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
   + 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
      Description of the main knots and mechanisms
      Reduction of the piston of the first cylinder in the provision of the top dead point (TDP) of the end of a step of compression
      Check of compression pressure - an order of carrying out and interpretation of results
      Removal and installation of a belt of the GRM drive and its covers
      Removal, check of a state and installation of cogwheels and natyazhitel of a belt of the GRM drive
      Removal, installation and adjustment of effort of a tension of a belt of the drive of auxiliary units
      Removal and installation of a cover of a head of cylinders
      Replacement of an epiploon of the camshaft
      Replacement of epiploons of a bent shaft
      Removal and installation of a head of cylinders assembled with the inlet pipeline and a final collector
      Check of serviceability of functioning of hydraulic pushers
      Removal, check of a state and installation of a flywheel
      Check of a state and replacement of support of the power unit
      Removal and installation of the pallet of a case of the engine
      Removal and installation of the oil pump and maslozabornik
   + Repair without extraction from the car of the diesel engine
   + Dismantle of the power unit and capital repairs of the engine
+ Cooling systems, heating
+ Power supply system
+ Engine electric equipment
+ Coupling
+ Transmission
+ Power shafts
+ Brake system
+ Suspension bracket and steering
+ Body and finishing of salon
+ Onboard electric equipment





Removal and installation of a head of cylinders assembled with the inlet pipeline and a final collector

REMOVAL

 PERFORMANCE ORDER

1. Park the car on the spacious flat horizontal platform with a hard coating.
2. Disconnect a negative wire from the battery.

If the stereosystem established on the car is equipped with the security device before disconnecting the battery make sure that you have the correct code for input of the audio system in action.

3. Empty the cooling system and turn out spark plugs.
4. Remove the air cleaner with components of an inlet air path (see the Head the Power supply system). Remove a sleeve of supply of the warmed-up air from branch pipes of the air cleaner and a plate of a casing of a final collector.
5. Dump residual pressure in a power supply system (see the Head the Power supply system).
6. Uncover the distributor with the wires connected to it by VV, also remove the runner and the filter. It is optional to remove a head of cylinders (the wire will be to disconnect VV from the ignition coil enough), however it will significantly expand working space and will facilitate access to the distributor.

7. Having in case of need addressed Chapter 3 materials, release fixing collars and disconnect hoses of a cooling path from a thermostat casing.

8. Disunite sockets of an electrical wiring of the following components:

a) Sensor of a detonation and l-probe. Release both sockets from the arm fixed over a flywheel;
b) The sensor of temperature/pressure of the soaked-up air on the inlet pipeline;
c) Control unit of a butterfly valve;
d) Hall's sensor from the ignition distributor;

e) The oil pressure sensor switch on a back wall of a head of cylinders.
f) An injector(s) of fuel and a plait of an electrical wiring on the inlet pipeline (in case of need see the Head the Power supply system). Release a plait from intermediate clamps and put it aside);
g) The sensor of temperature of cooling liquid (CTS) on a thermostat casing;
h) Having disunited all sockets, release plaits from intermediate clamps and take them aside.

9. Disconnect the following hoses:

a) The hose connecting the inlet pipeline to the electromagnetic valve of a purge of a coal adsorber (on a mudguard of an arch of the left wheel);
b) A vacuum hose of the amplifier of brakes from the inlet pipeline;
c) Hoses of giving and return of fuel from the fuel highway. Try to remember the direction of streams and color marking of hoses. Prepare for collecting the spilled fuel. At once to a zakuporta the open ends of hoses and unions in order to avoid hit in a power supply system of dirt and for the purpose of minimization of losses of fuel.

10. In a back part of the thermostat release wire clamps of fastening of a casing to the giving tube of the water pump passing behind the engine block. Disconnect remained from a thermostat casing (try to remember an order of their connection).
11. Take off a belt of the drive of auxiliary units (see the Section Removal, installation and adjustment of effort of a tension of a belt of the drive of auxiliary units).
12. Remove external covers of a gas-distributing belt and a pulley of a bent shaft (see the Sections Reduction of the Piston of the First Cylinder in the provision of the top dead point (TDP) of the end of a step of compression, Removal and installation of a belt of the GRM drive and its covers). Take off a gas-distributing belt from a camshaft cogwheel.
13. After removal of a gas-distributing belt the engine can be lifted back in a starting position, and the right support of the unit is connected.
14. In order to avoid casual contact of pistons with valves in the course of removal of a head, authors of the present manual recommend to develop a bent shaft back in situation by several degrees before VMT.
15. Remove a plate of the device of heating of the soaked-up air from the top part of a final collector.

... disconnect a reception pipe of system of production of the fulfilled gases from a collector. Remove laying.

16. Turn out a bolt of fastening of the directing tube of the probe of measurement of level of motive oil to a back part of a head of cylinders. At the corresponding complete set to an otboltita also remove a basic arm of the inlet pipeline.
17. Disconnect a gas cable (see the Head the Power supply system).
18. Uncover a head of cylinders (see the Section Removal and installation of a cover of a head of cylinders).

19. Working in the order specified illustrations...

... in stages (on a half-turn for approach) weaken bolts of fastening of a head so that the possibility of a reversing their hands appeared.

