Haynes Skoda Estelle 1977 to 1989 Owners Workshop Manual 1859601626, 9781859601624

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Essential Automotive Books from Haynes LAND ROVER [3) ae oeee

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Each manual features clear, easy-

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hundreds of step-by-step photos and illustrations that guide you through each task.

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From the simplest service to a major re-build, a Haynes Manual will help you keep your car running smoothly and efficiently for years.

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The complete! guide'to the inspection, maintenance and LC o-Tleto}§ braking systemsion all popular car and light’ commercial vehicles

The complete guide to the theory, and\practice of

AUTOMOTIVE

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TOOLS NANG rae cting, buying tools

automotive electricaliand electronic systems

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From basic theory to advanced techniques

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HOW

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BODYWORK

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IN-CAR

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This easy-to-follow, large format manual covers everything from painting and spraying through to waterproofing and rust prevention.

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Cen Re)neeim Chee) tile

PORTER

Expert, clearly illustrated,

practical advice on keeping an older car reliable and roadworthy without spending a fortune.

JOHN

WICKERSHAM

A full guide to maintenance tasks, repair work and improve-

Really practical DIY advice on choosing and fitting car radios,

ments for every caravan owner.

cassette players, CD units, in-car telephones and much more.

26

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1684744

Wi AUTHOR.

y.Q°°

COOMBER,

K?

I.M.

RENO

Skoda Es.c.ic Service and Repair Manual | M Coomber (604-192-10X7)

Models covered

All Skoda Estelle 105, 120, 130 and 136 models, Saloon and Rapid Coupe, including special/limited edition models 1046 cc, 1174 cc and 1289 cc Covers most features of Cabriolet models Does not fully cover ‘Sport’ conversion

ABCDE FG

© Haynes Publishing 1996 A book in the Haynes Service and Repair Manual Series All rights reserved. No part of this in any form or by any means, photocopying, recording or by any without permission in writing from

Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil, Somerset BA22 7JJ

;

book may be reproduced or transmitted electronic or mechanical, including information storage or retrieval system, the copyright holder.

Haynes Publishing Sparkford, Nr Yeovil, Somerset BA22 7JJ, England Haynes North America, Inc

861 Lawrence Drive, Newbury Park, California 91320, USA

ISBN 1 85960 162 6 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library.

Editions Haynes S.A. 147/149, rue Saint Honoré, 75001 PARIS, France

Page

004 0°5 0°6

Page

0°7

Tyre condition and pressure

Page

O11

Buying spare parts and vehicle identification numbers

Page

0°12

thtiéderétion Safety First! General dimensions, weights and capacities

Page Page

Roadside Repairs Routine maintenance

Identifying leaks

Page

0°13

Jacking and towing

Page

0°14

Jump starting

Page

0°15

Lubricants and fluids

Page

0°16.

2 424.289 stoP/1684744

Contents REPAIRS & OVERHAUL Engine and Associated Systems Engine (also see Chapter 12)

Cooling system (also see Chapter 12)

Page

1e1

Page

2e1

Fuel and exhaust systems (also see Chapter 12)

Page

3e1

Page

4e1

Page

5e1

Igniton system (also see Chapter 12)

Transmission Clutch (also see Chapter 12) Transmission (also see Chapter 12)

Page

601

Driveshafts, rear hubs, wheels and tyres (also see Chapter 12) Front hubs, suspension and steering (also see Chapter 12)

Page

/7e1

Page

8601

Page

9Q6 = voltage canbe * dangerous, especially to ia people with heart fe problems or a pacemaker. Don’t work on or near the ignition system with the engine running or 5 | the ignition switched on.

fo r

Oe5

Special hazards Hydrofluoric acid e This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 400°C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. e When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.

The battery e Batteries contain sulphuric acid, which

attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. e The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.

Air bags e Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and/or facia. Special storage instructions may apply.

Diesel injection equipment e Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.

