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





Dismantling, cleaning, check of a state and assembly of a head of cylinders

In company service centers of the Skoda company it is always possible to order the restored head that is often much more practical, than a waste of time and forces on performance enough difficult procedures of check and recovery repair of old.

DISMANTLING

Engines of 1.3 l

 PERFORMANCE ORDER

1. By means of the special tool serially squeeze springs of each of valves, removing crackers of the cutting lock from their cores. Releasing the tool, remove from plate valves of springs and springs (internal and external).
2. If when tightening a spring the plate does not give in and does not release access to crackers, it is necessary to knock slightly on a tool mandrel with the easy hammer.
3. Remove from the directing plug of a saddle of external and internal springs, then by means of flat-nose pliers accurately remove a maslootrazhatelny cap from the plug.
4. Take the valve via the combustion chamber.

5. At satisfactory condition of valves and the accompanying components, the detail should put as installation them on the engine, placing in the separate, in a special way marked packages.


Engines of 1.6 l and diesel

 PERFORMANCE ORDER

1. On the diesel engine remove nozzles of injection of fuel and a glow plug (see Chapters the Power supply system and Electric equipment of the engine). Remove a final knee of a branch pipe of a cooling path with laying / a sealing ring.
2. On the engine of 1.6 l turn out the case of the thermostat and the sensor switch of pressure of oil from a head of cylinders.
3. Remove a GRM drive belt cogwheel from a camshaft pin.

4. Prepare in a special way the marked packages for folding in them the removed components of the valvate mechanism. Installation of components in a casual order will result in the accelerated wear of details and premature violation of functioning of all mechanism.

5. Check covers of bearings of the camshaft for existence of factory marking. In case of need put tags independently with a chertilka or a center punch. Otdavaniye of nuts of fastening of bearing covers should be made gradually and evenly in order to avoid creation of internal tension in a shaft body. The order of weakening of fixture is described below.

6. First of all weaken nuts of covers of bearings No. No. 5, 1 and 3. Then you pass to covers of the 2nd and 4th bearings. Easing is made in a diagonal order in stages (on a half-turn for approach) until the possibility of an otdavaniye of nuts manually appears.

Covers are numbered consistently (with 1 on 5) from a GRM drive belt arrangement.

7. Remove an old epiploon from the camshaft pin turned towards the GRM drive. At assembly the epiploon is subject to replacement without fail.
8. Accurately, trying not to incline, take the camshaft from a head. Support a shaft since both ends and you watch that it did not cling cams and necks of bearings to ledges in a body to a head.
9. Take hydraulic pushers from the nests and put them as the installation on the engine contacting to the valve a surface down in order to avoid an oil effluence. Alternatively, pushers can be placed in the capacities filled with oil. Do not forget that installation of pushers at assembly in a casual order leads to the accelerated wear of components and premature failures of the valvate mechanism.
10. Turn a head and lay it sideways on a workbench. The special tool serially squeeze a spring of each of valves and take crackers of cutting locks. In case of "prikipaniye" of a saddle of a spring knock on the top sponges of the tool with the easy hammer.

11. Release the tool and remove the top saddle and actually a spring.
12. Flat-nose pliers remove an epiploon from a valve core. Take the valve from a head (from the surface interfaced to the block). In case of jamming of the valve in the directing plug accurately polish its face surface an emery paper. Working in a former order, remove all remained valves.

13. On the diesel engine it is necessary to check vortex cameras for existence of progar and traces of coking up. In case of need accurately beat out the defective camera, having passed a drift throughout an opening of the corresponding nozzle.


Cleaning

 PERFORMANCE ORDER

1. Carefully wash out a head solvent, having completely removed all traces of oil deposits. Special attention should be paid to a condition of necks of the camshaft, nests of pushers and the directing plugs of valves. Carefully scratch out all traces of material of old laying from the interfaced head surface. Turn a head and remove with a blunt knife coal deposits from the surfaces of combustion chambers and inlet ports.

Try not to allow erosion of working surfaces of valvate saddles. In conclusion wash out all head suitable solvent, having completely removed all traces of an abrasive.

