV
rp!nll e)DJq qllM 'uorlgsodu1 dnc
ll looc lsnp 'Mercs aqt uetq6psr puD 'lopad alorq aq1 A11n;
aq] Jo a6pa :aq1o eql pallll 6u;noq reUV 'ra^el
6 u r p u o d x a t e l - g d U 1 ;e q l 6 u l s n . r a p u 1 l i c l e e q M sserdep 'MeJcs eq] uesool MoN 'MeJcs 6ulpaepq
aql otrur uolsrd eql acrol puo uolsgd eql uo eql o1 pelcauuoc eqnl aql ]o Pua aql l! ul
dnc lsnp Meu eql llDlsul uaql 'spod e)Drq )srp o 6 r a u q n s p u D p ! n l l e l o J q a q l q l r m I 1 1 o t l . t o d' . t o l
s s o l 6 o A l q o r a ; a . r d' l e s s e ^ u D a l c D l l ! J ' u o t l c a u
luorl aq] uo 6u11cosuolsld ;o sdnc lsnp pa6o -uoc asoq aql e^oqD s! se)orq roer 3ql ]o loql
-uop e^ouer puD 6ur.r6ugualsDl eLll
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sdn3 (1sn6) en;1celord uolsld 6ugcoldeg sr selorq luor+ eq] ,o qcoe ]o MeJcs Burpaalq
e L l I ' a q n l r a q q n r D q l ! M 1 1a c o l d a r p u o M a r c s e q l
'secolJns
' 1 - ' 6: a 1 d o q 3 o l J e l e i ' l D M a u e r r ! o q l ;o doc reqqnr oql aloueu luacolpo
aql puD .rapulli{c leeqM sql lo Melcs 6u;pealq
;o Allssacau eql puD uorl!puoc r!sql 6ugsses eql uDelc ueql puo'IuD] 3qt u! ptnll eIDJq
- s o r o 3 ' q n q l e e q M e q t 6 u ! ^ o L u e rr e U D p a u ; o D
s! sooqs elDJq eql o1 sseccD - elxD lDeu aq1 dn do1 1sr;; 'selorq aql 6ulpaalq ueqM
'lcella 6ur>1o.rq ssol elelduoc o
lo
'sdnc
lsnp p u D l e ^ D r l a r l u e s 1 g1 n o q 6 n o q 1; o p a d e l o i q e q l
e q l r v r e u s r ' a 6 o u . r o pl s e l q D r ; s e q l J o u o ! l D c ! p u ! j o u o r l o D , , A 6 u o d s ,D , u ! s t l n s e ' tJ t D l o l u n o u D
6'S1-8'gl
r 5 . 9 - 1 5r 2
.

D i s m o n t l e t h e h o u s i n g ,r e m o v e o l d g r e o s e ,
c l e o n t h e i n d i v i d u o lp o r t s , o p p l y f r e s h g r e o s e ,
ond reossemble t h e h o u s i n g .S o o k t h e f e l t r i n g s
o n t h e l i n k s ( p u l l - r o d s )i n e n g i n eo i l .
1 5 . 1 0 W H E E L S A N D T Y R E S ,S N O W C H A I N S
Tyre Inflotion, Boloncing ond lnterchonge
of Wheels
p o r t s o g o i n s td i r e c t c o n t o c tw i t h s p e c i o lc h e m i -
col solvLntsor limit the durotion of this contoct
t o o m i n i m u mb e f o r eo c o m p l e t ew o s h i n g o f f o f
t h e s o l v e n t sw i t h w o t e r ( b y h o s i n g d o w n ,e t c . ) '
Keep the oil cooler, if fitted on the cor, in
c l e o n ' c o n d i t i o n .H o s e i t d o w n w h e n w o s h i n g
the cor, ond if dirt still sticks to the cooling
surfoces,use some of the detergents.
Bodywork Lubricotion