20. Make sure that to a head of cylinders did not remain connected any lines of communication. Remove a head from the block of cylinders (in case of need use the help of the assistant, in particular if the head is removed assembled with the pipeline and a collector).
21. Remove laying from the surface of the block interfaced to a head. Do not throw out it, having kept as a template.
22. If performance of capital repairs of a head is supposed.
Separation from a head of the inlet pipeline and final collector
23. The description of procedures of removal and installation of the inlet pipeline is provided to the Head the Power supply system.
24. In stages give the remained fixing nuts (at assembly of a nut are subject to replacement without fail) and remove from a head of cylinders a final collector with laying.
25. Carefully smooth out the interfaced surfaces, lay new laying, then establish a final collector. Screw new fixing nuts and tighten them with the required effort.

PREPARATION FOR ASSEMBLY

 PERFORMANCE ORDER

1. By means of the scraper made of soft material carefully smooth out the interfaced surfaces of a head and the block. Remove all traces of material of old laying and coal deposits from surfaces. Smooth out also the bottoms of pistons. Try not to allow hits of garbage in water galleries and maslostok (coal particles are capable to block tightly supply of oil to internal components of the engine) - close up all available openings with an adhesive tape. Gaps between walls of pistons and cylinders in the same purposes should be filled with jellied lubricant which then will be easy to be removed by means of a thin brush.
2. Check the interfaced surfaces of the block and a head of cylinders for existence of scratches, zadir and other mechanical damages. Insignificant defects can be removed by means of a file with small tooth. In case of more serious damages it is necessary to resort to machine machining.
3. Estimate planeness of the interfaced surfaces by means of a special template (an edge of a steel ruler) and the probe of lezviyny type.
4. Check a condition of bolts of fastening of a head, special attention paying them to a carving part. Wash out boats in solvent, then carefully dry. Defective bolts are subject to replacement. Measure length of each of fixing bolts for the purpose of identification of signs of their pulling (this check cannot be considered unambiguous as all bolts can be extended at identical length). Authors of the present manual recommend to make replacement of bolts of fastening of a head regardless of their state.

5. Banish bolted openings in the block of cylinders a suitable tap, cleaning a carving and restoring the damaged rounds.

In the absence of near at hand suitable tap of an opening can be cleaned by means of the self-made adaptation manufactured of a long hairpin with the carving which is sawn through lengthways.

6. In order to avoid damage of pistons and valves authors of the present manual recommend to take away before installation of a head a bent shaft on 90 ° from the provision of VMT back (in case of need address materials of the Section Description of the Main Knots and Mechanisms).

ASSEMBLY

 PERFORMANCE ORDER

1. Make sure of compliance of replaceable laying on a standard size removed from the engine. Carefully wipe the interfaced surfaces of a head and the block of cylinders with pure dry rags, then lay new laying on the block, having tracked correctness of combination of all provided openings. Laying has to keep within marking up. Screw in couple of bolted openings of the block long hairpins with the vents which are sawn through in a face part under the screw-driver. These hairpins will be used as the directing pins at installation of a head.

2. Make sure of correctness of combination of adjusting tags of a cogwheel of the camshaft and an internal cover of a gas-distributing chain (see the Section Reduction of the Piston of the First Cylinder in the provision of the top dead point (TDP) of the end of a step of compression). Try not to allow shaft provorachivaniye in the course of installation of a head.
3. By means of the assistant accurately put on assembly of a head with the pipeline and a collector the directing hairpins. Before final lowering of a head on the block once again make sure of correctness of placement of laying.
4. Slightly grease a carving and the lower surfaces of heads of fixing bolts with high-quality refractory lubricant.
5. Accurately fill each of bolts in the opening and acquire manually.

6. In the set order...

. in stages tighten bolts with effort of the first stage of tightening.

7. Moving in a former order, tighten bolts with effort of the second stage.

8. Having used a special goniometer, or the template made of a dense cardboard, hold on bolts on a corner of thirds of a stage of tightening.

9. In conclusion hold on bolts on a corner of the fourth stage.
10. Establish into place a cover of a head of cylinders (see the Section Removal and installation of a cover of a head of cylinders).
11. If removed, install into place ignition distributor components (see the Head Elektrooborudovaniye of the engine).
12. Establish a hose collar of nipple connection of the giving tube on a thermostat casing.
13. Connect a gas cable, in case of need make its adjustment (see the Head the Power supply system).
14. Establish the directing tube of the probe of measurement of level of motive oil on a head. Tighten a fixing bolt.
15. Connect to a final collector a reception pipe of system of production of the fulfilled gases (see the Head the Power supply system). Establish a plate of a casing of the device of heating of the soaked-up air.
16. At the taken-off gas-distributing belt bring the engine into the provision of VMT (see the Section Reduction of the Piston of the First Cylinder in the provision of the top dead point (TDP) of the end of a step of compression).
17. Prop up the engine, disconnect the right support and slightly lower the power unit. Remove external covers of a gas-distributing belt and a pulley of a bent shaft (see the Section Removal and installation of a belt of the GRM drive and its covers).
18. Now the unit can be lifted in and to connect its right support (see the Section Removal and installation of a belt of the GRM drive and its covers).
19. Establish a belt of the drive of auxiliary units and adjust effort of its tension (see the Section Removal, installation and adjustment of effort of a tension of a belt of the drive of auxiliary units).
20. Further assembly is made an order, the return to a dismantle order:

a) Restore initial connection of all hoses and an electrical wiring;
b) Establish into place assembly of the air cleaner (see the Head the Power supply system);
c) Fill the cooling system and check the level of motive oil;
d) Connect a negative wire to the battery.