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
   - Dismantle of the power unit and capital repairs of the engine
      Removal from the car of the power unit - preparation and precautionary measures, general information about a suspension bracket of the power unit
      Removal, partition and installation of the power unit
      Capital repairs of the engine - preliminary data
      Dismantling, cleaning, check of a state and assembly of a head of cylinders
      Removal, check of a state and installation of the camshaft and pushers of valves (engine of 1.3 l)
      Removal and installation of an intermediate shaft (diesel engine)
      Removal, check of a state and installation of conrod and piston assemblies
      Removal and check of a condition of a bent shaft
      Cleaning and check of a condition of the block of cylinders/case of the engine
      Check of a state and selection of inserts of radical and conrod bearings of a bent shaft
      Engine assembly order after performance of capital repairs
      Installation of a bent shaft and check of working gaps of radical bearings
      Installation of piston rings
      Installation of conrod and piston assemblies on the engine and check of working gaps of conrod bearings
      Initial start of the engine after completion of its capital repairs
+ 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





Installation of conrod and piston assemblies on the engine and check of working gaps of conrod bearings

Engine of 1.3 l

Check of working gaps of bearings

 PERFORMANCE ORDER

1. At installation of the pierced bent shaft complete with company inserts of production of the Skoda company need for the checks described below disappears.
2. Check of a working gap in conrod bearings has to be made in the presence of the slightest doubts at assessment of degree of wear of conrod necks of a shaft, and also after a pro-point of a shaft and a complete set by its inserts of not company production. Check can be made by one of two methods.
3. The first method yields less exact results and demands a pribolchivaniye of covers to the lower heads of rods, undressed on necks of a shaft (inserts at the same time have to be enclosed in the beds). Fix covers of the lower heads of rods by old nuts, having tightened them with the required effort. Further, by means of a nutromer or Columbus equipped with a vernier scale measurement of internal diameters of assembled bearings is performed. Diameter of the corresponding neck of a bent shaft is subtracted from the result received for each of assemblies then.
4. The second method is based on application of the calibrated wire from the Plastigauge set (see the Section Installation of a Bent Shaft and Check of Working Gaps of Radical Bearings). All components have to are carefully wiped and are established without lubricant.
5. Lay along NMT of necks of cranks which are in provisions the pieces of a plastic wire corresponding on length from measuring set. Put on rods necks, establish to the place of a cover of conrod bearings and tighten nuts/bolts of their fastening with the required effort. Try not to displace the pieces of the calibrated wire laid on shaft necks.
6. Without turning rods, uncover and determine the size of working gaps of bearings by extent of flattening of a wire. Measurement of thickness of the flattened-out wire is performed on the scale put on packing to the Plastigage set. Compare results of measurements to requirements of Specifications. If results of measurements differ from stipulated in Specifications, it is necessary to check whether the established inserts are correctly picked up for the size. Make sure also that between backs of inserts and beds of bearings foreign particles did not get. Once again measure diameters of conrod necks of a bent shaft. If width of the flattened-out piece of the calibrated wire from one of the ends is more than from opposite, it is necessary to check the corresponding neck of a shaft for existence of excessive conicity. In case of need replace an insert or give a shaft to a pro-point with a selection of new inserts of the corresponding repair size (with belittling). In conclusion carefully scratch out traces of the flattened-out wire from shaft necks edge of an old credit card. Turn a shaft, having brought pistons of the second and third cylinders into provisions of NMT and repeat check for the remained bearings.


