Skoda Fabia

since 2000 release

Repair and operation of the car



Skoda Fabia
+ 1.1. Description of the car
- 2. Engine
   2.1. Removal of the top casing of the engine
   + 2.2. Installation of the piston of the first cylinder in the provision of VMT of a step of compression
   2.3. Replacement of a belt of the drive of the generator
   + 2.4. Replacement and adjustment of a tension of a belt of the drive of the camshaft
   2.5. Replacement of a chain of the drive of the camshaft
   2.6. Selection of a distributive gear wheel of a bent shaft
   2.7. Replacement of laying of a head of the block of cylinders
   2.8. Replacement of an epiploon of the camshaft
   2.9. Replacement of oil scraper caps
   2.10. Replacement of a forward epiploon of a bent shaft
   2.11. Back epiploon of a bent shaft
   + 2.12. Repair of a head of the block of cylinders
   - 2.13. Repair of the engine
      2.13.1. Dismantling of the engine
      2.13.2. Troubleshooting
      2.13.3. Assembly
      2.13.4. Check of a compression
+ 3. Lubrication system
+ 4. Power supply system
+ 5. Cooling system
+ 6. System of production of the fulfilled gases
+ 7. Transmission and running gear
+ 8. Steering
+ 9. Brake system
+ 10. Electric equipment
+ 11. Body
+ 12. Electrical circuitries



2.13.2. Troubleshooting

GENERAL INFORMATION

Scheme of measurement of diameter of the cylinder

And, In – the directions of measurements;

1, 2, 3 – numbers of belts

Measurement of a preliminary tightness of connecting rods of engines of 1,4 l, 55 and 74 kW

a – outer diameter;

b – diameter of the lower head of a rod

Measurement of a vystupaniye of an adjusting pin of the diesel engine of 1,9 l, 74 kW

1 – disk of the sensor of frequency of rotation of a bent shaft;

2 – bolt;

3 – adjusting pin;

and – a pin vystupaniye

Details of conrod and piston group are shown in drawings (see rice. Details of conrod and piston group of the engine with a capacity of 1,4 l, 55 and 74 kW, rice. Details of conrod and piston group of engines of 1,0 l, 37 kW and 1,4 l, 50 kW and rice. Details of conrod and piston group of the diesel engine of 1,9 l, 74 kW).

PERFORMANCE ORDER
1. Clear heads of pistons of a deposit. Clean flutes under piston rings, it is convenient to do it by a fragment of an old piston ring.
2. Examine pistons: if on them there are teases, traces of a progar, deep scratches, cracks, pistons it is necessary to replace.
3. Measure gaps in locks of piston rings. For this purpose insert a ring into the cylinder in which it worked (at engines of 1,0 l, 37 kW and 1,4 l, 50 kW from above, at other engines from below). Then advance a ring the piston as a mandrel, in the cylinder that it was established in it without distortions at distance about 15 mm from edge of the cylinder. Measure by the probe a gap in the ring lock, as shown in the drawing. Values of gaps are given in the tab. A gap in the lock of a piston ring.
4. If the measured gap exceeds maximum permissible, replace a ring. If the gap is less nominal, accurately grind off a file ring end faces.
5. Check gaps between rings and flutes on the piston. For this purpose insert a ring into a flute in which it stood, as shown in the drawing, and measure by the probe a gap.
6. The nominal gap for petrol engines makes 0,04–0,08 mm, maximum permissible – 0,15 mm (gaps are specified only for compression rings), at diesel engines the nominal gap for the top compression ring has to be 0,06–0,09 mm, lower – 0,05–0,08 mm, a maximum permissible gap for compression rings – 0,25 mm; for oil scraper rings a nominal gap of 0,03-0,06 mm, maximum permissible – 0,15 mm. If at least one of gaps exceeds maximum permissible, replace the piston with rings.
7. Examine cylinders. If on a mirror of cylinders there are scratches, teases, sinks and so forth, chisel cylinders under the repair size (see the tab. Sizes of cylinders and pistons) or replace the block of cylinders, at engines of 1,0 l, 37 kW and 1,4 l, 50 kW replace sleeves of cylinders. At the called defects more than 0,5 mm in depth the block is not subject to repair, it needs to be replaced.
8. Clear a deposit in the top part of cylinders. If there the corbel owing to wear of cylinders was formed, remove it a shaber.
9. Measure diameters of cylinders by means of a nutromer. Diameter of the cylinder is measured in two perpendicular directions A and B (see rice. Scheme of measurement of diameter of the cylinder) and three belts, at the same time the belt 2 passes on the middle of the cylinder, and belts 1 and 3 will be spaced from edge of the cylinder on 10 mm from above and from below. If the measured diameter at least in one cylinder exceeds nominal more than on 0,08 mm at petrol engines and on 0,1 mm – at diesel, it is necessary to chisel cylinders under the following repair size or to replace the block of cylinders.
Prevention