T h e p r o c e d u r e so r e o u t l i n e d i n C h o p t e r s1 0 . 1 R o u t i n em o i n t e n o n c ei n c l u d e st h e l u b r i c o t i o n
through 10.3. Snow choins ond their use ore o f d o o r h i n g e so n d l i m i t e r s ,h i n g e s o n d r e l e o s e
deolt with in Chopter 10.6. m e c h o n i s m io f t h e e n g i n eb o n n e t o n d b o o t l i d ,
Wheel Toe-in - see Chopter 16.1. t h e r e l e o s em e c h o n i s mo f t h e s p o r ew h e e l , o n d
"Shock the leverogeof windscreen wipers. Lubricotion
Shock Absorbers- see Chopter 8.3 o f i n n e r d o l o rm e c h o n i s m si s i n c l u d e di n s p e c i o l
Absorbers ".
mqintenonce.
Lubricote oll occessiblemechcnismswith
h i g h - q u o l i t yg r e o s e sw h i c h d o n o t d r y , d o n o t
EQUTPMENT
15.11 ELECTRTCAL oxldize, ond protect the mechonisms ogoinst
c o r r o s i o nf o r o l o n g t i m e . O i l i s n o t s u i t o b l ed u e
Checking electrolyte level ond topping up -- to its short-timeefJect.Any greosecon be used
see Chopter 13.2. t o l u b r i c q t et h e d o o r l i m i t e r so n d t h e f r o n t s e o t
Sporking plugs - electrode gop odiustment, s l i d er o i l s .
etc. - see Chopter 13.7.
Stqrter motor - exqminqtion ond renewol of Lubricotionof SporeWheel Corrier Bearings-
brushes,etc. - see Chopters13.11through 13.14. R e m o v et h e s p o r ew h e e l ,c l e o n t h e h i n g e s ,o n d
lgnition timing, odiustment of contoct breoker o p p l y o i l o n i h e i t u p p e r s i d e s . I n o d d i t i o n ,r u b
point gop, distributor lubricotion - see Chop- i n g r e o s eo f o n y b r o n d .
ter 15.3.
Lubricotion of Windscreen Wiper Leveroge-
R e m o v et h e c o v e r o f t h e i o i n t ( o p l o s t i c c u p ) ,
15.12 BODYWORK- UNDERBODY f i l l i t w i t h g r e o s e ,l u b r i c o t et h e i o i n t , o n d r e i n -
stoll tlre cover.
Woshing ond Mointenonce
The Lubricotion of Inner Door Mechonisms
T h e v i s i b l e p o r t s o f t h e b o d y q r e f i n i s l r e di n i s p o s s i b l eo n l 'yd oo fot re r r e m o v i n gt h e d o o r p o n e l
o h o r d s y n t h e t i cb o k i n g v o r n i s h ,t h e r e m o i n i n g ond the inner m e c h o n i s m .U s e o n l y r e -
p o r t s i n s y n t h e t i cv o r n i s h . commendedgreosebrcnds.Lubricotethe bowden
T h e u n d e r b o d yi s s p r o y - c o o t e w d ith o plostic c o b l e o f t h J w i n d o w w i n d - u p m e c h o n i s mw i t h
c o m p o u n d- f o r d e t o i l e d i n f o r m o t i o n s, e e C h o p -
'14.9.
ter Follow the usuol procedures when
w o s h i n g ,c l e o n i n go n d p o l i s h i n gt h e c o r , o n d
observethe specific instructionsfor the use of
w o s h i n g o n d c l e o n i n g p r e p o r o t i o n s i,s s u e d b y
their monufocturers.
A l l l i g h t s w i t h t h e e x c e p t i o no f h e o d l o m p s
hove cosings of plostic moteriols qnd they
s h o u l db e c l e o n e do n l y w i t h w o t e r o r s h o m p o o s .
W h e n h o s i n gd o w n t h e c o r rc o v e rt h e v o l t o g e
r e g u l o t o ro f t h e o l t e r n o t o ro n d t h e i g n i t i o n c o i l
t o p r o t e c t t h e m o g o i n s t s p l o s h i n gw i t h w o t e r ,
ond do not sproy woter direct on the door lock
o n d t h e l i d c o v e r i n gt h e f u e l t o n k f i l l e r n e c k .

