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





Removal, partition and installation of the power unit

REMOVAL

 PERFORMANCE ORDER

Dismantle of the engine from the car is possible only assembled with transmission. The partition of the power unit for the purpose of carrying out capital repairs of the engine can be made later on a workbench or the assembly stand. Assembly of the unit falls from a motive compartment down and then is taken from under the car. Take care of providing sufficient free space under the car and reliability of fixing of the last in the lifted situation (see the Section Removal from the car of the power unit - preparation and precautionary measures, general information about a suspension bracket of the power unit).

1. Park the car on the flat horizontal platform with a hard coating so that around remained rather free space. Remove a cowl (see the Head an engine Assembly order after performance of capital repairs).
2. If the engine understands, merge engine oil and remove an oil filter. Smooth out, screw into place and strongly tighten a drain stopper of the pallet of a case.
3. Prop up wedges back wheels and strongly cock the parking brake. Poddomkratte a car front, having lifted it on height, sufficient for dismantle of the power unit. Reliably record the lifted vehicle on strong props. Remove both forward wheels.
4. Merge gearbox oil, then carefully smooth out, screw into place and tighten a drain stopper.
5. Empty the cooling system.

6. Otboltite a reception pipe of system of production of the fulfilled gases also disconnect it from a flange of a final collector. On petrol models "walk" on an electrical wiring from the l-probe to the socket and disconnect the sensor. Release the socket from a basic arm.

7. According to the instructions provided in the Head the Transmission disconnect a rod of the choice of transfers and a bar of the mechanism of switching from RKPP.

8. Remove the air cleaner (or only an air inlet sleeve) - see the corresponding Part of the Head the Power supply system. On petrol models of 1.3 l and 1.6 l equipped with system of the distributed injection (MPFI) uncover the throttle case.
9. Disconnect the rechargeable battery and remove the generator.

10. Turning counterclockwise an adjusting nut of the drive of coupling, as much as possible weaken a cable. Release the cable core from the coupling switching off lever, and a cover - from the basic arm. Otboltite a basic arm of a cable also remove it together with the grounding tire (if the last is provided).

11. Give a fixing nut with a side setup, then extend a speedometer drive cable for the purpose of a drive conclusion from gearing with a back part of the transmission up. Alternatively, turn out a bolt of a fixing plate and take a driving gear wheel from a box.

12. Disconnect an electrical wiring from the sensor switch of fires of the backing located from below under a forward part of a case of RKPP. At the corresponding complete set, release a sensor switch electrical wiring from a clamp on assembly of a starter.

13. Shift from the main plug of the traction relay of a starter a rubber protective cover back, then give a nut and disconnect the wire going from the battery from the plug. Accurately disunite the bayonet socket of the traction relay.

14. Disconnect an electrical wiring from the oil pressure sensor switch. On petrol models the sensor switch is located from below on a forward wall of the block of cylinders (models of 1.3 l, or in a back part of a head of cylinders (model of 1.6 l), on diesel models - at the left end face of a head.

15. Disconnect электропроводкуот the sensor of temperature of cooling liquid (CTS) located on a thermostat casing, or a cranked branch pipe of a cooling path (the sensor is installed on a branch pipe)...

... and also from the sensor switch...

... and cooling system fan electric motor.

16. On models with the power steering or To/in take off a belt of the drive of auxiliary units.
17. On equipped In models perform the following procedures:

a) Disconnect a hose from a vacuum receiver;
b) Disconnect an electrical wiring from the K/V compressor;
c) Otboltite the compressor from the engine, take him aside and strongly tie up. Try not to allow tension of hoses of refrigerator lines.
18. On models with the power steering remove the steering pump (see the Head Podvesk and steering). There is no need to disconnect hydraulic lines, it is only enough not to subject of them to excessive loadings at pump shift. The pump should be installed so that lines could not be damaged in the course of removal of the power unit.


Petrol models

 PERFORMANCE ORDER

1. On models of 1.3 l with the central injection (SPFI) disconnect the following lines of communication from the inlet pipeline / case of a throttle:

a) Hoses of giving and return of fuel;
b) A throttle case electrical wiring (release bandages, release a plait from intermediate clamps and take him aside);
c) Cable of the drive of a butterfly valve (gas cable);
d) Hose of the vacuum amplifier of brakes;
e) Hoses of a cooling path;
f) Hose of a purge of a coal adsorber;
g) CTS electrical wiring.

