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 and check of a condition of a bent shaft

Assembly of a bent shaft - general information

The bent shaft is forged from steel. The shaft has three radical and four conrod necks. Cranks with conrod necks of the first and second cylinders are located between the first and second radical necks of a shaft; between the second and thirds radical necks located cranks of the third and fourth conrod necks.

 


and - Width of a radical neck
b - Ø conrod neck
And - Ø of a radical neck

For the purpose of decrease in the loading falling on radical bearings cranks are equipped with the shod counterbalances counterbalancing the centrifugal forces arising between two next support.

All cranks and necks of a bent shaft are equipped with internal maslotoka on which oil arrives to inserts of bearings.

Cranks are not subject to processing. As for necks and both pins of a bent shaft, they are carefully processed. Both radical, and conrod necks are exposed to superficial training by current of high frequency. Diameter of radical necks makes 60 mm, conrod - 45 mm.

The end face of a back pin of a bent shaft is equipped with a flange under landing of a flywheel. Consolidation of landing of a back pin in the block is reached by means of an epiploon of the size of 85х105х12 mm.

The forward pin of a shaft represents the neck used under landing of a gear wheel / asterisk of the belt/chain drive of the camshaft, and also a pulley of a wedge-shaped belt of the drive of auxiliary units (the water pump and the generator). Sealing of landing of a forward pin is provided with a forward epiploon (42х58х8 mm).

Both epiploons are made of a ftorkauchuk and differ in the increased reliability and durability.

The size of an axial side play of a shaft is controlled by installation of special remote rings and a persistent washer which are established on the first radical neck of a shaft. Remote rings are stopped from a provorachivaniye by the ledge provided on outer side. The admissible size of an axial side play of a bent shaft is presented in Specifications at the beginning of the present Chapter.

Persistent rings besides the nominal thickness (1.480 ÷ 1.490 mm), are issued also repair sizes: 1.605 ÷ 1.615 mm, 1.703 ÷ 1.740 mm and 1.855 ÷ 1.865 mm.

Rings of the bigger size always should be established from the pro-polished side surface of a cheek of a crank. From a persistent washer the ring of the nominal size is always established.

In case of wear the persistent washer (loss of smoothness of side surfaces) is subject to replacement.

All bent shafts on production are exposed to static and dynamic balancing with an accuracy of 0.2 Nanometers.

Covers of radical bearings of a bent shaft are made of cast iron and fasten to the block of cylinders by means of bilateral bolts of M11. On covers tags in the form of figures "1", "2" or "3" are cast. At the same time the cover with number "1" has to be established on the bearing, next to the GRM drive, with number "3" - on the next to a flywheel, and number "2" - on average.

Inserts of bearings of a bent shaft are executed from the thin steel strip covered from within with a layer of alloy of special structure. Thickness of a layer makes 0.35 mm. Radical inserts have width of 24 mm at a thickness of 2.5 mm, conrod - 22 m at 1.5 mm.

On all length of each of the top radical inserts there passes the flute serving for a supply of the engine oil arriving through an opening of an oval form in an insert. On face surfaces of half rings of inserts the locks providing unambiguity of landing of half rings and their fixing from a provorachivaniye are equipped.

and — Radical inserts
b — Connecting rods
1 — the Top inserts
2 — the Lower inserts


Connecting rods differ in smoothness of a surface and are not equipped with locks.

No marking, on inserts is provided, and therefore, their thickness is defined by means of a micrometer.

Inserts remain suitable for the further use if they are not too worn-out, do not leave an excessive working gap of bearings, are free from cracks, scratches and chips of a blanket. defective inserts are subject to replacement without fail. Authors of the present manual recommend to make replacement of inserts in a set for all bearings at the same time.

Before starting check of a condition of a bent shaft, it needs to be cleared of traces of lubricant and dirt. In case of detection of obvious defects, and also in case of lack of confidence in assessment of a condition of a shaft, it should be replaced. Upon completion of any kind of recovery repair it is necessary to clean all maslotok of a shaft carefully. (at first use kerosene, then blow openings compressed air).

REMOVAL

 PERFORMANCE ORDER

1. Remove a head of cylinders, a chain and asterisks of the GRM drive (see the Part Repair without extraction from the car of the petrol engine of 1.3 l of the present Chapter). Record sleeves of cylinders.
2. Uncover with bent a shaft of the lower heads of rods. In case of need remove conrod assemblies (see the Section Removal, check of a state and installation of conrod and piston assemblies).
3. Before starting extraction of a bent shaft, perform the following operations:

a) Temporarily put on a shaft pin an external persistent washer (flutes of maslotok outside from a bearing cover), combine a lock tag with a groove on a cover and put a washer against the stop in the nest. Make sure that the tag of an internal persistent washer also enters a reciprocal groove in the cover;
b) Having established a persistent washer, put on the big remote plug (a slanted inner edge to the block), an adjusting washer, a segment spline (the slanted party inside) and an asterisk of a gas-distributing chain;
c) Establish a pulley of a bent shaft, screw a pulley bolt (do not forget about a washer) and tighten it with the required effort, having taken the appropriate measures against a shaft provorachivaniye (see the Section Removal, check of a state and installation of a flywheel). Let's notice that the wrong installation of persistent washers will lead to jamming of a shaft in the course of tightening of a bolt of a pulley. As a result of such jamming washers easily can be damaged.