Woshing ond Core of Underbody Mechonisms

The underbody mechonisms ore protected
with o synthetic vornish which stonds well the Fig.15.1211-Lubricotion of Windscreen Wiper
usuol woshing procedures.Protect oll rubber LeverogeJoint - ioint cover

230
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aull
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'p!l
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lceqo lo leeqs pron6 eql 6u;r '6u111t1
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1e; l! 1 aq1 'l.ro1col eql ul lnoqDno:ql uats{s
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'Jalourer
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' a c o d s a u g D u ae q l u ! 'euasoJel ul padd;p
uo eu!l xapul eql luol - r o 1l o g c e d s o J o ' e u l l u e d l n l
a 6 o . r o l s a q l ] o ; 1 o q A l e l o t u g x o . r d d oq o D a r P l n o q s qlolc D qlrvr Apoq oql uor, slods .tol a^oued
uortrpuoc ploo ul p!nb!l eqt lo la^el eql
'6u1lt+ stods ro1 6ulnoueg
1 o u r 6 1 . reoq t e l D , l
- o u a l a p A ; 1 o c 1 u e q cl o u u D c q c ! q M p ! n b ! l D q 1 ! M
' s c r r q D ] p e l D u ! L U o le u . l o s
- r o 6 u r 1 1 1 ;; o u q 6 u o a q l l o l o q l s D a p o l 6 a r - u o s ,o
a L l l l o e l n l x ! u r e z e e J l ! l u D p e . r o d e . r dA ; n n e uD q l l M s . r a A o eg q ] J o u o r l o l o d e s e q l s s n D c P l n o c q c ! q M
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u o r l - r o d p a l o . r o d o n ao q l q s ! u o l d e : p u D ( u r o 6 o 6 u g p u e d a ps o r r q o l c l 1 e q 1 u A s. r o ;s 1 u a 6 o 6 u 1 u o a l c
'puD qr!M pauoalc oq plnoLls itrelsloqdn el!lxal^
u : n l L r a L l lp u o l ! s s a r d a p ' 6 u 1 u e s o o 1r e t l D ' a l q o l ! D ^ Do s l o a l D s l u a E o
t l e l a q t o 1 A 1 1 q 6 t 1g st urnl) doc aql a^ouau
6uguoelc lolcadg 'doos PUD JaIDM uIlDMeInl
arnlx!l1l ezeorllluv lo luauqslue1de5 Lll!M slolJelou ctlsold lo s-le^oc puo A-ra1s1oq
dn ruoJl pelouer ]saq ejo lllp pLlDsulDls
'Aluo :alont qllM
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- a r e q l ' ( s r o l l q g q u tu o ! s o l J o c u l D l u o c s e z o a i l l l u o Aralsloqdn uDolC ol
llrlonb-r"16gqu ) ralsAs eql u! uo!soloc ,o uolt
- D r x J o ,a q l l u e n a t d o l ' a ' ! ' u o l l c o a n l s o J l o c l n o ' e l q D o u e p M o q e q l A q ( u 1 - p a > 1 c n sp) - 1 e q
- q l r r u r6 u r 1 ; r JD e l n s u a o l l e p J o u ! C " O L - ' x o . t d d o eq uDc sD llo qcnu sD lluo 6u1sn1to autDuo
the p ' f il o
pwes) The greoter portion of the filling
will out through the outlets ond this will
suffice in the event of droining before dismon'
tling the engine.
3.-Uncouple the hoses from the engine line
i n t h e e n g i n e b o y - S e e F i 1 . 1 5 . 1 3 1 AP. r o c e e d i n g
from und6r the vehicle, pull the hoses behind
the cross beorer of the georbox, ond let the
liquid flow from the hoses.
4. Remove the droin plug of the cylinder
b l o c k o n d , i f n e c e s s o r y ,f r e e t h e o u t ' f l o w u s i n g
o length of wire, etc.

