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





Cleaning and check of a condition of the block of cylinders/case of the engine

Cleaning

 PERFORMANCE ORDER

1. Remove all hinged units and components, and also electric sensors and switches from the block. For full-volume cleaning it is necessary to remove also release traffic jams of water galleries - drill small openings in traffic jams, screw in them self-tapping screws and, the screws which grasped flat-nose pliers by heads, take traffic jams from the block.
2. Scratch out all traces of material of old laying and sealant from the interfaced surfaces of the block. Try not to damage pro-masonry/sealing surfaces.
3. Take all caps of oil galleries (where they are provided). Caps are put very hardly and, perhaps, will demand drilling with the subsequent restoration of a carving a tap. At assembly of the engine replacement of caps is made without fail.
4. If the case is strongly polluted, it is necessary to resort to steam cleaning. After return of the block from cleaning it is necessary to clean maslotok and galleries again. Wash out all internal cavities of the block warm water. Continue washing until clear water does not begin to follow from openings. Carefully dry the block, then slightly oil its interfaced surfaces and mirrors of cylinders in order to avoid corrosion development. If there is an access to a source of compressed air, use it for acceleration of process of drying and a purge of openings, channels and galleries.

When using compressed air put on goggles!

5. If the case of the engine is polluted not too strongly, will be to wash out it hot soap water with application of a rigid brush enough. It is not necessary to try to save time for washing of the block - belong to this procedure with all responsibility. Regardless of the chosen cleaning method, as a result of its all oil openings and channels have to be absolutely pure, and the block - carefully dried up. In order to avoid corrosion development slightly oil mirrors of cylinders.

6. All fixing openings in the block need to be "banished" the tap suitable by the size, having carefully removed corrosion products, old sealant and other deposits from carving rounds. Besides, such "pro-race" will help to restore the damaged rounds. Whenever possible, blow openings compressed air, having removed from them shaving and garbage.

All traces of lubricant and solvent in order to avoid destruction of casting of the block with hydraulic pressure have to be completely removed from deaf openings when tightening bolts.

7. Grease with suitable sealant new caps of oil galleries and screw them in the openings in the block. Strongly tighten caps.
8. If you are not going to start immediately assembly of the engine, wrap the block in a pure plastic bag. Do not forget to take care of protection of the interfaced surfaces and mirrors of cylinders against corrosion also.

CHECK

 PERFORMANCE ORDER

1. Examine casting of the block on existence of cracks and traces of corrosion. Check whether a thread in any of fixing openings is stripped. If there were suspicions on internal leak of cooling liquid, perhaps, it makes sense to address specialists of car service, having asked them to execute careful check of a condition of the block with use of the special equipment. In case of need make recovery repair, or replace the block.

2. Take sleeves of cylinders and check their mirrors for existence of scratches and zadir. For the purpose of keeping of production admissions sleeves of three dimensional groups are issued. The corresponding marking is put to a wall of each of sleeves.
3. For more exact assessment of degree of wear of sleeves it is necessary to perform measurement of their diameters in several points. Enter a nutromer into a sleeve of the first cylinder and measure its diameter in three various sections parallel to an axis of a bent shaft. One measurement is performed in the top part of a sleeve, directly under edge of a fillet of step wear, the second - in the central part of a sleeve and the third - at once over its lower cut. Measurements are performed in two planes - a parallel and perpendicular axis of a bent shaft.
4. Compare results of measurements to requirements of Specifications. If any of results exceeds the limit of admissible range, the corresponding sleeve is subject to replacement.
5. For definition of a gap of landing of pistons in sleeves of cylinders it is necessary to subtract from diameter of a sleeve diameter of the piston measured on his skirt (see the Section Removal, check of a state and installation of conrod and piston assemblies).
6. Alternatively, fill the piston in the corresponding sleeve and by means of the probe of lezviyny type measure the size of a side play of its landing. The piston has to be entered into a sleeve in normal situation, and the side play is measured on one of its persistent surfaces, directly over the lower cut of a sleeve.
7. If the size of a gap exceeds the admissible value stipulated in Specifications, it is necessary to make replacement of the piston. If the piston klinit in the lower part of the course, with gradual weakening of landing in process of its advance up, means conicity of a sleeve takes place. Jamming of edges of the probe at shift on perimeter of the forming surface of the piston tells it about ovality of a sleeve.
8. Repeat the procedure, having estimated a condition of sleeves of each of cylinders.
9. In case of identification of signs of excessive wear, or damages of mirrors, defective sleeves are subject to replacement.
10. As replaceable sleeves, only the same dimensional group, as failed have to be established. The same treats pistons. At the same time the size of pistons has to correspond on group to the size of sleeves. The corresponding marking is applied on walls of sleeves and the bottom of pistons.
11. If degree of wear of mirrors is low, will be to make replacement of piston rings only enough.
12. Mirrors of sleeves at the same time are subject to a honingovaniye for the purpose of ensuring correctness of landing to them of new piston rings.
13. Implementation of the procedure of a honingovaniye requires the special tool (хон) allowing to apply on a mirror surface uniform shaped a pattern in the form of a grid. Such uniform "ruggedization" of a mirror provides quality extra earnings of piston rings and guarantees due tightness of landing of pistons in sleeves. Hona of two types, both intended for use complete with the electric drill are issued. Hon of type "the bottle brush" represents a rigid cylindrical brush with abrasive inserts in a bristle. More widespread superficial хон it is equipped with a nozzle in the form of the grinding stones equipped with the sprung legs. Authors of this manual recommend to the beginning amateur mechanics to use the khan of the first type.

At desire the honingovaniye is always possible for quite reasonable payment to charge to experts of a workshop of car service.