2. On models of 1.3 l and 1.6 l with the distributed injection (MPFI) disconnect:

a) Hoses of giving and return of fuel from the fuel pressure regulator;
b) A vacuum hose from the fuel pressure regulator;
c) A power supply system electrical wiring (release bandages, release plaits from intermediate clamps and take them aside);
d) An electrical wiring of the sensor of temperature/pressure of the soaked-up air;
e) On models of 1.3 l - an ignition coil block electrical wiring;

f) Hose of a purge of a coal adsorber;
g) A hose of the vacuum amplifier of brakes from the inlet pipeline;
h) A detonation sensor electrical wiring on the back party of the block of the engine.
i) On the models equipped To/in you otboltit the compressor and shift it from the engine aside, without disconnecting any refrigerator lines at all.
j) Release hoses/tube of a refrigerator path from intermediate clamps and also take them aside from the engine.

3. Disconnect an electrical wiring of the sensor of Hall. On models of 1.3 l the 3-contact electric socket is installed or in the arm fixed on a thermostat casing, or from above on a transmission case. On models of 1.6 l the socket of an electrical wiring of the sensor is on the ignition distributor.

4. If did not do it earlier, disconnect an electrical wiring from the ignition coil.
5. Uncover the distributor, the runner and the filter.


Diesel models

 PERFORMANCE ORDER

1. Disconnect a hose of the servo-driver of the amplifier of brakes from the vacuum pump (see the Head the Brake system).
2. Disconnect a vacuum hose from the EGR valve (see the Head the Power supply system).

3. As required perform the following procedures (see the Part the Power supply system of the diesel engine of the Head of the Power supply system):

a) Release and turn out hollow bolts of nipple connections, then disconnect hoses of giving and return of fuel from TNVD;
b) Release a fixing collar and disconnect a hose of pumping of nozzles from port on the fuel return union;
c) Release collars and remove an inlet air hose from a cover of the inlet pipeline;
d) Disconnect a gas cable from TNVD;
e) Disconnect an electrical wiring from EGR valves and stabilization of turns of idling in a back part of a motive compartment. Try to remember adjusting position of sockets;

f) Disconnect the multicontact socket of a plait of an electrical wiring located under the top support of the left rack of a forward suspension bracket; The Socket has carving landing and for its rassoyedineniye it is necessary to turn a casing. Having dismembered connection, take internal consolidation. Pay attention to existence of the directing marking of red color defining a socket joint order. In order to avoid hit in the socket of moisture and dirt wrap both of its half in a polyethylene film;

g) Disunite two electric sockets installed in an arm on the left side of the engine. Also disconnect the grounding wire located slightly above. Wrap halves of the disunited sockets in a polyethylene film;

h) Where it is required, disunite the generator electrical wiring plait socket.


All models

 PERFORMANCE ORDER

1. Following the instructions provided in Heads Electric equipment of the engine and the Power supply system identify sites of an electrical wiring of systems of electric equipment of the engine, ignition and food which remain connected to sensors and actuation mechanisms on the block of the power unit. Disunite all remained sockets preventing dismantle of the power unit, previously accurately marking them regarding correctness of subjoining at assembly.
2. Depending on model, the power unit can be equipped with one or more tires of grounding. tires usually fasten or on a transmission case, near the right support of the unit, or in the basis of the directing tube of the probe of measurement of level of motive oil. Disconnect all tires.
3. Take power shafts from transmission differential. In order to avoid damage of CV JOINTS at once tie up the released ends of shaft a wire to suspension bracket elements.
4. You will hang out the power unit by means of the winch or a beam, having completely removed its weight from support, but not breaking horizontal position of an arrangement. As extraction of the unit from a motive compartment is made through the lower aperture, it will be unreasonable to prop up it from below.
5. In order to avoid damage of the pallet of a case, enclose an old floor mat, plywood, or just a leaf of a cardboard under a motive compartment. After lowering the unit needs to be displaced forward, having carried out under a bumper for the purpose of final extraction from under the car therefore very opportunely there will be an existence near at hand of a cart jack.