2. A thin wire brush smooth out plates and cores of valves, previously blunt knife having scratched out from them the bulk of coal deposits.

Try not to allow erosion of working surfaces of plates of valves.

3. With use of solvent carefully wipe all other removed components. Then carefully dry them. Prepare replaceable epiploons / маслоотражательные caps.


Check of a state

Casting of a head

 PERFORMANCE ORDER

Repair of valves and heads of the diesel is not possible (except for grinding in). In case of damage or wear components are subject to replacement.

1. Attentively examine casting of a head, checking it for existence of cracks around fixing openings, saddles of valves and candle niches. In case of detection of defects of crossing points between saddles of the next valves address for consultation specialists of car service.

2. Check a condition of working facets of saddles of valves. Insignificant defects it can be eliminated by grinding in of valves. In case of identification of deep cavities, cracks, traces of a progar and other serious defects restoration of a head becomes possible only in the conditions of a workshop of car service.

3. Check planeness of surfaces of interface of a head to the block, the inlet pipeline and a final collector. You perform measurements on diagonals of surfaces. Compare results to requirements of Specifications. On petrol engines elimination of insignificant not planeness by means of an emery paper is allowed.

4. Requirements to the minimum admissible height of a head of cylinders are also provided in Specifications. When performing a pro-point of a head do not forget about the next moments:
a) The pro-point of a head is allowed only with preservation of the minimum adjusting height (if that is stipulated - see Specifications);
b) Upon completion of a pro-point the interfaced surfaces it is also necessary to pierce facets of saddles of valves, having brought them into accord with the new height of a head. Not implementation of this requirement is fraught with damage of components as a result of impact of valves with the bottoms of pistons;
c) Before starting a pro-point of saddles of valves make sure that there is a material reserve, sufficient for repair performance. Removal of a layer of excessive thickness can lead to too strong vystupaniye of rods of valves over end faces of the directing plugs and, as a result, - to violation of serviceability of functioning of hydraulic pushers. Consult to experts.

For some modifications of engines it is possible to buy replaceable valves of the shortened length - address in company service centers of the Skoda company.


The camshaft - engines of 1.6 l and diesel


 PERFORMANCE ORDER

The description of procedures of removal and installation of the camshaft on models of 1.3 l is provided in the Section Removal and installation of a belt of the GRM drive and its covers.

1. On the camshaft identification marking in the form of the tags stamped on its parties between cams of the drive of inlet and final valves is provided. Interpretation of marking can be executed by experts company service center of the Skoda company.

2. Make visual check of the camshaft on existence on working surfaces of cams and necks of signs of wear and other defects. Surfaces have to be absolutely smooth and have slightly dim polishing. Presence of scratches, zadir, cavities or sites, zapolirovanny to gloss, testifies approach of the termination of service life of a shaft. As soon as the layer of superficial training is damaged, there is a bystry wear of a shaft and in case of identification of this sort of signs it should be replaced.

At detection of defects of cams check also a condition of contact surfaces of the corresponding hydraulic pushers.

3. On diesel engines estimate degree of wear of a driving gear wheel of the vacuum pump.
4. In case of identification of signs of an overheat of the processed shaft surfaces (decolouration or bluish coloring), it is necessary to assume possible violation of serviceability of functioning of the lubrication system. The overheat often leads to deformations of a shaft therefore it is necessary to determine the size of its beating. Lay a shaft pins in deepenings of two V-shaped blocks and by means of the dial measuring instrument of plunger type measure beating size on the central neck. If the result of measurement exceeds the admissible value stipulated in Specifications, the shaft is subject to replacement.

5. For assessment of size of an axial side play of the camshaft temporarily lay it back in a head of cylinders and establish covers of the first and last bearings, having tightened their fixing nuts with the required effort. Fix the dial measuring instrument from the forward pin of a shaft (turned towards a GRM drive belt arrangement), parallel to a shaft axis. Push a shaft against the stop back (towards a flywheel arrangement), press a measuring instrument plunger to an end face of a forward pin and nullify the device. Now displace a shaft forward at all length of its course and read the instrument of the measuring instrument. Make sure of correctness of check, again having shifted a shaft back and having convinced that the arrow of the device returned to zero value.

