Skoda Felicia

Since 1994 of release

Repair and car operation



Shkoda Felitsija
+ Cars of mark Skoda Felicia
+ The maintenance instruction
+ Routine maintenance
- Engine repair
   + Repair without extraction from the car of the petrol engine of 1.3 l
   + Repair without extraction from the car of the petrol engine of 1.6 l
   + Repair without extraction from the car of the diesel engine
   - Dismantle of the power unit and engine major repairs
      Removal from the car of the power unit - preparation and safety measures, the general data on a suspension bracket of the power unit
      Removal, partition and installation of the power unit
      Engine major repairs - preliminary data
      Dismantling, clearing, check of a condition and assemblage of a head of cylinders
      Removal, check of a condition and installation of a camshaft and pushers of valves (the engine 1.3)
      Removal and installation of an intermediate shaft (the diesel engine)
      Removal, check of a condition and installation of shatunno-piston assemblages
      Removal and check of a condition of a cranked shaft
      Cleaning and check of a condition of the block of cylinders/kartera of the engine
      Check of a condition and selection of loose leaves radical and шатунных bearings of a cranked shaft
      Assembly order of the engine after major repairs performance
      Installation of a cranked shaft and check of working backlashes of radical bearings
      Installation of piston rings
      Installation of shatunno-piston assemblages on the engine and check of working backlashes шатунных bearings
      Initial start of the engine after end of its major repairs
+ Systems of cooling, heating
+ The power supply system
+ Engine electric equipment
+ Coupling
+ Transmission
+ Power shafts
+ Brake system
+ Suspension bracket and steering
+ Body and salon furnish
+ Onboard electric equipment



Dismantling, clearing, check of a condition and assemblage of a head of cylinders

In the firm services-centres of company Skoda always it is possible to order the restored head that frequently it appears is much more practical, than expenditure of time and forces for performance enough difficult procedures of check and regenerative repair of the old.

DISMANTLING

Engines of 1.3 l

 PERFORMANCE ORDER

1. By means of the special tool serially compress springs of each of valves, removing from their cores crackers of the cutting lock. Releasing the tool, remove from valves of a plate of springs and springs (internal and external).
2. If at сжимании springs the plate does not give in and does not release access to crackers, it is necessary to knock slightly on оправке the tool with an easy hammer.
3. Remove from the directing plug of a saddle of external and internal springs, then by means of flat-nose pliers accurately remove from the plug маслоотражательный a cap.
4. Take the valve through the combustion chamber.

5. At a satisfactory condition of valves and accompanying components, details should be put as their installation on the engine, placing in separate, in special way marked packages.


Engines of 1.6 l and diesel

 PERFORMANCE ORDER

1. On the diesel engine remove atomizers of injection of fuel and a candle накаливания (Heads the Power supply system and an engine Electric equipment see). Remove a final knee of a branch pipe охладительного a path with a lining / a sealing ring.
2. On the engine of 1.6 l turn out from a head of cylinders the case of the thermostat and the gauge-switch of pressure of oil.
3. Remove from a pin of a camshaft a cogwheel of a belt of drive ГРМ.

4. Prepare in special way marked packages for folding in them of removed components клапанного the mechanism. Installation of components in a casual order will lead to the accelerated deterioration of details and premature infringement of functioning of all mechanism.

5. Check up covers of bearings of a camshaft on presence of factory marks. In case of need put labels independently чертилкой or кернером. Отдавание fastening nuts подшипниковых covers it is necessary to make gradually and in regular intervals in order to avoid creation of internal pressure in a shaft body. The order of easing of fixture is described more low.

6. First of all ослабьте nuts of covers of bearings №№ 5, 1 and 3. Then pass to covers of 2nd and 4th bearings. Easing is made in a diagonal order in stages (on a half-turn for the approach) until there will be a possibility отдавания nuts manually.

Covers are numbered consistently (with 1 on 5) from outside arrangements of a belt of drive ГРМ.

7. Remove an old epiploon from the pin of a camshaft turned towards drive ГРМ. At assemblage the epiploon is subject to replacement without fail.
8. Accurately, trying not to incline, take a camshaft from a head. Support a shaft from both ends watch, that it did not cling cams and necks of bearings to ledges in a body to a head.
9. Take hydraulic pushers from the nests and combine them as installation on the engine, a surface contacting to the valve downwards in avoidance вытекания oils. Alternatively, pushers can be placed in the capacities filled with oil. Do not forget that installation of pushers at assemblage in a casual order conducts to the accelerated deterioration of components and premature refusals клапанного the mechanism.
10. Turn a head and lay its side on a workbench. The special tool serially compress a spring of each of valves and take crackers of cutting locks. In a case “прикипания” spring saddles knock on the top sponges of the tool with an easy hammer.