N o t e : I n o l l , o b o u t 8 5 0 / 0( 1 0 . 5 l i t r e s ) o f t h e
coolont will f low out, ond the differenceshould
be reckoned with when refilling the system-

A l l o n t i f r e e z e so r e t o o c e r t o i n e x t e n t h o r m f u l
F i g . 1 5 . 1 3 / 4- H e o t e r L i n e o n E n g i n e
t o t h e s k i n . l t i s t h e r e f o r e n e c e s s o r yt o p r o t e c t ond Droin Plug
oneself qgoinst contoct with the liquid, es-
1 - droin plug
peciolly the eyes (do not touch them with
2 * pump ond heoter connecting line
3 - thermostot ond heoter connecting lirre

fingers soilded witlr the liquid). Wosh ony

stolns off the skin os quickly os possible with
soop woter etc. Rinse the stoins off the vor-
nished cor bodY with woter.

Fridex-Spolqno Antifreeze

As clreody mentioned, the cooling system is

F i g . 1 5 . 1 3 1-2C o o l i n g S y s t e mB l e e d C o c k
filled with this liquid,or with o solutionof its
concent'rote with soft woter, in the foctory.
For the preporotion of this solution olw.oys
use soft ond cleon woter. In the following toble,
its concentrotion in dependenceon its freezing
resistonce is indicoted. Alternotively, the con-
centrotion con be determined from the density.

Volume Ports
D e n si ti yt F r e e z in g
II ot + 2 0 oC
o t +20 ' point "C
FridexS p o l o n oi W o t e r i
--
I -10
21 79 1.029
1 2 ; t.oqs -20
38 62 I 1.055 -25
'1,5 1.O57 -27
1
44 56 1.062 -30
47 53 |I 1.067 -35
I 1 i 1.074 -40
53 47 i 1.080 -45
-1,5 4
I
I
-60
F i g . - 1 5 . 1 3-/ 3F u e l T o n k G u o r d S h e e t o n d P i P e
DroinPlugs

232
 rol luaudtnbf
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a6o4
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1 6 . -1 1 6 . 2
16.1 EQUTPMENTFOR SUBTROPTCAL
REGIONS
Stondord equipment of cors for subtropicol
regionswhere the temperoturedoes not exceed
+40oC, or where increosedcooling efficiency is
requiredgenerolly:
1 . C o p p e r r o d i o t o r ( c o p p e r l o m i n o t i o n s )f o r
oll types.
2. Oil cooler for oll types, the some os thot
fitted in the stondord 12OLS model.
3. Cost finned oil sump for oll types includ-
ing occessories (longer oil pump suction
s t r o i n e ro n d l o n g e r o i l d i p s t i c k ) , l i k e t h o t f i t -
ted in stondord 120L ond 120LS models.
4 . O i l t e m p e r o t u r es i g n o l l i n gt e l e t h e r m o m e t e r
( 1 2 5 + 3 ' C ) i n c o r t y p e S 1 2 0 t - S .T h e p r i m o r y
e l e m e n ti s m o u n t e di n o s p e c i o lc o n n e c t i o nf i t -
t e d t o t h e o i l c o o l e ro u t l e t .T h e w o r n i n g l o m p
o n t h e i n s t r u m e n tp o n e l i s r e d o n d w i t h o u t
o s y m b o l ( t h e i n s t r u m e n tp o n e l h o s o d i f f e r e n t
w i r i n g f o r t h e c o n n e c t i o no f t h e w o r n i n g l o m p
t o t h e t e r m i n o lb o o r d ) .
The coble of the primory element is con-
nected to the terminol "10" of the terminol
boord "111" (morking occording to wiring dio-
g r o m i n F i g . 1 3 . 1 / 1 ) .T h e c o b l e i s l e d o u t o t
the engine together with cobles to the engine
temperoturegouge ond the oil pressureswitch.
16.2 EQUTPMENTFOR TROP|CAL REGTONS
Stondord equipment of cors for tropicol re-
gions where the temperoturedoes not exceed
234
f 50 oC, or where on extro high cooling ef-
f i c i e n c y i s r e q u i r e dg e n e r o l l y :
1. Copper rodiotor (copper lominotions) for
oll cor types.
2. Oil cooler for oll types like thot fitted in
stondord S 120 LS mod6l. The bolt connecting
the rodiotor hose of the outlet from the engine
timing geor cover to the rodiotor hos, however,
n o b y - p o s sh o l e s .
3. Cost finned oil sump for oll cor types -
refer to Chopter 16.1,porogroph3.
4. Oil temperoturesignolling telethermometer
(125+3oC) for types 120 L ond 120 LS. For
loyout see Chopter 16.1,porogroph4.
5. Thermostot with o nominol opening tem-
perotureof +75oC for oll types.
6 - I n c r e o s e dv o l u m e o f c o o l o n t ( s t o r o g e )
tonk - 4 litres for oll types.
7. Fr-relpump with o longer priming lever.
I t i s i n s t o l l e do n t h e e n g i n e o n t w o i n s u l o t i n g
pcrds
M o i n t e n o n c eo f o i r c l e c n e r :
T h e s t o n d o r do i r c l e o n e r f i l t e r e l e m e n t ( t h e
some for oll cor types) must be chonged in
dust-lodenenvironmentsofter every 2,000 kilo-
metres.On dusty roods in deserts,this element
must be inspected doily ond reploced doily, it
necessory.
Keep the coolont level ot obout the middle
of the tonk or only slightly obove the middle.
T h e t o t o l v o l u m e i s 1 35 l i t r e s o p p r o x i m o t e l y
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 M P 1 - 1 1 1 F l y w h e e lc o t c h

