Skoda Felicia

since 1994 release

Repair and operation of the car



Skoda Felicia
+ Cars of the Skoda Felicia brand
+ Maintenance instruction
+ Routine maintenance
+ Repair of the engine
+ Cooling systems, heating
+ Power supply system
+ Engine electric equipment
+ Coupling
+ Transmission
+ Power shafts
- Brake system
   General information
   System design, description of separate knots and mechanisms
   Pumping of hydraulic system
   Replacement of hoses and tubes of a hydraulic path of the brake system
   Replacement of blocks of disk brake mechanisms of forward wheels
   Replacement of boots of drum brake mechanisms of back wheels
   Check of a state, removal and installation of disks of forward brake mechanisms
   Removal, check of a state and installation of reels of brake mechanisms of back wheels
   Removal, capital repairs and installation of supports of brake mechanisms of forward wheels
   Removal, capital repairs and installation of wheel cylinders of back brake mechanisms
   Removal, capital repairs and installation of the main brake cylinder (MBC)
   Removal and installation of a pedal of a foot brake
   Check of serviceability of functioning, removal and installation of the vacuum amplifier of brakes
   Removal, check of a state and installation of the control valve of the vacuum amplifier of brakes with a hose
   Adjustment of the parking brake
   Removal and installation of the lever of the parking brake
   Removal and installation of cables of the drive of the parking brake
   Check of serviceability of functioning, removal and installation of the valve regulator of pressure in hydraulic contours of brake mechanisms of back wheels
   Removal, installation and adjustment of the sensor switch of stoplights
   System of anti-blocking of brakes (ABS) - the general information
   Removal and installation of components of the ABS systems
   Removal and installation of the vacuum pump (diesel models)
   Check of a state and capital repairs of the vacuum pump (diesel models)
+ Suspension bracket and steering
+ Body and finishing of salon
+ Onboard electric equipment





Removal, capital repairs and installation of the main brake cylinder (MBC)

Before starting performing procedures attentively study the text of the prevention at the beginning of the Section System Design, the description of separate knots and mechanisms.

At assembly new fixing nuts and a sealing ring will be necessary.

REMOVAL

Models without ABS

 PERFORMANCE ORDER

1. Carefully wipe the surface of the GTTs tank and uncover with it. Take the filter and pump out hydraulic liquid from the tank.

Do not suck away brake fluid a mouth at all - use the syringe or a rubber pear! Alternatively, open the gate of pumping of any of brake mechanisms, connect to it a drain hose and empty the tank, extorting liquid in drain capacity by squeezing of a pedal of a foot brake.

2. Release a lock uvula of fastening of the tank and remove the last from the basic plugs on GTTs.
3. Wipe surfaces of walls of the cylinder around nipple connections of brake lines. Under unions for collecting the spilled liquid enclose rags. Remembering an order of connection of tubes, release nipple nuts and disconnect lines. At once to a zakuporta the open ends of tubes and unions for the purpose of minimization of losses of brake fluid and in order to avoid hit in system of dirt. Collect traces of the spilled liquid by rags.
4. Give nuts of fastening of GTTs on the block of the servo-driver of the vacuum amplifier of brakes, remove washers.

At assembly of a nut are subject to replacement without fail.

5. Remove GTTs from the block of the servo-driver of the vacuum amplifier together with a sealing ring.

The sealing ring at assembly is subject to replacement without fail.

6. In view of absence on sale of replaceable internal components, capital repairs of the failed GTTs are not possible. It is necessary to replace defective assembly new. The only subjects to replacement with components are rubber plugs of support of fastening on tank GTTs. Both plugs are just densely put in the nests.


The equipped ABS models

 PERFORMANCE ORDER

On the models equipped with ABS before a rassoyedineniye of hydraulic brake lines without fail switch-off the rechargeable battery. It is necessary to connect the battery only after connection of all hydraulic lines of a brake path. Violation of this requirement is fraught with hit in the hydraulic modulator of air which removal in the course of usual pumping of system (see the text of the Section) is not possible and demands use of a special electronic tester (VAG 1552).

1. Disconnect a negative wire from the battery, then uncover the GTTs tank. Pump out hydraulic liquid from the tank.

Do not suck away brake fluid a mouth at all - use the syringe or a rubber pear!

2. Remove a finger of fastening of a lock uvula of a clamp and accurately remove the tank from the GTTs case, having released it from rubber sealing plugs.
3. Wipe surfaces of walls of the cylinder around nipple connections of brake lines. Under unions for collecting the spilled liquid enclose rags. Remembering an order of connection of tubes, release nipple nuts and disconnect lines. At once to a zakuporta the open ends of tubes and unions for the purpose of minimization of losses of brake fluid and in order to avoid hit in system of dirt. Collect traces of the spilled liquid by rags.
4. Give nuts of fastening of GTTs on the block of the servo-driver of the vacuum amplifier of brakes, remove washers.

At assembly of a nut are subject to replacement without fail.

5. Release a basic arm of the hydraulic modulator from the servo-driver block, then remove GTTs with a sealing ring.

The sealing ring at assembly is subject to replacement without fail.

6. In view of absence on sale of replaceable internal components, capital repairs of the failed GTTs are not possible. It is necessary to replace defective assembly new. The only subjects to replacement with components are rubber plugs of support of fastening on tank GTTs. Both plugs are just densely put in the nests.