_

0°6

Dimensions, Weights & Capacities

General dimensions, weights and capacities For modifications, and information applicable to later models, see Supplement at end of manual

Overall dimensions 4.160 m (163.8 in) 1.595 m (62.8 in) 1.4 m (55.2 in) approx 170 mm (6.7 in)

Height (loaded) Ground clearance

Kerb weights (approximate) Og arta eias Gases uicolis. atigamel eo)Breined aitorahtaco eatin asSe SVEN 120 LE, LS and LSE

Ree ts

855 875 875 885

kg kg kg kg

(1885 (1929 (1929 (1951

Ib Ib Ib Ib

a wr rere

Capacities Engine oil:

105 S and L, 120 L and LE 120 GLS, LS and LSE Cooling system

4 litres (7 pints) 4.6 litres (8.1 pints) 12.5 litres (22 pints)

Gearbox and final drive:

From dry Drain and refill Hydraulic system Steering box Fuel tank

2.5 litres (4.4 pints) 2.0 litres (3.5 pints) 0.5 litres (0.88 pints) approx 0.16 litres (0.28 pints) 38 litres (8.4 gal)

Routine Maintenance

«7

Routine maintenance For modifications, and information applicable to later models, see at end of manual The maintenance instructions listed below are basically those recommended by the vehicle manufacturer. They are supplemented by additional maintenance tasks which, through practical experience, the author recommends should be carried out at the intervals suggested. The additional tasks are primarily of a preventive nature in that they will assist in eliminating the unexpected failure of a component due to fair wear and tear. The levels of the engine oil, cooling water, windscreen washer water and battery electrolyte, also the tyre pressures, should be checked weekly or more frequently if experience dictates this to be necessary. Similarly it is wise to check the level of the fluids in the clutch and brake master cylinder reservoir at monthly intervals. If not:checked at home, it is advantageous to use regularly the same garage for this work as they will get to know your preferences for particular oils and the pressures at which you like to run your tyres.

og

Routine Maintenance

Every 6000 miles (10 000 km) or — 6 months — whichever comes first In addition to the work specified in the previous schedules

Every 36 000 miles (60 000 km) or 3 years— whichever comes first ;

In addition to the work specified in the previous schedul

(_] Check the valve clearances. LJ Change the engine oil and filter - models 1984 on. _L] Remove

the carburettor fuel inlet pipe and clean the

| | Inspect the driveshaft

strainer models 1984 on.

Every 12 000 miles (20 000 km)or

[] Check the suspension rubber bushes for — deterioration. |_] Repack the front hub bearings with grease. On models with semi-trailing arm rear SHeperaiot the rear hub bearings with grease. |_| Inspect the rear brake linings. | |]Have the engine compartment and the underside car body steam cleaned. Heyer for rust ae wiring, etc. :

or / repack _

of the ae

Every 60 000 miles (100 000 km) or =Syears—whichever comes first

— WwW hichever comes {St

dn addition to the work specified in the previous schedules

(J

rubber boots for damage on

deterioration.

| |]Have the front wheel alignment checked if steering is heavy or uneven tyre wear is noted. (_] Check the steering rack for damage or leaks. _] Check the steering box oil level. a Check the stub axlé turning force. Inspect the front disc pads. Check the headlamp alignment. — Check the windscreen wiper blades. |] Lubricate locks, hinges, catches, seat runners, etc. [_] Clean the interior of the car and wash and polish the exterior.

12 months

_

Check the engine mountings for damage or deterioration and renew if necessary.

7 Renew all the braking system rubber seals and Herbie hydraulic hoses.

(_] Check the starter motor mounting bolts for tightness. : Renew the air cleaner element. |} Check the carburettor, manifold and exhaust fittings for tightness. : |] Examine the exhaust system for leaks.

_] Renew the spark plugs.

_

CL] Renew the contact breaker points. CJ Check the transmission oil level (photo).

Every 24 000 miles (40 000 km) or 2 years— whichever comes first| Inaddition to the work specified in the previous schedules

|_| Drain and renew the coolant. Drain and renew the transmission oil*. |] Renew the hydraulic fluid by bleeding.

|_] Check the handbrake for satisfactory operation.

-[] Check the brake servo unit (where applica for _ satisfactory operation. : “The manufacturers recommend a five-year interval, but owners may

feel it desirable to adopt a two-year interval

Remove dipstick (A) to check engine oil level. Other

maintenance check points shown are:

B Coolant hoses and connections for leaks and security C Drivebelt for tension and conditon D Water pump bearing lubri a

Routine Maintenance

Kingpin grease nipple location (arrowed)

o-9

Transmission drain plugs (A) - gearbox and differential housing. Also shown is the level plug (B)

Top up the transmission oil, filling through tube to correct level

o10

Routine Maintenance

Engine compartment - 120 LSE 1 Air cleaner 2 Ignition coil 3 Alternator

4 Distributor 5 Engine oil filler cap 6 Water pump

7 Distributor/carburettor vacuum hose 8 Exhaust downpipes

9 Coolant header tank 10 Carburettor

Routine Maintenance

0°11

I"

Tyre condition and pressure It is very important that tyres are in good condition, and at the correct pressure - having a tyre failure at any speed is highly dangerous.