Check of an axial side play of the camshaft it has to be made at the hydraulic pushers of valves removed from a head.

6. Compare result of check exceeds the limit of the admissible range stipulated in Specifications, it is necessary to consider options of the forthcoming replacements of a head, a shaft and covers of its bearings - address for consultation specialists of car service.
7. The difference between diameters of bearings and necks of a shaft determines size working gaps in bearings and also should not exceed the limit of admissible range.
8. Diameter of necks of a shaft does not make a reservation manufacturers in any way in view of what authors of the present manual do not recommend to make this check by direct measurements with application of a micrometer and nutromer.
9. More suitable way of assessment of gaps of bearings in this case is check with use of the special Plastigauge set. The size of a gap is determined by extent of flattening of pieces of the soft calibrated wire from set at its tightening between the working surfaces of bearings and necks of a shaft. Measurement of width of the flattened-out pieces of a wire is performed on the scale applied on set packing.
10. The detailed step-by-step description of performance of this check is given below. It is necessary to notice that the same method is the basis for definition of working gaps in radical and conrod bearings of a bent shaft (see the Section Removal and installation of a head of cylinders assembled with the inlet pipeline and a final collector).
11. Make sure of absoluteness of purity and dryness of working surfaces of the camshaft, a head of cylinders and covers of bearings. Establish a shaft on the regular place in a head.
12. Lay along shaft necks pieces of the calibrated wire from set.
13. Slightly grease bearing surfaces of each of covers with the special silicone structure preventing sticking of a wire. Establish covers on the places and tighten nuts of their fastening with the required effort (see the instructions provided in the subsection "Assembly").

If step-by-step tightening of fixture is provided, tighten nuts with effort only of the first stage. Do not allow a shaft provorachivaniye after installation of covers.

14. Accurately uncover, lifting them strictly vertically not to break a form of the flattened-out wire pieces. If a wire, despite the taken measures, a podlipl to working surfaces of covers, the procedure it is necessary to repeat.
15. On the scale applied on set packing measure width of the flattened-out wire pieces. Graduation of a scale such is that the read instrument directly equals to the size of the defined gap.
16. Compare the received results to requirements of Specifications. In case of an exit of size of gaps out of admissible limits the camshaft and a head of cylinders are subject to replacement. Let's notice that in company service centers of the Skoda company it is possible to order the camshaft of the repair size with a set of the corresponding inserts, but only in a set with a replaceable head.
17. In conclusion, take a shaft and remove all traces of the flattened-out calibrated wire from his necks and working surfaces of covers, having carefully scratched out them edge of a credit or payphone card. Then wipe surfaces, having finally cleared it of the silicone remains.


Valves and the accompanying components

 PERFORMANCE ORDER

On one of engines the pro-point of plates of valves is not provided. The only admissible way of restoration of quality of consolidation is grinding in of valves to their saddles. If it is not possible to achieve satisfactory result by such grinding in, valves should be replaced.

1. Attentively examine each of valves, estimating degree of their wear. Check cores of valves for existence of signs of step wear, scratches, zadir and other mechanical damages. By means of a micrometer measure diameter of each core in several places.

2. Check plates of valves for existence of cracks, cavities and traces of a progar. Minor defects can be eliminated in the course of grinding in (see below), in case of more serious wear valves are subject to replacement.
3. Check a condition of face surfaces of cores of valves. Existence on them deep cavities and other defects of this sort can be caused by malfunction of hydraulic pushers (engines of 1.6 l and diesel).
4. Serially stacking valves in the V-shaped block, by means of the dial measuring instrument estimate the size of a beating of their plates. Admissible values by manufacturers it is not stipulated, however at the noticeable size of a beating the defective valve should be replaced.

5. Having filled the valve in the corresponding directing plug, besides by means of the dial measuring instrument, estimate the size of its landing gap. The valve core end face during measurement has to settle down aflush with the top cut of the plug.

6. At an excessive side play of the valve in the plug both components (both the valve and the plug) are subject to replacement.

The directing plugs внатяг are put in the nests in a head of cylinders and their extraction requires a hydraulic press in view of what performance of this work will be more correct to be charged to specialists of car repair shop.