11. Release the tool and remove the top saddle and actually a spring.
12. Flat-nose pliers remove an epiploon from a valve core. Take the valve from a head (a surface from outside interfaced to the block). In case of valve jamming in the directing plug accurately polish its face surface an emery paper. Operating in a former order, remove all remained valves.

13. On the diesel engine it is necessary to check up vortical chambers on presence прогаров and traces закоксовывания. In case of need accurately beat out the defective chamber, having passed выколотку in an aperture of a corresponding atomizer.


Cleaning

 PERFORMANCE ORDER

1. Carefully wash out a head solvent, completely having removed all traces of oil adjournment. It is necessary to give special attention to a condition of necks of a camshaft, nests of pushers and directing plugs of valves. Cautiously scratch out from an interfaced surface of a head all traces of a material of an old lining. Turn a head and a blunt knife remove coal adjournment from surfaces of chambers of combustion and inlet ports.

Try not to admit erosion of working surfaces клапанных saddles. In summary wash out all head suitable solvent, completely having removed all traces of an abrasive.

2. A thin wire brush smooth out plates and cores of valves, preliminary a blunt knife having scratched out from them a great bulk of coal adjournment.

Try not to admit erosion of working surfaces of plates of valves.

3. With solvent application carefully wipe all other removed components. Then carefully them dry. Prepare replaceable epiploons/maslootrazhatelnye caps.


Condition check

Head moulding

 PERFORMANCE ORDER

Repair of valves and a diesel engine head is not obviously possible (except for grinding in). In case of damage or deterioration components are subject to replacement.

1. Attentively examine head moulding, checking it on presence of cracks around fixing apertures, saddles of valves and candle niches. In case of detection of defects of crosspieces between saddles of the next valves address for consultation to experts of car-care centre.

2. Check up a condition of working facets of saddles of valves. Insignificant defects can be eliminated by grinding in of valves. In case of revealing of deep cavities, cracks, traces прогара and other serious defects head restoration becomes possible only in the conditions of a car-care centre workshop.

3. Check up planeness of surfaces of interface of a head with the block, the inlet pipeline and a final collector. Measurements make on diagonals of surfaces. Compare results to requirements of Specifications. On petrol engines elimination insignificant неплоскостности by means of an emery paper is supposed.

4. Requirements also are resulted in the minimum admissible height of a head of cylinders in Specifications. At performance проточки a head do not forget about following moments:
a) Protochka of a head is supposed only with preservation of the minimum adjusting height (if that is stipulated - Specifications see);
b) On termination of проточки it is necessary to pierce interfaced surfaces also facets of saddles of valves, having brought them into accord with new height of a head. Not performance of the given requirement is fraught with damage of components as a result of impact of valves with the bottoms of pistons;
c) Before to start to проточке saddles of valves make sure that there is sufficient for performance of repair a material stock. Removal of a layer of an excessive thickness can lead too strong выступанию rods of valves over end faces of directing plugs and, as consequence, - to infringement of serviceability of functioning of hydraulic pushers. Consult to experts.

For some updatings of engines it is possible to get replaceable valves of the truncated length - address in the firm services-centres of company Skoda.


Camshaft - engines of 1.6 l and diesel


 PERFORMANCE ORDER

The description of procedures of removal and camshaft installation on l models 1.3 is resulted in Section Removal and installation of a belt of drive ГРМ and its covers.

1. On a camshaft identification marks in the form of the labels stamped on its parties between cams of a drive of inlet and final valves are provided. Marks decoding can be executed experts of the firm service-centre of company Skoda.

2. Make visual check of a camshaft on presence on working surfaces of cams and necks of signs of deterioration and other defects. Surfaces should be absolutely smooth and have slightly dim polishing. Presence of scratches, задиров, cavities or заполированных to shine of sites testifies approach of the termination of service life of a shaft. As soon as the layer of superficial training appears damaged, there is a fast deterioration of a shaft and in case of this sort of revealing of its signs it is necessary to replace.

At detection of defects of cams check up also a condition of contact surfaces of corresponding hydraulic pushers.