It is forbidden to measure diameters of cylinders in the block fixed at the stand for assembly of the engine for an arm of a support of the power unit as in this case the result can be wrong.


10. Measure diameter of the piston at distance of 10 mm from bottom edge in the plane, perpendicular to a piston finger, as shown in the drawing. If the received value differs from nominal more than on 0,04 mm, the piston needs to be replaced.
11. Examine inserts of radical and conrod bearings: if on them there are cracks, teases, chips, a vykrashivaniye and so forth, replace inserts. On inserts it is forbidden to carry out any subracing works.
12. Examine persistent half rings of a bent shaft: if on them teases are found, risks, peelings, half rings it is necessary to replace. On half rings it is forbidden to carry out any subracing works.
13. If on surfaces of a bent shaft on which epiploons work there are deep risks, scratches, zaboina, teases, it is necessary to replace a bent shaft.
14. If on radical and conrod necks there are insignificant teases, risks, scratches, it is necessary to proshlifovat them to the next repair size. This work needs to be performed at car repair shop. After that polish necks and dull sharp edges of oil channels with an abrasive cone. Then wash out a shaft and blow compressed air oil channels. After grinding of necks establish inserts of the repair sizes. The sizes of necks of bent shafts are specified in the tab. Sizes of necks of bent shafts.
15. Measure an axial gap of a bent shaft. For this purpose install in the block of cylinders a bent shaft with persistent half rings and covers of radical bearings. Tighten bolts of fastening of covers the moment of 75 N · m at engines of 1,0 l, 37 kW and 1,4 l, 50 kW and 65 N · m at the diesel engine of 1,9 l, 74 kW. Fix the indicator so that his leg rested against an end face of a bent shaft. Shift a bent shaft from the indicator against the stop and install the indicator on zero, then shift a bent shaft to the opposite side against the stop. The indicator will show gap size. If the gap exceeds maximum permissible, it is necessary to replace persistent half rings. The nominal axial gap for engines of 1,0 l, 37 kW and 1,4 l, 50 kW makes: 0,03–0,13 mm, maximum permissible – 0,26 mm; for the diesel engine of 1,9 l, 74 kW a nominal gap of 0,07-0,17 mm, maximum permissible – 0,37 mm.
16. Check gaps between necks of a bent shaft and inserts of radical and conrod bearings. Gaps can be calculated, having measured diameters of necks of a bent shaft and diameters of radical and conrod bearings for what establish covers of bearings with inserts into place and tighten bolts of their fastening the corresponding moments. The manufacturer recommends to measure gaps by means of the plastic calibrated wire as follows:
      – carefully clear bearings, necks of a bent shaft and inserts of oil deposits;
      – lay a bent shaft on beds of radical bearings with the established inserts;
      – put on necks of a bent shaft of cutting of the calibrated plastic wire;
      – establish covers of bearings with the inserts established in them and tighten bolts of their fastening the corresponding moments. At the same time do not turn a bent shaft;
      – uncover bearings. The gap is determined by extent of flattening of a wire by means of a scale on packing of a wire.
For the diesel of 1,9 l, 74 kW the nominal gap in radical bearings makes 0,03–0,08 mm, maximum permissible – 0,17 mm, in conrod bearings a maximum permissible gap – 0,08 mm.
For engines of 1,4 l, 55 and 74 kW a nominal gap in conrod bearings of 0,020-0,061 mm, maximum permissible – 0,091 mm. If gaps exceed maximum permissible, it is necessary to proshlifovat a bent shaft under the following repair size.
17. Examine a flywheel if teeths of its wreath are damaged, replace a flywheel or its wreath. For replacement of a wreath bring down an old wreath from a flywheel, for simplification of operation it is possible to heat a wreath. Then heat a new wreath to 150 °C, put on a flywheel, if necessary striking evenly all perimeter of a wreath, besiege it against the stop. If on a surface of a prileganiye of the conducted clutch plate colors of a pobezhalost (the flywheel was overheated), then, perhaps, landing of a gear wreath on a flywheel weakened are visible. Defect is revealed at car repair shop. The flywheel with the weakened landing of a gear wreath needs to be replaced.
18. Replace rods if they are bent or in the presence of zadir in the top head. Rods need to be replaced only assembled with covers as they are processed in common.
19. At engines of 1,4 l, 55 and 74 kW check a preliminary tightness of connecting rods. For this purpose measure the outer diameter of an in mm (see rice. Measurement of a preliminary tightness of connecting rods of engines of 1,4 l, 55 and 74 kW) of an insert and diameter of b of the lower head of a rod, having established previously its cover and having tightened bolts of its fastening the corresponding moment. Then on a formula c = a - b calculate the size of a preliminary tightness. The minimum admissible tightness has to make 1,5 mm. If the measured tightness turned out less minimum admissible, replace inserts.
20. At the diesel engine check a vystupaniye of an adjusting pin. For this purpose on a bent shaft turn off three bolts 2 (see rice. Measurement of a vystupaniye of an adjusting pin of the diesel engine of 1,9 l, 74 kW) fastenings also remove a disk 1. Measure a vystupaniye and a pin over an end face of a bent shaft, it has to be 2,5–3,0 mm.
21. At engines of 1,0 l, 37 kW and 1,4 l, 50 kW check a vystupaniye of sleeves of cylinders over the top plane of the block of cylinders, as shown in the drawing. At the same time a sleeve with the laying which is put on it 12 (see rice. Details of conrod and piston group of engines of 1,0 l, 37 kW and 1,4 l, 50 kW) need to be pressed to the block densely. 0,07–0,12 mm have to be equal to Vystupaniye.
22. If the measured value does not keep within the specified limits, it is necessary to pick up new laying of a sleeve. In spare parts laying 0,10 thick is delivered; 0,12; and 0,14 mm. The difference in values of a vystupaniye of sleeves is allowed no more than on 0,04 mm.