Final installation of conrod and piston groups

 PERFORMANCE ORDER

1. Before implementation of the procedure make sure of correctness of landing of sleeves in cylinders of the block and reliability of their fixing by special rectangular washers (see the Section Cleaning and check of a condition of the block of cylinders/case of the engine). The bent shaft and covers of radical bearings have to be finalized on the engine.
2. Wipe backs of inserts and enclose them in the beds in the lower heads of rods and their covers. At installation of new inserts, track that from them traces of the preserving lubricant were completely removed - use kerosene or other suitable solvent for rubbing of inserts. Dry wipe pure inserts неворсящейся with rags. Wipe with the same rags rods.
3. Densely put inserts in a bed, having tracked hit of the directing uvulas in reciprocal selections in rods and conrod covers. Try not to touch a working surface of inserts. Old inserts, suitable for further use, have to be established strictly in former provisions.
4. Grease mirrors of cylinders, pistons and piston rings with pure motive oil. Spread out conrod and piston assemblies on a pure working surface as their installation on the engine.
5. Begin with installation of conrod and piston assembly of the first cylinder. Make sure that locks of piston rings are still deployed the friend in relation to the friend under the correct corners (see the Section Installation of Piston Rings). Press out rings a mandrel of the special tool.
6. At the top enter the corresponding assembly into the first cylinder of the engine a rod forward. Take care of incidentally not to scratch a cylinder mirror. Track that the tag in the form of an arrow was directed to the bottom of the piston towards a GRM drive arrangement. Pay attention that a rod have to it is developed maslotoky also forward on the engine.

7. Упершись the wooden handle of the hammer in the piston bottom, push his skirt in the cylinder, having densely pressed the tool mandrel which is pressing out rings to the surface of the block. Continuing to press densely a mandrel, push the piston further until its bottom appears aflush with the surface of the block of cylinders interfaced to a head.

8. Make sure of correctness of landing in the beds of inserts of the conrod bearing. Plentifully grease a neck of the first crank of a bent shaft with pure engine oil. The same oil both inserts.
9. Watching to damaging a sleeve mirror, accurately put on the lower head of a rod the shaft neck given to situation by NMT.

10. Establish a cover of the conrod bearing, having tracked correctness of combination of landing tags.

11. Screw fixing nuts (a rim to a cover) and in stages evenly tighten them with the required effort. Check freedom of rotation of a bent shaft, then you pass to installation of the next assembly.

12. Working in a similar manner, install all remained conrod and piston assemblies on the engine.
13. Check freedom of a provorachivaniye of a shaft. Presence of insignificant resistance is quite natural and is explained by a neprirabotannost of new components, however existence of obvious breakthroughs and points of jamming is not admissible in any way.


Engines of 1.6 l and diesel

Check of working gaps of bearings


 PERFORMANCE ORDER

It is meant that the bent shaft is already installed in the engine (see the Section Installation of a Bent Shaft and Check of Working Gaps of Radical Bearings).

1. As well as in radical, in conrod bearings there has to be strictly certain working gap providing effective greasing of the rubbing surfaces of sliding.
2. Lay the block of cylinders on a workbench a case up. Bring cranks of the first and fourth cylinders into provisions of NMT. Determination of size of working gaps in bearings can be made by one of two methods.
3. The first method yields less exact results and demands a pribolchivaniye of covers to the lower heads of rods, undressed on necks of a shaft (inserts at the same time have to be enclosed in the beds).

Correctness of orientation of covers is important extremely (see the Section Removal, check of a state and installation of shatunnoporshnevy assemblies). Fix covers of the lower heads of rods by old bolts / nuts, having tightened them with the required effort. Further, by means of a nutromer or Columbus equipped with a vernier scale measurement of internal diameters of assembled bearings is performed. Diameter of the corresponding neck of a bent shaft is subtracted from the result received for each of assemblies then.

4. The second method is based on application of the calibrated wire from the Plastigauge set (see the Section Installation of a Bent Shaft and Check of Working Gaps of Radical Bearings). All components have to are carefully wiped and are established without lubricant.
5. Lay along NMT of necks of cranks which are in provisions the pieces of a plastic wire corresponding on length from measuring set. Make sure of correctness of landing of inserts in the beds, then put on rods necks, establish to the place of a cover of conrod bearings (track correctness of combination of marking)
6. Tighten nuts/bolts of their fastening with effort of the first stage. Try not to displace the pieces of the calibrated wire laid on shaft necks.
7. Without turning rods, uncover and determine the size of working gaps of bearings by extent of flattening of a wire. Measurement of thickness of the flattened-out wire is performed on the scale put on packing to the Plastigage set. Compare results of measurements to requirements of Specifications.
8. If results of measurements significantly differ from stipulated in Specifications, it is necessary to check whether the established inserts are correctly picked up for the size. Make sure also that between backs of inserts and beds of bearings foreign particles did not get. Once again measure diameters of conrod necks of a bent shaft. If width of the flattened-out piece of the calibrated wire from one of the ends is more than from opposite, it is necessary to check the corresponding neck of a shaft for existence of excessive conicity. In case of need replace an insert or give a shaft to a pro-point with a selection of new inserts of the corresponding repair size (with belittling).
9. In conclusion carefully scratch out traces of the flattened-out wire from shaft necks edge of an old credit card. Turn a shaft, having brought pistons of the second and third cylinders into provisions of NMT and repeat check for the remained bearings.
Check of a pretightness of landing of inserts of conrod bearings on engines of 16 l.