3. On diesel engines estimate deterioration degree приводной gear wheels of the vacuum pump.
4. In case of revealing of signs of an overheat of the processed surfaces of a shaft (decolouration or bluish colouring), it is necessary to assume possible infringement of serviceability of functioning of system of greasing. The overheat frequently leads to shaft deformations, therefore it is necessary to define size of its palpation. Lay a shaft pins in deepenings of two V-shaped blocks and with the help циферблатного a measuring instrument плунжерного type measure palpation size on the central neck. If the result of measurement exceeds the admissible value stipulated in Specifications, the shaft is subject to replacement.

5. For an estimation of size axial люфта a camshaft temporarily lay it back in a head of cylinders and establish covers of first and last bearings, having tightened their fixing nuts with demanded effort. Fix циферблатный a measuring instrument from outside a forward pin of a shaft (turned towards an arrangement of a belt of drive ГРМ), in parallel a shaft axis. Push a shaft against the stop back (towards a flywheel arrangement), press плунжер a measuring instrument to an end face of a forward pin and null the device. Now displace a shaft forward for all length of its course and read the measuring instrument instrument. Make sure of correctness of check, again having shifted a shaft back and having convinced that the arrow of the device has returned to zero value.

Check axial люфта a camshaft it should be made at the hydraulic pushers of valves removed from a head.

6. Compare result of check falls outside the limits the admissible range stipulated in Specifications, it is necessary to consider variants of forthcoming replacements of a head, a shaft and covers of its bearings - address for consultation to experts of car-care centre.
7. The difference between diameters of bearings and shaft necks defines size working backlashes in bearings and also should not fall outside the limits an admissible range.
8. Diameter of necks of a shaft does not make a reservation in any way manufacturers in view of what composers of the present Management do not recommend to make the given check by direct gaugings with application of a micrometer and нутромера.
9. More suitable way of an estimation of backlashes of bearings in this case is check with application of special set Plastigauge. The backlash size is defined on degree of flattening of pieces of the soft calibrated wire from a set at сжимании it between working surfaces of bearings and shaft necks. Measurement of width of the flattened out pieces of a wire is made on put on packing of a set to a scale.
10. The detailed step-by-step description of performance of the given check is more low resulted. It is necessary to notice that the same method is taken as a principle definitions of working backlashes in radical and шатунных bearings of a cranked shaft (see Has undressed Removal and installation of a head of cylinders in gathering with the inlet pipeline and a final collector).
11. Make sure of absoluteness of cleanliness and dryness of working surfaces of a camshaft, a head of cylinders and covers of bearings. Establish a shaft on the regular place in a head.
12. Lay along necks of a shaft pieces of the calibrated wire from a set.
13. Slightly grease подшипниковые surfaces of each of covers with the special silicone structure preventing sticking of a wire. Establish covers on the places and tighten nuts of their fastening with demanded effort (the instructions resulted in subsection "Assemblage") see.

If the step-by-step tightening of fixture is provided, tighten nuts with effort only the first stage. Do not suppose проворачивания a shaft after installation of covers.

14. Accurately remove covers, lifting them strictly vertically not to break the form of the flattened out pieces of a wire. If a wire, despite the taken measures, подлипла to working surfaces of covers, procedure has to be repeated.
15. On put on packing of a set to a scale measure width of the flattened out pieces of a wire. Scale graduation is that that the read instrument directly equals to size of a defined backlash.
16. Compare the received results to requirements of Specifications. In case of an exit of size of backlashes for admissible limits the camshaft and a head of cylinders are subject to replacement. We will notice that in the firm services-centres of company Skoda it is possible to order a camshaft of the repair size with a set of corresponding loose leaves, but only in the complete set with a replaceable head.
17. In summary, take a shaft and remove from its necks and working surfaces of covers all traces of the flattened out calibrated wire, carefully having scratched out their edge of a credit or payphone card. Then wipe surfaces, definitively having cleared it of the silicone rests.


Valves and accompanying components

 PERFORMANCE ORDER

On one of engines проточка plates of valves it is not provided. Unique admissible way of restoration of quality of consolidation is grinding in of valves to their saddles. If to achieve satisfactory result by such grinding in it is not possible, it is necessary to replace valves.

1. Attentively examine each of valves, estimating degree of their deterioration. Check up cores of valves on presence of signs of step deterioration, scratches, задиров and other mechanical damages. By means of a micrometer measure diameter of each core in several places.

2. Check up plates of valves on presence of cracks, cavities and traces прогара. Minor defects can be eliminated in the course of grinding in (see more low), in case of more serious deterioration valves are subject to replacement.
3. Check up a condition of face surfaces of cores of valves. Presence on them of deep cavities and other this sort of defects can be caused malfunction of hydraulic pushers (engines of 1.6 l and diesel).
4. Serially stacking valves in the V-shaped block, with the help циферблатного a measuring instrument estimate size of palpation of their plates. Admissible values by manufacturers it is not stipulated, however at appreciable size of palpation it is necessary to replace the defective valve.