4. By means of the dial measuring instrument of plunger type measure an axial side play of a bent shaft. Fix the measuring instrument so that its plunger rested against an end face of a forward pin of a shaft, and settled down parallel to an axis of the last. Shift a shaft against the stop back, nullify the device, then push a shaft forward at all length of its course and consider the indication of the measuring instrument. Compare result to requirements of Specifications. The size of an axial side play is regulated by selection of a persistent washer.

5. Alternatively axial side play of a shaft can be measured by means of the probe of lezviyny type. Shift a shaft until the end of its course towards a flywheel, then the probe measure gap thickness between a cheek of the first crank and a persistent washer.

6. Remove all temporarily installed components. Also remove a flywheel (see the Section Removal, check of a state and installation a flywheel).

7. Turn out fixing screws and remove assembly of a casing of a back epiploon from a shaft pin. Remove laying of a casing (if that is provided). At assembly laying is subject replacements without fail.

8. Check covers of radical bearings for existence of identification marking. Usually marking is presented by tags in the form of figures with 1 on 3, reading out from the party of a pulley. If marking is absent, then put it independently (use a center punch as did it when marking conrod covers).

Besides number of a cover the arrangement of tags has to specify the adjusting direction of covers unambiguously.

9. Turn out fixing bolts and uncover radical bearings together with inserts.
10. Take a bent shaft and remove a persistent washer from its right pin. Try to remember the adjusting provision of a washer.
11. Take the top inserts of radical bearings from the beds and put them together with lower, as installation on the engine.


Engines of 1.6 l and diesel

 PERFORMANCE ORDER

If performance of any works on restoration of conrod and piston assemblies is not supposed, need for removal of a head and pistons disappears. Will only be to shift pistons up cylinders enough, having removed the lower heads of rods from necks of a bent shaft. Work is recommended to be performed at the assembly stand.

1. According to the instructions provided in 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 perform the following procedures:

a) Remove a cogwheel of the belt drive of the GRM drive from a bent shaft;
b) Remove components of assembly of coupling and a flywheel;
c) Remove the case pallet, a maslootrazhatel (if it is provided) and the oil pump with a maslozabornik;
d) Remove assemblies of casings of forward and back epiploons.
2. In case of need remove pistons with rods (see the Section Removal, check of a state and installation of conrod and piston assemblies).

3. Working measure the size of an axial side play of a bent shaft in the manner similar described for the engine of 1.3 l. The size of an axial side play is regulated by selection of thickness of persistent washers.

4. Alternatively the side play can be defined by means of the probe of lezviyny type, having measured by it the maximum size of a gap between a cheek of the 2nd crank and a persistent washer. Compare the received result to requirements of Specifications.

5. Check covers of radical bearings for existence of factory marking. Digital tags are put as an arrangement of covers in the direction from the GRM drive to a flywheel.

6. In stages (on 1/4 turns for approach) weaken bolts of fastening of covers, then turn out them manually. Having slightly tapped the hammer with soft brisk, uncover together and inserts. Attach inserts to the covers an adhesive tape.

7. Carefully take a bent shaft. Try not to allow losses of the top inserts of radical bearings. As the shaft weighs quite a lot, it will be reasonable to resort to the help of the assistant. Lay the removed shaft on a plain working surface, having propped up it wooden wedges.

8. Take the top inserts and put them together with lower as installation on the engine. Remove the persistent washers established on both sides of the 3rd crank.
9. Pay attention to the dredging pierced in covers and the block - this dredging is provided for hit of ledges of inserts in them and defines unambiguity of installation of the last.

CHECK

 PERFORMANCE ORDER

1. Carefully wash out a bent shaft solvent and dry it. Wash out openings of maslotok and make sure of passability of the last (use a special brush). In order to avoid damage of new inserts chamfer edges of openings.
2. Check a condition of radical and conrod necks of a shaft. In case of identification of signs of uneven wear, zadir, cracks, cavities and other damages, the shaft should be given to a pro-point with the subsequent replacement of bearings with repair.

3. By means of a micrometer measure diameters of radical and conrod necks of a shaft. By measurement of diameter in various points of necks, check the last for existence of signs of ovality or conicity. Compare results of check to requirements of Specifications, in case of need give a shaft to a pro-point.

4. Check a condition of the surfaces of both pins of a shaft contacting to epiploons. In case of identification of the zadir, roughnesses and other damages capable to lead to failure of a new epiploon, it is necessary to ask for the help specialists of car service where the corresponding recovery repair of pins can be executed.
5. By means of the dial measuring instrument of plunger type determine the size of a side beating of a bent shaft in its middle part. The shaft should be laid in V-shaped blocks. Try not to damage the surfaces of necks and pins of a shaft during performance of check. The maximum admissible value of a side beating of a bent shaft is not stipulated by manufacturers, however authors of the present manual recommend to accept the size of 0.05 mm as a starting point. At excess of this value the shaft should be replaced, or to deliver for recovery repair in a workshop of car service.

6. On engines of 1.3 l it is necessary to determine by a micrometer thickness of persistent washers. Worn-out washers are replaced in couple from among corresponding to them on dimensional group. If the shaft was exposed to a pro-point, one of washers after selection can refuse to thickness another, and has to establish from the inside (closely to a crank cheek).

7. The description of procedures of check of a condition of inserts of radical and conrod bearings see in the Section Check of a State and Selection of Inserts of Radical and Conrod Bearings of a Bent Shaft.