7. By means of a caliper of vernier type measure the free length of each of valvate springs. As admissible values of length of springs are not stipulated by manufacturers, the only way of check of their state is comparison of results of measurements with a length of a new spring. Authors of the present manual recommend to make replacement of valvate springs during capital repairs of the engine regardless of their state.

8. Having established a spring vertically, estimate quality of its tortsovka. In case of need make replacement.

9. Loading valves with special freights, estimate the size of the effort developed by springs. It is better to charge performance of this check to specialists of car repair shop. Installation of the sunk springs leads to increase in the general noise background of the engine and decrease in compression pressure in cylinders.


Grinding in of valves

 PERFORMANCE ORDER

1. Restoration of the lost density closing of valves is made by their grinding in to the saddles. Grinding in is carried out with use of several gradation of pritirochny paste and the device for capture of the valve by means of a sucker.

2. Apply on the condensed surfaces of a head of cylinders of a little fine pritirochny paste. Turn a head combustion chambers up and fill the valve in the corresponding directing plug. Fix a capture sucker on the plate plane of the valve and begin reciprocating rotary the movements ми to grind in it a working facet to седл. From time to time raise the valve for the purpose of paste redistribution.

3. Continue grinding in until on a surface of a facet of a saddle the continuous ring of opaque polishing of uniform thickness does not appear. Repeat the procedure for each of the remained valves.
4. In case of strong damage of working facets grinding in should be begun with application at the first stage of coarse-grained paste, gradually passing to more fine gradation. It is previously necessary to make sure that the residual thickness of a plate and a saddle allow to make rather deep grinding in. On models of 1.6 l and diesel engines at removal of excessively thick layer of material there is a risk of too strong vystupaniye of cores of valves over cuts of the directing plugs that is fraught with violation of serviceability of functioning of hydraulic pushers. Before starting grinding in, consult at specialists of car service.
5. Upon completion of the first stage of grinding in (with rough paste) carefully wash away abrasive traces solvent, then you pass to more fine paste.
6. Having finished grinding in, wash out a head and valves solvent and carefully dry components.


Assembly - the engine of 1.3 l

 PERFORMANCE ORDER

When using old components it is necessary to install them on the engine strictly in a former order. This condition comes into force also after completion of grinding in of new valves - they have to be installed in a head strictly in those saddles to which got used.

1. Grease cores of valves and fill them in the corresponding guides of the plug.

2. Since the first valve, put on it saddles at first of internal, then external springs.

3. Oil maslootrazhatelny caps pure motive and install them on the directing plugs (company caps of Skoda are supplied with special plastic protectors which are used when clothing a cap on the valve).

4. Having put on a cap a core, put him on the directing plug. Try not to damage cap sponges in the course of lowering it lengthways on a valve core.

5. Having used a face head of the corresponding size, or a piece of a pipe of suitable diameter as a mandrel, densely put a cap on the plug. If used, remove a plastic protector from the end of a core of the valve.

6. Put on the saddles internal and external springs)...

... from above put on a plate of a clamp.

7. By means of the special tool squeeze valvate springs and put in a flute on a core crackers of the cutting lock.

It is temporary the small amount of jellied lubricant applied on their inside will help to record crackers to a tool otpuskaniye. Release the tool and repeat the procedure for the remained valves.

8. Having finished installation of all valves, lay a head on a workbench and tap it the hammer through wooden whetstone for the purpose of shrinkage of components.
9. Install a head on the block of cylinders (see the Part Repair without extraction from the car of the petrol engine of 1.3 l of the present Chapter).


Assembly - engines of 1.6 l and diesel

 PERFORMANCE ORDER

When using old components it is necessary to install them on the engine strictly in a former order. This condition comes into force also after completion of grinding in of new valves - they have to be installed in a head strictly in those saddles to which got used.

1. On diesel engines if removed, blows of the hammer through wooden whetstone put perpendicularly in the nests vortex cameras. Pay attention to existence in nests of the directing flutes.