Capital repairs

 PERFORMANCE ORDER

1. The leak of brake fluid developing between a flange of GTTs and the case of the servo-driver of the vacuum amplifier of brakes or increase in the course of a pedal of a foot brake testify to need of performance of capital repairs of assembly of the cylinder. Repairs are recommended to be made in the conditions of masterful car repair shop.
2. Remove GTTs.
3. Release the tank of brake fluid from plugs of reception nests through passage of GTTs.
4. Take rubber plugs through passage from nests.
5. Take pins of restriction of the course of pistons from inlet openings of the cylinder - to turn assembly upside down enough and to shake.
6. Deploy the cylinder vertically and, striking with a landing flange in wooden whetstone, serially beat out from it at first one piston, then the second.
7. Attentively examine the interfaced surface of the case of the cylinder on existence of cavities and mechanical damages. Minor defects can be removed by grinding with use of fine-grained polishing paste. Upon completion of grinding wipe the processed surface with methyl alcohol. In case of more serious damages the cylinder should be replaced.
8. Wash out all removed components in pure brake fluid, or methyl alcohol.

Do not apply to washing of the GTTs components at all gasoline or other solvents on an oil basis as remove contact will lead to destruction of rubber elements. Having finished washing, attentively study a condition of details, paying special attention to elasticity of cuffs of pistons (for removal from pistons of old cuffs it is possible to use the screw-driver; to lead use of the screw-driver for installation of new cuffs to irreversible failure).

9. Check also a condition of the rubber plugs through passage taken from nests under landing of connecting branch pipes of the tank of brake fluid.
10. Having replaced the worn-out or failed components, you can start assembly of the device (see further).
11. Moisten a cylinder mirror with pure brake fluid.
12. Install on pistons sealing cuffs, and on their cores of a washer under installation of springs.
13. Put on a returnable spring a core of shorter piston (an end face of smaller diameter [rounds with the shortened step?] forward). Fill assembly of the piston with a spring in the cylinder (a spring forward). Having rested a drift against a piston bottom, squeeze its spring approximately on 0.5 cm and, holding assembly in this situation, fill the corresponding pin of restriction of a piston stroke in an inlet opening.
14. Working in the manner similar described in the previous paragraph put on a returnable spring a core of the second piston. Fill assembly of the piston with a spring in the cylinder (a spring forward). Enter a drift into deepening in an end face of the piston and, overcoming spring resistance, bury the piston at about 2 cm below the interfaced surfaces of a landing flange. Holding the piston in this situation, fill a persistent pin in the second inlet opening of the cylinder.
15. As far as time having pressed a drift, check freedom of movement of pistons in the cylinder.
16. Remove a drift and with effort put in openings under landing of a persistent pin rubber plugs through passage.
17. Before installation of assembly of GTTs check the size of a vystupaniye of an adjusting tip of a rod of a pusher of the servo-driver of the vacuum amplifier and depth of landing of the piston in the cylinder (distance from the interfaced flange surfaces to the bottom of deepening in the piston). The difference between results of the first and second measurements has to make 0.3 ÷ 0.6 mm. Existence of such gap is an indispensable condition of correct functioning of GTTs and the vacuum amplifier. Correction of a gap is reached by rotation of a tip on the end of a bar of a pusher. Remark: In the conditions of the masterful station servicing definition of an adjusting gap of a pusher is made by means of special adaptation.
18. Now you can start assembly installation.

INSTALLATION

 PERFORMANCE ORDER

1. Carefully smooth out the interfaced surfaces of GTTs and the block of the vacuum amplifier. Establish in a flute from the back party of the case of the cylinder a new sealing ring.
2. Place GTTs on the block of the vacuum amplifier. Make sure that the rod of a pusher of the servo-driver enters the central part of the piston of the cylinder. Establish washers, screw new fixing nuts and tighten them with the required effort.
3. Wipe nipple knots of brake tubes and connect the last on the former places to GTTs. Strongly tighten cap nipple nuts.
4. Slightly grease with fresh brake fluid rubber sealing plugs in the top part of GTTs and densely put in them the tank of hydraulic liquid. Fix the tank on the cylinder, having latched a lock uvula of a clamp.
5. Fill in in the GTTs tank fresh hydraulic liquid (to mark MOVE) and execute full pumping of hydraulic system (see the Section Pumping of Hydraulic System). Establish into place a tank cover. Before starting operation of the car check serviceability of functioning of the brake system.


The equipped ABS models

 PERFORMANCE ORDER

1. Carefully smooth out the interfaced surfaces of GTTs and the block of the vacuum amplifier. Establish in a flute from the back party of the case of the cylinder a new sealing ring.
2. Having taken aside from the block of the servo-driver of the vacuum amplifier the hydraulic modulator, establish on the regular place place GTTs. Track that the rod of a pusher of the servo-driver entered the central part of the piston of the cylinder. Return into place the modulator, having put its arm on hairpins of the block of the vacuum amplifier, then establish washers, screw new fixing nuts and tighten them with the required effort.
3. Slightly grease with fresh brake fluid rubber sealing plugs in the top part of GTTs and densely put in them the tank. Fix the tank on the cylinder, having established a lock finger.
4. Before connection of brake lines it is necessary to remove air from the main cylinder. For this purpose fill in fresh hydraulic liquid in GTTs and establish drain capacity under unions. Ask the assistant several times at an interval of 5 seconds to squeeze out a pedal of a foot brake. When from the cylinder liquid, free from air bubbles, begins to be pushed out, pumping can be stopped. Fill in liquid also in brake tubes. Ask the assistant to squeeze out a pedal and to record it in the lower situation and connect brake tubes to the cylinder. Strongly tighten cap nipple nuts. After connection of both tubes the pedal can be released. Remove drain capacity and wash away splashes clear cold water.
5. Fill in in the GTTs tank fresh hydraulic liquid (to mark MOVE) and execute full pumping of hydraulic system (see the Section Pumping of Hydraulic System). Establish into place a tank cover. Before starting operation of the car check serviceability of functioning of the brake system.