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
   - Repair without extraction from the car of the diesel engine
      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 tightness of combustion chambers
      Removal and installation of a belt of the GRM drive and its covers
      Removal and installation of a natyazhitel and cogwheels of a belt of the GRM drive
      Removal, installation and adjustment 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 an epiploon of an intermediate shaft
      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
      Flywheel - removal, check and installation
      Support of the power unit - check and replacement
      The pallet - removal, check and installation
      Removal and installation of the oil pump and assembly of a maslozabornik
   + 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.
3. Empty the cooling system (see the Head Routine maintenance).
4. Take off a belt of the drive of auxiliary units (see the Section Removal, installation and adjustment of a tension of a belt of the drive of auxiliary units).
5. Having squeezed lock uvulas, release a spring collar and remove an air inlet sleeve from a cover of the inlet pipeline.
6. Perform the following procedures (see the Head of the Cooling system, heating):
a) Release collars and disconnect radiator hoses from branch pipes on a head of cylinders;
b) Release collars and disconnect a hose of a broad tank, and also inlet and final hoses of a heater from branch pipes on a head of cylinders.

7. According to the instructions provided in the Head the Power supply system perform the following procedures:

a) Disconnect from nozzles and a head of TNVD and remove fuel supply tubes;
b) Disconnect a returnable hose of nozzles from the TNVD returnable union;
c) Previously accurately having marked an electrical wiring, disunite all electric sockets of a power supply system.

8. Working in the order described in 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, Removal and installation of a cover of a head of cylinders, perform the following operations:

a) Uncover a head of cylinders;
b) Remove external covers of a gas-distributing belt and throw off a belt from a camshaft cogwheel;
c) Remove a natyazhitel of a gas-distributing belt, and also cogwheels of the camshaft and TNVD.
9. 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.
10. 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.
11. Turn out fixing screws and remove an internal cover of a gas-distributing belt.

12. According to indications of the Head the Power supply system of the Head Elektrooborudovaniye of the engine perform the following procedures:

a) Under the car turn out fixing bolts and separate a reception pipe of system of production of the fulfilled gases from a flange of a final collector;
b) Remove the EGR valve and its connecting fittings from the inlet pipeline and a final collector;
c) Otboltite the giving wire from a candle of heat of the fourth cylinder.

13. Disunite the socket of an electrical wiring of CTS and two sockets put in the next arm.

14. Disconnect an electrical wiring from the sensor switch of pressure of motive oil and the grounding tire located below.

15. 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. At assembly bolts are subject to replacement without fail.

16. 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).
17. If the head "stuck" and does not give in to separation from the block, do not try to bring down it blows of the hammer at all - do not forget about the directing pins! Instead, carefully shake assembly for a pipeline/collector - do not try to enter the lever between the interfaced surfaces!
18. Remove laying from the surface of the block interfaced to a head. Do not throw out it, having kept as a template. Check durability of landing of the directing pins, in case of need take from the nests.


Separation from a head of the inlet pipeline and final collector

 PERFORMANCE ORDER

1. Having laid a head on a workbench, turn out five bolts of fastening of a cover of the inlet pipeline. Uncover also its sealing laying.
2. Turn out fixing bolts and remove from a head four inlet pipes assembled with the pipeline. Remove sealing laying.
3. In stages weaken and turn out fixing nuts (at assembly defective nuts are subject to replacement) and remove from a head of cylinders a final collector with laying.
4. 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.
5. Lay new laying on a head, then establish on it assembly of the inlet pipeline. Serially establish each of inlet pipes, then screw fixing bolts 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 or a fine-grained emery paper. In case of more serious damages it is necessary to resort to machine machining. Estimate planeness of the interfaced surfaces by means of a special template (an edge of a steel ruler) and the probe of lezviyny type.
3. 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.

4. 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. Identification marking can have an appearance of the punched openings, рисок, or warranty number, located on edge of laying. If replacement of pistons was not made, laying of the same standard size, as removed in the course of dismantle has to be installed on the engine.

2. Otherwise new laying is selected by results of measurements of height of a vystupaniye of new pistons.
3. Carefully wipe the interfaced surfaces of a head and the block of cylinders with pure dry rags, then lay new laying on the block, accurately putting on it the directing pins. If the directing pins are not provided, instead of them couple of the paragraph made according to instructions 4 subsections Preparation for assembly of devices for a carving clearing can be screwed in bolted openings of the block. Laying has to keep within marking up.
4. 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.

5. Slightly grease a carving and the lower surfaces of heads of fixing bolts with lubricating oil.

6. Accurately fill each of bolts in the opening and acquire manually.

7. In the set order in stages tighten bolts with effort of the first stage of tightening, then repeat the procedure and tighten bolts with effort of the second stage.

8. Having tightened bolts with effort of the second stage, use a special goniometer, or the template made of a dense cardboard and hold on bolts on a corner of thirds of a stage of tightening. In conclusion hold on bolts on a corner of the fourth stage.
9. Establish into place a GRM drive belt vnutrennyuyukryshka, strongly tighten bolts of its fastening.
10. 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).
11. Prop up the engine, disconnect the right support and slightly lower the power unit (see the Section Removal and installation of a belt of the GRM drive and its covers). Now establish into place cogwheels of a gas-distributing belt (see the Section Removal and installation of a natyazhitel and cogwheels of a belt of the GRM drive). Establish a belt and adjust effort of its tension, then establish into place external covers and a pulley of a bent shaft (see the Section Removal and installation of a belt of the GRM drive and its covers).
12. Now the engine can be lifted and installed to the place of a support of the power unit again (see the Section Removal and installation of a belt of the GRM drive and its covers).
13. Establish a belt of the drive of auxiliary units and adjust effort of its tension (see the Section Removal and installation of a belt of the GRM drive and its covers).
14. Further installation is made as it should be, the return to a dismantle order:

a) The description of procedures of installation of the EGR valve and a wire of food of a glow plug is provided in the Head the Power supply system;
b) Following the instructions provided in the Head the Power supply system, connect the giving fuel hoses to nozzles and a head of TNVD. Restore initial connection of an electrical wiring of a power supply system. Connect a returnable hose to the TNVD corresponding union;
c) Do not forget connect the multicontact socket of a braid of an electrical wiring of the engine;
d) Establish into place a cover of a head of cylinders (see the Section Removal and installation of a cover of a head of cylinders);
e) Address materials of the Head of the Cooling system, heating restore initial connection of hoses of a radiator and a broad tank. Connect an electrical wiring to CTS;
f) Connect a negative wire to the battery.
15. In conclusion fill in necessary amount of engine oil of the required grade in the engine.