5. Having filled the valve in the corresponding directing plug, besides with the help циферблатного a measuring instrument, estimate size of its landing backlash. The end face of a core of the valve during measurement should settle down заподлицо with the top cut of the plug.

6. At excessive люфте the valve in the plug both components (both the valve and the plug) are subject to replacement.

Directing plugs внатяг are planted in the nests in a head of cylinders and for their extraction the hydraulic press in view of what performance of the given work will charge more correctly to experts of a car repair shop is required.

7. By means of a calliper нониусного type measure free length of each of клапанных springs. As admissible values of length of springs are not stipulated by manufacturers, unique way of check of their condition is сравнивание results of measurements with length of a new spring. Composers of the present Management recommend to make replacement клапанных springs during engine major repairs without dependence from their condition.

8. Having established a spring vertically, estimate its quality торцовки. In case of need make replacement.

9. Loading valves with special cargoes, estimate size of effort developed by springs. It is better to charge performance of the given check to experts of a car repair shop. Installation of the given springs conducts to increase of the general noise background of the engine and decrease компрессионного pressure in cylinders.


Grinding in of valves

 PERFORMANCE ORDER

1. Restoration of the lost density closing of valves is made by their grinding in to the saddles. Grinding in is carried out with application of several gradation притирочной pastes and adaptations for capture of the valve by means of a sucker.

2. Put on condensed surfaces of a head of cylinders a little мелкодисперсной притирочной pastes. Turn a head combustion chambers upwards and fill the valve in the corresponding directing plug. Fix a capture sucker on a plane of a plate of the valve and begin reciprocating rotary movements ми to grind in its working facet to седл. From time to time raise the valve for the purpose of paste redistribution.

3. Continue grinding in until on a surface of a facet of a saddle there will be no continuous ring of matte polishing of a uniform thickness. Repeat procedure for each of the remained valves.
4. In case of strong damage of working facets grinding in should be begun with application at the first stage of coarse-grained paste, gradually passing to more мелкодисперсным to gradation. It is preliminary necessary to make sure that the residual thickness of a plate and a saddle allow to make deep enough grinding in. On models 1.6 of l and diesel engines at removal of excessively thick layer of a material there is a risk too strong выступания cores of valves over cuts of directing plugs that is fraught with infringement of serviceability of functioning of hydraulic pushers. Before to start grinding in, consult at experts of car-care centre.
5. On termination of the first stage of grinding in (with rough paste) carefully смойте traces of an abrasive solvent, then pass more мелкодисперсной to paste.
6. Having finished grinding in, wash out a head and valves solvent and carefully dry components.


Assemblage - the engine of 1.3 l

 PERFORMANCE ORDER

At use of old components it is necessary to establish them on the engine strictly in a former order. The given condition comes into force also after end of grinding in of new valves - they should be established in a head strictly in those saddles to which got used.

1. Grease cores of valves and fill them in corresponding directing plugs.

2. Since the first valve, put on it saddles at first internal, then external springs.

3. Grease маслоотражательные caps with pure impellent oil and establish them on directing plugs (firm caps Skoda are supplied by special plastic protectors which are used at cap clothing on the valve).

4. Having put on a cap a core, plant it on directing plug. Try not to damage a sponge of a cap in the course of its lowering lengthways on a valve core.

5. Having taken advantage in quality оправки of a face head of the corresponding size, or a piece of a pipe of suitable diameter, densely plant a cap on the plug. If used, remove from the end of a core of the valve a plastic protector.

6. Plant on the saddles internal and external springs)...

... From above put on a clamp plate.

7. By means of the special tool compress клапанные springs and plant in a flute on a core crackers of the cutting lock.

Temporarily to fix crackers to отпускания the tool the small amount консистентной the greasings, put on their inside will help. Release the tool and repeat procedure for the remained valves.

8. Having finished installation of all valves, lay a head on a workbench and обстучите its hammer through wooden брусок on purpose усадки components.
9. Establish a head on the block of cylinders (the Part Repair without extraction from the car of the petrol engine of the present Chapter of 1.3 l see).


Assemblage - engines of 1.6 l and diesel

 PERFORMANCE ORDER

At use of old components it is necessary to establish them on the engine strictly in a former order. The given condition comes into force also after end of grinding in of new valves - they should be established in a head strictly in those saddles to which got used.