Tyre wear is influenced by driving style - harsh braking and acceleration, or fast cornering, will all produce more rapid tyre wear. As a |general rule, the front tyres wear out faster

than the rears. Interchanging the tyres from front to rear ("rotating" the tyres) may result in ‘more even wear. However, if this is completely effective, you may have the expense of replacing all four tyres at once! Remove any nails or stones embedded in the tread before they penetrate the tyre to cause deflation. If removal of a nail does reveal that

4

the tyre has been punctured, refit the nail so that its point of penetration is marked. Then immediately change the wheel, and have the tyre repaired by a tyre dealer. Regularly check the tyres for damage in the form of cuts or bulges, especially in the sidewalls.

Periodically remove

the wheels,

and clean any dirt or mud from the inside and outside surfaces. Examine the wheel rims for signs of rusting, corrosion or other damage. Light alloy wheels are easily damaged by "kerbing" whilst parking; steel wheels may also become dented or buckled. A new wheel is very often the only way to overcome severe damage.

New tyres should be balanced when they are fitted, but it may become necessary to rebalance them as they wear, or if the balance weights fitted to the wheel rim should fall off. Unbalanced tyres will wear more quickly, as will the steering and suspension components. Wheel imbalance is normally signified by vibration, particularly at a certain speed (typically around 50 mph). If this vibration is felt only through the steering, then it is likely that just the front wheels need balancing. If, however, the vibration is felt through the whole car, the rear wheels could be out of balance. Wheel balancing should be carried out by a tyre dealer or garage.

y

Tread Depth - visual check

Tread Depth - manual check

Tyre Pressure Check

Alternatively, tread wear can be monitored with a simple, inexpensive device known as a tread depth indicator gauge.

Check the tyres pressures been used,

the tyre pressures regularly with cold. Do not adjust the tyre immediately after the vehicle has or an inaccurate setting will result.

Shoulder Wear

Centre Wear

Uneven

Wear

Underinflation (wear on both sides) Under-inflation will cause overheating of the tyre, because the tyre will flex too much, and the tread will not sit correctly on the road surface. This will cause a loss of grip and excessive wear, not to mention the danger of

Overinflation Over-inflation will cause rapid wear of the centre part of the tyre tread, coupled with reduced grip, harsher ride, and the danger of shock damage occurring in the tyre casing. Check and adjust pressures

sudden tyre failure due to heat build-up. Check and adjust pressures Incorrect wheel camber (wear on one side) Repair or renew suspension parts Hard cornering Reduce speed!

If you sometimes have to inflate your car’s tyres to the higher pressures specified for maximum load or sustained high speed, don’t forget to reduce the pressures to normal afterwards.

Front tyres may wear unevenly as a result of wheel misalignment. Most tyre dealers and garages can check and adjust the wheel alignment (or "tracking") for a modest charge. Incorrect camber or castor Repair or renew suspension parts Malfunctioning suspension Repair or renew suspension parts Unbalanced wheel Balance tyres Incorrect toe setting Adjust front wheel alignment Note: The feathered edge of the tread which typifies toe wear is best checked by feel.

The original tyres have tread wear safety bands (B), which will appear when the tread depth reaches approximately 1.6 mm. The band positions are indicated bya triangular mark on the tyre sidewall (A).

Tyre tread wear patterns

0¢12

Routine Maintenance

Buying spare parts Spare parts are available from many sources, for example, Skoda garages, other garages and accessory shops, and motor factors. Our advice regarding spare parts is as follows: Officially appointed Skoda garages - this is the best source of parts which are peculiar to your car and otherwise not generally available (eg, complete cylinder heads, internal gearbox components, badges, interior trim, etc). It is also the only place at which you should buy parts if your car is still under warranty; nonSkoda components may invalidate the warranty. To be sure of obtaining the correct parts it will always be necessary to give the storeman your car’s engine and chassis number, and if possible, to take the old part along for positive identification. Remember