14. Prepare хон one of the types described above, the electric drill, enough pure rags, a little honingovochny oil and goggles.

15. Clamp хон in an electric drill cartridge. Moisten mirrors of cylinders with honingovochny oil and fill хон in the first sleeve, previously having squeezed its sprung grinding stones (if the nozzle of the second type is used). Include a drill and at once begin to move a nozzle up-down the cylinder, trying to obtain emergence on a mirror of the cylinder of a uniform shaped pattern in the form of a grid with a romboobrazny cell which parties are crossed at an angle about 60 °. Some manufacturers of piston rings insist on other values of angles of crossing of strokes of a pattern - study the instructions attached to a set of new piston rings.

Do not forget to put on goggles!

16. Do not feel sorry for oil at a honingovaniye of cylinders. Do not remove more material from a sleeve mirror, than it is really necessary for achievement of the required result. Do not take хон from a sleeve until its rotation finally does not stop - all this time continue to make back and forth motions by a drill. After a drill stop, continue rotation of her boss in the former direction manually and take a nozzle from the cylinder.
17. Carefully wipe a mirror with pure rags and you pass to a honingovaniye of a sleeve of the following cylinder. Having finished the procedure, wash out the block of cylinders hot water with soap, having completely removed all traces of an abrasive and honingovochny oil. Cleaning can be considered finished when when carrying out on mirrors of sleeves the spot of gray color does not remain the white rags moistened in oil on the last.
18. For extraction of sleeves turn the block of cylinders and lay it on wooden blocks. Now sleeves can be beaten out from cylinders by means of the drift made of solid wood.
19. After all sleeves are released, lay the block of cylinders sideways and take sleeves manually.
20. Remove sealing washers from the bases of sleeves and measure their thickness. Washers of various sizes are issued and by their selection adjustment of size of a vystupaniye of sleeves over the surface of the block is carried out. Pick up replaceable washers for each of sleeves.
21. The main geometrical characteristics of sleeves are submitted on illustrations. If sleeves are in good repair and are subject to further use, mark them by means of an adhesive tape regarding belonging to the cylinder.

and — Designation of a dimensional class of a sleeve
b — the Place of measurement of internal diameter

22. Before installation carefully wipe the interfaced surfaces of sleeves and a side, then by processing remove with a fine-grained emery paper all agnails, teases and roughnesses capable to lead to failure of new sealing washers.

23. Carefully wipe sleeves and establish on them new sealing washers of the required thickness. Oil walls of sleeves pure motive.

24. At installation of old sleeves you watch correctness of combination of the landing tags put in the course of dismantle. Try not to allow losses of sealing washers in the course of landing of sleeves in cylinders. At the first stage of a sleeve it is necessary to push in cylinders manually against the stop. Further sleeves zastukivatsya by the hammer via the wooden block against the stop in a landing coat hanger.

25. Having established all four sleeves, measure the size of their vystupaniye over the block plane - use a steel line and the probe of lezviyny type. Compare results of measurements to requirements of Specifications.

26. In case of need take incorrectly put sleeve and replace on it a sealing washer. Washers 0.10, 0.12 and 0.14 mm thick are issued.
27. Having replaced a washer, establish a sleeve and again check the size of its vystupaniye.

28. Having finished correction of landing of sleeves, temporarily record them in cylinders special rectangular washers


Engines of 1.6 l and diesel

 PERFORMANCE ORDER

1. Visually check casting of the block for existence of cracks and traces of corrosion. Check whether a thread in any of fixing openings is stripped. If there were suspicions on internal leak of cooling liquid, perhaps, it makes sense to address specialists of car service, having asked them to execute careful check of a condition of the block with use of the special equipment. In case of need make recovery repair, or replace the block.
2. Check mirrors of cylinders for existence of scratches and zadir. At detection of this sort of defects it is necessary to check a condition of the corresponding pistons (see the Section Removal, check of a state and installation of conrod and piston assemblies). The defects which are in an initial stage of development can be eliminated at this stage by a block pro-point in the conditions of a workshop of car service.
3. For more exact assessment of degree of wear of cylinders it is necessary to perform measurement of their diameters in several points. Enter a nutromer into the first cylinder and perform measurement of its diameter in three various sections parallel to an axis of a bent shaft. One measurement is performed in the top part of the cylinder, directly under edge of a fillet of step wear, the second - in the central part of the cylinder and the third - at distance about 10 mm over its lower cut.

The block has to be installed on a workbench strictly horizontally.

4. Repeat measurements, in the planes, perpendicular axes of a bent shaft this time. Write down results of all six measurements and compare them to requirements of Specifications. If the difference of diameters any of two cylinders exceeds the limit of admissible range, cylinders are subject to a pro-point with the subsequent replacement of pistons on new, the corresponding repair size. The only alternative to a pro-point of cylinders is full replacement of the block complete with pistons.
5. Having used records of results of measurements of diameters of pistons (see the Section Removal, check of a state and installation of conrod and piston assemblies), calculate gaps of landing of pistons in cylinders by subtraction of these diameters from diameters of cylinders. As requirements to landing of pistons at the time of drawing up the present manual by manufacturers are not stipulated, address for consultations experts company service center of the Skoda company.
6. Lay the block on a workbench, a case down and by means of a steel line and the probe of lezviyny type check planeness its interfaced surfaces. If results of check exceed the admissible value stipulated in Specifications, the block can is subjected to a pro-point (only for petrol engines) or replaced. On diesel engines performance of a pro-point of the block is not possible.
7. Before assembly of the engine it is necessary to make a honingovaniye of cylinders.
8. Slightly oil mirrors of cylinders pure motive in order to avoid corrosion development. Until the beginning of assembly wrap the block in a plastic bag and move away him to the safe place.