6. Turn out a through bolt of a back support of the power unit - see Part A or B of the present Chapter.

7. Mark the adjusting provision of the left support of the transmission. Give самоконтрящуюся a nut, two bolts and remove a support plate from the top part of a pillow.

8. On models of 1.3 l take a rubber cap from the right mudguard,

having provided thereby access to a through bolt of the right support. Give a nut and take a bolt.

9. On diesel models and models of 1.6 l turn out from below two bolts of the right support directly over a pulley of a bent shaft. Remove washers.
10. Make sure that no communications prevent extraction of the power unit, secure with the help of the assistant and begin to bring accurately assembly out of a motive compartment, trying not to cling to surrounding components, such as a reception pipe of system of production of the fulfilled gases or (at the corresponding complete set) fittings of system of hydrostrengthening of a wheel. Having lowered the unit on the floor/worker the platform of a cart jack, accurately take assembly from under the car.
11. At once transfer the power unit to the assembly stand, or a strong workbench where its dismantling and capital repairs will be made.


Office of the transmission

 PERFORMANCE ORDER

1. Take care of reliability of fixing of the unit on the stand/worker of a surface (in the latter case it is necessary to use in advance prepared wooden bars and wedges)
2. Remove a starter (see the Head Elektrooborudovaniye of the engine).
3. At the corresponding complete set give fixing boats and remove a flywheel cover plate from RKPP case.
4. Give fixture (nuts/bolts) of fastening of a case of the transmission to the engine block. Pay attention that one of bolts is used for fastening of a basic arm of the coupling drive cable removed earlier. Trying not to incline, separate the transmission from the engine, carefully removing from the directing pins. Take freely put pins and put to the reliable place.
5. In case of need remove the coupling switching off mechanism, assembly of a basket and a frictional disk (see the Head Stsepleniye).

INSTALLATION

 PERFORMANCE ORDER

1. If the partition of the unit was not made, pass to paragraph 4 material at once.
2. Slightly grease vents of main shaft RKPP with refractory lubricant (not too be zealous in order to avoid risk of pollution of a frictional clutch plate). Accurately press a box to the engine block, monitoring hit of the directing pins in reciprocal openings.
3. Establish fixing bolts / nuts and by hand tighten them.

It is not necessary to use fixture for a compulsory joint of a box with the engine at all! Make sure of density and uniformity of pressing to each other of the interfaced surfaces a dome of coupling and the block of the engine, only after it start tightening of fixture with the required effort. Do not forget that one of bolts is used for fastening of a basic arm of a cable of the drive of coupling.

4. At the corresponding complete set establish into place a plate of a cover of a flywheel and fix it by bolts.
5. Start assembly of the power unit under a car front.
6. Connect a lifting rigging to block eyes and hang out assembly above the ground
7. By means of the assistant bring the unit to a motive compartment of the car, having provided a possibility of connection of the right support. Tighten fixing bolts (or a through bolt with a nut) with the required effort. On models of 1.3 l establish a rubber cap in an opening of access of the right mudguard.
8. Connect the left support of the transmission - do not forget to lay the plate removed when dismantling on the place. Achieve combination of the landing tags put in the course of dismantle, then tighten bolts and самоконтрящуюся a nut with the required effort
9. Working as it should be, the return to a dismantle order, establish into place a back support of the power unit. Tighten support fixture with the required effort.
10. Disconnect a lifting rigging.
11. Further assembly is made as it should be, the return to a dismantle order. Pay attention to the next moments:

a) Track correctness of laying of plaits of an electrical wiring, without allowing contact of wires with the rubbing or warmed surfaces;
b) Track correctness of laying and reliability of fixing by collars of all hoses. Replace spring collars and collars of the twisted type more reliable worm or screw;
c) At connection of a rod of the choice of transfers do not forget to replace a cylindrical pin, and for fixing use a collar of worm type (see the Head the Transmission);
d) The order of gas station of the cooling system is described in the Head Routine maintenance (depending on engine type);
e) On diesel models after connection to TNVD of a driving cable of cold start do not forget to check and adjust system of cold start.
12. At primary start of the engine check all pipelines, hoses and joints of components for existence of signs of leak of air, cooling liquid, oil and fuel.

Before starting the engine after performance of capital repairs study the remarks provided in the Section Initial start of the engine after completion of its capital repairs.