1. On diesel engines if removed, hammer blows through wooden брусок plant perpendicularly in the nests vortical chambers. Pay attention to presence in nests of directing flutes.

2. With the help циферблатного a measuring instrument define size выступания vortical chambers over a head surface. If results of measurements exceed the admissible value stipulated in Specifications, it is necessary to make special machining of a head in a workshop of car-care centre for the purpose of prevention of risk of damage of chambers as a result of contact to pistons.

3. Turn a head and lay it on pair wooden blocks. Where it is required, establish at first the bottom saddles of springs the convex party to a head.

4. Greasing cores of valves with pure impellent oil...

... Serially establish them in corresponding directing plugs. Put on the end of a core of the first of valves a special plastic protector.

5. Lower маслоотражательный a cap in pure impellent oil and, having put on it a core...

... Densely plant on directing plug. In quality оправки take advantage of a deep face head of the suitable size.

6. Put on a core of the valve a spring.

7. From above on a spring establish the top saddle...

... Then compress assemblage by the special tool and establish in a flute on стержнесухари the cutting lock.

8. Repeat procedure for the remained valves. For усадки components обстучите end faces of cores of valves a hammer with soft brisk, then make sure of reliability of keeping of the top saddles of springs crackers.

9. Slightly grease with pure impellent oil of a wall of hydraulic pushers and establish them in the nests in a head. Push pushers in nests against the stop them in cores of valves, then grease contacting to cams of a camshaft of a surface.

10. Grease necks of a cranked shaft and подшипниковые surfaces in a head with pure impellent oil, then cautiously lay a shaft on the regular place. Strongly keep a shaft for the ends try not to admit damage of its necks and cams.

11. On diesel models grease with pure impellent oil of a sponge of a new epiploon and put on it a pin of a cranked shaft. Advancing an epiploon along a pin, plant it in the bottom half of casing in a head (the Part Repair without extraction from the car of the diesel engine see).

12. Grease the top part of necks of a camshaft and establish on them covers of bearings.


Petrol engines of 1.6 l

 PERFORMANCE ORDER

1. Make sure of correctness of orientation of covers of bearings of a camshaft. Covers should appear are developed by wider ledges of moulding towards an inlet part of a head. Identification marks should be read at a sight at a head from the final party.

2. Establish on the places of a cover of 2nd and 4th bearings and tighten nuts of their fastening in a diagonal order with effort of the first stage.

3. Grease with hermetic interfaced surfaces of covers of 1st and 5th bearings. Establish on the places 1st, 3rd and 5th covers and tighten fixing nuts with effort of 1st stage.

4. Moving to a diagonal order, hold on fixture of all covers on a corner of the second stage of a tightening (take advantage of a goniometer or template specially made of a dense cardboard).
5. Screw bolts of fastening of a cover of 5th bearing and tighten them with demanded effort.

6. Grease sponges of a new epiploon with pure impellent oil and put on it a camshaft pin. Having taken advantage in quality оправки of a deep face head of the suitable size, begin to knock an epiploon perpendicularly in a nest in a casing against the stop it in the internal terminator (the Part Repair without extraction from the car of the petrol engine of the present Chapter of 1.6 l see).

7. Establish into place a casing of the thermostat and the gauge-switch of pressure of impellent oil.


Diesel engines

 PERFORMANCE ORDER

1. Fixing apertures are drilled in covers asymmetrically that defines unambiguity of installation of the last.

2. At installation of covers of bearings the camshaft should be developed working ledges of cams of valves of the first cylinder upwards.
3. Establish covers of 2nd and 4th bearings and in a diagonal order in regular intervals tighten them with demanded effort.
4. Now establish covers of 1st, 3rd and 5th bearings. Tighten fixing nuts with demanded effort, then make sure of correctness of landing of a cover of 5th bearing, slightly having knocked on a camshaft end face.
5. Establish a branch pipe охладительного a path, in case of need having replaced its lining / a sealing ring.
6. Establish to the place of an atomizer of injection of fuel and a candle накаливания.


All engines

 PERFORMANCE ORDER

1. According to the instructions resulted in Parts Repair without extraction from the car of the petrol engine of 1.6 l, Repair without extraction from the car of the diesel engine of the present Chapter, execute following procedures:

a) Establish into place a camshaft cogwheel;
b) Establish the inlet pipeline and a final collector with new linings.

2. Establish a head on the block of cylinders (the Part Repair without extraction from the car of the petrol engine of 1.6 l or Repair without extraction from the car of the diesel engine of the present Chapter see).