The engine number location

that. many parts are available on a factory exchange scheme -—any parts returned should always be clean! It obviously makes good sense to go to the specialists on your car for this type of part for they are best equipped to supply you. Other garages and accessory shops — these are often very good places to buy material and components needed for the maintenance of your Car (eg, oil filters, spark plugs, bulbs, fan belts, oils and grease, touch-up paint, filler paste, etc). They also sell general accessories, usually have convenient opéning hours, often charge lower prices and can often be found not far from home. Motor factors — good factors will stock ail of the more important components which wear out relatively quickly (eg, clutch components, pistons, valves, exhaust systems, brake cylinders/pipes/hoses/seals/shoes and pads,

etc). Motor factors will often provide new or reconditioned components on a_ part exchange basis — this can save a considerable amount of money.

Vehicle identification numbers The engine number

is situated

on the

cylinder block adjacent to the water pump flange (photo). The chassis number is stamped on a plate attached to the bulkhead panel inside the front luggage compartment (photo) on the rear bulkhead next to the engine compartment lid retainer and on the shroud above the radiator.

The chassis number plate location

Roadside Repairs — o-1s

:

Identifying leaks Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies.

Sump oil

_

Warning: Most automotive oils and fluids are poisonous. Wash them off skin, and change out of contaminated clothing, without delay. S

Oil from filter

Gearbox oil 7

...or from the ake or he oilfilter.

:

Brake fluid

SS

Leaking antifreeze often leaves a crystalline

deposit like this.

Gearbox oil can leak from the seals at the inboard ends of the driveshafts.

Power steering fluid

:

(IS

A leak occurring at a wheel is almost

certainly brake fluid.

RE

Power steering fluid may leak from the pipe

connectors on the steering rack.

o14

Roadside Repairs

Jacking If the car is to be raised for service or repair operations it is essential that the correct jacking procedure be adhered to. It is most important that only the specified jack and support points are employed in order to prevent accidents and damage to the vehicle. The jack supplied with the car is really only designed for the purpose of changing a wheel

in the event of a puncture and should not be relied on for supporting the car during repair operations under the vehicle. Trolley or pillar jacks are more suitable for this purpose but even then they should be supplemented with axle stands or blocks to ensure complete working safety. Only jack up on firm level ground and chock the wheels to prevent the

car rolling off the jack. Unless a wheel has to be removed most operations under the car are best carried out with the car on ramps if available. If supporting the car on blocks or chassis stands position them at the points shown in the illustration.

attached is located through the bracket and secured with a cotter pin. The tow pin and cotter pin were supplied with the car when new and should be used if available.

If a trailer is to be towed, only fit an approved towbar unit and ensure that the total weight towed is not in excess of 400 kg (881 Ib) if the trailer itself is not fitted with brakes.

Towing In the event of the car breaking down or being in need of a tow. a front-mounted towing bracket is fitted and it must be used. Do not attach rope to suspension or steering components! The pin to which the tow rope is

The Skoda sidewinder jack in position ensure that it is fully engaged

Support the car at the points shown

:

|

Roadside Repairs

‘AEN ermStarting ;

n

ees

15

Jump starting When jump-starting a car using a booster battery, observe the following precautions:

v Before connecting the booster battery, make sure that the ignition

Bd ono.

v

i

Make sure that the booster battery is the same voltage as the discharged one in the vehicle.

v

the masse is being eee FORDE AnH YIN ano ies VEIN,

ergnmon'S

nsure that that allall electrical VE (lights, electrical equipm equipment heater, wipers Baie atk

switched off.

the two vehcles MUST NOT TOUCH ee

v

Make sure that the transmission is in

:

neutral (or PARK, in the case of automatic transmission).

2

the positive (+) terminal of the flat battery

Connect the other end of the red lead to

the positive (+) terminal of the booster battery.

A

to the negative (-) terminal of the booster battery

i 1 I i L

\~

4 |

Connect the other end of the black jump lead to a bolt or bracket on the engine block, well away from the battery, on the vehicle to be started. Make sure that the jump leads will not come into contact with the fan, drivebelts or other moving parts of the engine.

Start the engine using the booster “bees

=a

2

Ss SB es

Se es Ss SS

Se eS

ee

eee

eee

battery, then with the engine running at idle speed, disconnect the jump leads in the reverse order of connection.