MP 1-112 Thrust beoring supportingbush

MP 1-113 Volve supportingplote

MP 1-114 Volve spring instoller

MP 1-121 Wqter plrmp shoft drift

M P 1 - 1 2 2 W o t e r p u m p b e o r i n gd r i f t

MP 1 123 Woter pump beoring drift

l= MP 1-128 Gouge for corburettor throttle disks

238
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 MP 3-108 Pinion beoring extrqctor

MP 3-109 Lock pin guides

M P 3 - 1 1 1 P i n i o n c l o m P i n gb r o c k e t

1 7 . 4 R E A RA X L E

M P 5 - 1 0 1 B o c k l o s hg o u g e

MP 5-102 Pinion beoring retoining fixture

MP 5 104 Differentiql odiustirrg support (2. )

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MP 5-116 Seolingring drift

MP 5-151 Pinion odiusting gouge

MP 5-152 Wheel hub puller

17.5 FRONT AXLE

MP 6-150 Front oxle ossemblybroclket

MP 6-105 Steering orm drift

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MP 6-126/A Wheel beoring inner roce extroctor

MP 6127 Wheel beoring inner roce drift

M P 6 - 1 2 9 P r e s s i n g m o n d r e l o f w h e e l beoring outer roces

MP 6-130 Pressing mondrel of wheel beoring outor roces

M P t i - 1 3 1 S e o l i n gr i r r g d r i f t

MP 6--140 Disc-brokegouge

MP 6--134 Expondingpliers
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17.7 COMPLETE CAR

MP 8-101 Cement syringe

MP 8-102 Rodiotor fon hub puller

MP 8-152 Toe-in gouge

T MP 8-157 Comber gouge

&:* MP 8-158 Reor oxle olignment check gouge

MP 8-159 Check gouge for underbody (front)

MP 8-160 Check gouge for underbody (reor)

MP 8-161 Window frome moulding fitting fixture

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sKoDA.(GB)LTD

PARTSDEPARTMENT
Bergen Way, North'Lynn Industrial Estpte,
K i n g sL y n n ,N o r { o l k .

T e l e p h o n eK: i n g sL y n n ' 6 1 Z €

; , s e d a n d r e - p r i n t e db y . J e m t e c hP r i n t i n gL t d . ,
- ) l l i r r l ) o ! [ , r el -, l a i t s ,E r g l a n d .