10. Measure by Columbus equipped with a vernier scale the internal diameter of collected lower heads of rods. Then measure the outer diameter of inserts. Subtract results of the second from results of the first calculation - the received size defines a pretightness of landing of inserts and should not be lower than the value stipulated in Specifications. Otherwise inserts are subject to replacement.


Final installation of conrod and piston groups

 PERFORMANCE ORDER

1. The bent shaft and covers of radical bearings have to be installed on the engine (see the Section Installation of a Bent Shaft and Check of Working Gaps of Radical Bearings).
2. Make sure of correctness of landing of inserts in the beds. At installation of new inserts, track that from them traces of the preserving lubricant were completely removed - use kerosene or other suitable solvent for rubbing of inserts. Dry wipe pure inserts неворсящейся with rags. Wipe with the same rags rods.
3. Densely put inserts in a bed, having tracked hit of the directing uvulas in reciprocal selections in rods and conrod covers. Try not to touch a working surface of inserts. Old inserts, suitable for further use, have to be established strictly in former provisions.
4. Grease mirrors of cylinders, pistons and piston rings with pure motive oil. Spread out conrod and piston assemblies on a pure working surface as their installation on the engine.
5. Begin with installation of conrod and piston assembly of the first cylinder. Make sure that locks of piston rings are still deployed the friend in relation to the friend under the correct corners (see the Section Installation of Piston Rings). Press out rings a mandrel of the special tool.
6. At the top enter the corresponding assembly into the first cylinder of the engine a rod forward. Take care of incidentally not to scratch a cylinder mirror. Track that the tag in the form of an arrow was directed to the bottom of the piston towards a GRM drive arrangement. Pay attention that a rod have to it is developed maslotoky also forward on the engine.
7. Упершись the wooden handle of the hammer in the piston bottom, push his skirt in the cylinder, having densely pressed the tool mandrel which is pressing out rings to the surface of the block. Continuing to press densely a mandrel, push the piston further until its bottom appears aflush with the surface of the block of cylinders interfaced to a head.
8. Make sure of correctness of landing in the beds of inserts of the conrod bearing. Plentifully grease a neck of the first crank of a bent shaft with pure engine oil. The same oil both inserts.
9. Watching to damaging a sleeve mirror, accurately put on the lower head of a rod the shaft neck given to situation by NMT.

10. Establish a cover of the conrod bearing, having tracked correctness of combination of landing tags.

11. Screw fixing nuts (a rim to a cover) and in stages evenly tighten them with the required effort. Check freedom of rotation of a bent shaft, then you pass to installation of the next assembly.

12. Working in a similar manner, install all remained conrod and piston assemblies on the engine.
13. Check freedom of a provorachivaniye of a shaft. Presence of insignificant resistance is quite natural and is explained by a neprirabotannost of new components, however existence of obvious breakthroughs and points of jamming is not admissible in any way.


Diesel engines

 PERFORMANCE ORDER

1. At installation of new pistons or the new block of the shortened complete set it is necessary to check height of a vystupaniye of VMT of pistons given to situation over a head of cylinders for the purpose of selection of the required laying of a head.
2. Turn the block a case down and lay it on wooden blocks. Fix the dial measuring instrument of plunger type on the block, nullify it and press a plunger to the bottom of the piston of the first cylinder. Slowly turning a bent shaft manually, carry out the piston through VMT. Write down the indication.
3. Repeat the procedure, having measured the size of a vystupaniye of the piston of the 4th cylinder, then turn a shaft on 180 ° and take measurements for pistons of the 2nd and 3rd cylinders.
4. If results of measurements differ from each other, as the basic indication it is necessary to take maximum. Compare result to requirements of Specifications.
5. At installation of old pistons, suitable for further use, it is necessary to pick up the laying equal for thickness of old removed from the engine.