0°16

Lubricants and Fluids

HI4 460

Component or system 1 Engine

Lubricant type/specification Multigrade engine oil

2 Transmission

Gear oil, viscosity SAE 80EP or 90EP

3 Steering box

Gear oil, viscosity SAE 90EP or 140EP

4 Water pump

General-purpose grease

5 Front wheel bearings

General-purpose grease

6 Kingpins

General-purpose grease :

7 Brake hydraulic system

Hydraulic fluid to SAE J1703

8 Steering rack

Gear oil, viscosity SAE 90EP

11

Chapter 1 Engine For modifications, and information applicable to later models, see Supplement at end of manual

Contents

|

Big-end and main bearings — examination and renovation........ 13 Camshaft and camshaft bearings — examination and renovation ... 17 AMIS Ait HETILCAC Naorcta.comrate Sy hese alge Shella Cee atran EN avecatl 39 Connecting rods to crankshaft - reassembly ............+0.055 37 Crankshaft — examination and renovation ............000e0 eee 12 Crankshaft oil seal (rear) - refitting 2.0.0.0... 0cece cece eee eee 38 Crankshaft pulley and flywheel- assembly .........-..-..+04- 42 EFS inentt a hOUPUCIGer cute ctorcicneuale a siaedichecaral avonsvelelaireiie a von engai 32 GSVlinGeRDIOCK—GISIMANUING 0 cits wpe eeaeieyacistinaes vuln gee cscssa erees 10 Cylinder bores — examination and renovation ..............+4+- 14 Cylinder head, pistons and bores — decarbonisation ............ eS Gyiinder head = nentinG eas sss cease oie ele ee wee eaten Olws 45 Gylinderhead'— removal... 2 aya See ce gee bees 9 Cylinder liners — fitting to crankcase ......... 6.eee eeeee eee 36 Engine - ancillary components removal ........-.--++++eeeeee 8 Engine and transmission — refitting .... 02.2.0. eee eenee eee ee 49 Engine and transmission removal — general notes ...........--. 4 Engine and transmission — removal .......... +2eee eee eee 5 Engine —- component examination and renovation (general) ....... 11 Engine dismantling (general) ... 2.056... eecee eee ees ifs Engine — final assembly ...... 22... - 6 eee eee eee ee teens 47 Engine - initial start-up after overhaul ..... 0... 62-6 e eee eens 50 6 Engine only — removal ......... 0.6.6 e cece eee ett eens ...-- 6. +e eee cree teens 31 Engine - reassembly (general)... engine |... io lees eee See end of Chapter Faultfinding Flywheel and starter ring —- removal and refitting ............... 20

General description and maintenance .......-..-++-+++es+ee: Gudgeon pin and small end - examination and renovation ....... Half axles refitting! y sci crt ae ee alipmsteet a eevee eoaene cee oP Major operations possible — engine in car .....-....e seer reese Major operations requiring engine removal ........-..--+++++++Oil cooler — removal, inspection and refitting ...........-.-+.+: Oil filter — removal and renewal .......... 00:0 cece Oil pressure relief valve — removal, inspection and reassembly .... Oil pump - removal, inspection and assembly ...........-+-+-Oil pump suction unit and sump - assembly ........-..+-+55-Pistons and connecting rods — assembly .........----++-+0-e: eee Pistons and connecting rods - refitting ..........++.eeeee Pistons and rings - examination and renovation ...........-.-Piston rings — refitting .... 2.2.00. e ce eee tee ee ee eee Rockers and rocker shaft - dismantling and inspection .......... 0050 ccece eee ee tenes Rocker shaft- assembly ......... SUMP FEMOVALION a). «8g. terwere aeead o = m eedlnye a a mrenefoie ocriemenins Tappets (cam followers) - examination and renovation .......... Timing sprockets and chain - examination and renovation ....... Timing sprockets, chain and cover - refitting ........--..+++++5Valves and valve seats — examination and renovation ........... see eeee eee Valves and valve springs - refitting ...........-.2.60 eeeeee eee eee Valve clearances — adjustment .......... eee Valve guides — examination .... 6.6... e eee ee eee WAIVES —TeImOVAl =: sam « cixinie oe weeceieedn eperte n eaatle © aslaces tGehmips

Degrees of difficulty Easy, suitable for

novice with little experience

B&

ds x

Fairly easy, suitable

for beginner with some experience

S

SS

x

| Difficult, suitable for Fairly difficult, suitable x experienced DIY for competent DIY mechanic mechanic

x