2. By means of the dial measuring instrument determine the size of a vystupaniye of vortex cameras over a head surface. If results of measurements exceed the admissible value stipulated in Specifications, it is necessary to make special machining of a head in a workshop of car service for the purpose of prevention of risk of damage of cameras as a result of contact with pistons.

3. Turn a head and lay it on pair of wooden blocks. Where it is required, establish at first the lower saddles of springs by the convex party to a head.

4. Oiling cores of valves pure motive...

... serially establish them in the corresponding guides of the plug. Put on a special plastic protector the end of a core of the first of valves.

5. Lower a maslootrazhatelny cap in pure motive oil and, having put on it a core...

... densely put on the directing plug. As a mandrel use a deep face head of the suitable size.

6. Put on a spring a valve core.

7. From above on a spring establish the top saddle...

... then squeeze assembly by the special tool and establish in a flute on sterzhnesukhar of the cutting lock.

8. Repeat the procedure for the remained valves. For shrinkage of components tap end faces of cores of valves the hammer with soft brisk, then make sure of reliability of keeping of the top saddles of springs crackers.

9. Slightly oil pure motive walls of hydraulic pushers and establish them in the nests in a head. Push pushers in nests against the stop them in cores of valves, then grease contacting to surface camshaft cams.

10. Grease necks of a bent shaft and bearing surfaces in a head with pure motive oil, then carefully lay a shaft on the regular place. Strongly hold a shaft for the ends and try not to allow injuries of his necks and cams.

11. On diesel models oil pure motive sponges of a new epiploon and put on it a pin of a bent shaft. Advancing an epiploon along a pin, put it in the lower half of the casing in a head (see the Part Repair without extraction from the car of the diesel engine).

12. Grease the top part of necks of the camshaft and establish on them covers of bearings.


Petrol engines of 1.6 l

 PERFORMANCE ORDER

1. Make sure of correctness of orientation of covers of bearings of the camshaft. Covers have to are developed by wider ledges of casting towards an inlet part of a head. Identification marking has to be read at a view of a head from the final party.

2. Establish covers of the 2nd and 4th bearings on the places and tighten nuts of their fastening in a diagonal order with effort of the first stage.

3. Grease with sealant the interfaced surfaces of covers of the 1st and 5th bearings. Establish the 1st, 3rd and 5th covers on the places and tighten fixing nuts with effort of the 1st stage.

4. Moving in a diagonal order, hold on fixture of all covers on a corner of the second stage of tightening (use a goniometer or the template which is specially made of a dense cardboard).
5. Screw bolts of fastening of a cover of the 5th bearing and tighten them with the required effort.

6. Oil sponges of a new epiploon pure motive and put on it a camshaft pin. Having used a deep face head of the suitable size as a mandrel, begin to knock an epiploon perpendicularly in a nest in a casing against the stop it in the internal limiter (see the Part Repair without extraction from the car of the petrol engine of 1.6 l of the present Chapter).

7. Establish into place a casing of the thermostat and the sensor switch of pressure of motive oil.


Diesel engines

 PERFORMANCE ORDER

1. Fixing openings are drilled in covers asymmetrically that defines unambiguity of installation of the last.

2. At installation of covers of bearings the camshaft has to be deployed by working ledges of cams of valves of the first cylinder up.
3. Establish covers of the 2nd and 4th bearings and in a diagonal order evenly tighten them with the required effort.
4. Now establish covers of the 1st, 3rd and 5th bearings. Tighten fixing nuts with the required effort, then make sure of correctness of landing of a cover of the 5th bearing, having slightly knocked on a camshaft end face.
5. Establish a branch pipe of a cooling path, having in case of need replaced its laying / a sealing ring.
6. Establish to the place of a nozzle of injection of fuel and a glow plug.


All engines

 PERFORMANCE ORDER

1. According to the instructions provided in Parts Repair without extraction from the car of the petrol engine of 1.6 l, Repair without extraction from the car of the diesel engine of the present Chapter perform the following procedures:

a) Establish into place a camshaft cogwheel;
b) Install the inlet pipeline and a final collector with new laying.

2. Install a head on the block of cylinders (see the Part Repair without extraction from the car of the petrol engine of 1.6 l or Repair without extraction from the car of the diesel engine of the present Chapter).