Gap in the lock of a piston ring

Piston ring
Engines
1,0 l, 37 kW
1,4 l, 50 kW
1,4 l, 55 and 74 kW
Diesel of 1,9 l, 74 kW
Nominal, mm:
  – top
compression
0,2 – 0,5
0,4 – 0,72
0,2 – 0,5
0,2 – 0,4
  – lower
compression
0,2 – 0,5
0,3 – 0,62
0,4 – 0,7
0,2 – 0,4
  – oil scraper
0,4 – 1,4
0,4 – 1,4
0,4 – 1,4
0,25 – 0,5
Maximum permissible, mm:
  – top
compression
1,0
1,0
1,0
1,0
  – lower
compression
1,0
1,0
1,0
1,0
  – oil scraper
1,0

Sizes of cylinders and pistons

Diameter, mm
Engine of 1,4 l, 55 and 74 kW
Diesel of 1,9 l, 74 kW
Piston
Cylinder
Piston
Cylinder
Nominal
76,47
76,51
79,47
79,51
The first repair
76,72
76,76
79,72
79,76
The second repair
76,97
77,01
79,97
80,01

Sizes of necks of bent shafts

Size of necks
Engine of 1,4 l, 55 and 74 kW
Diesel of 1,9 l, 74 kW
Diameter of a radical neck, mm
Diameter of a conrod neck, mm
Diameter of a radical neck, mm
Diameter of a conrod neck, mm
Nominal
 54,00 – 0,017  
– 0,037
47,80 – 0,022  
– 0,037
 54,00 – 0,022  
– 0,042
 47,80 – 0,022  
– 0,042
The first repair
53,75 – 0,017  
– 0,037
47,55 – 0,022  
– 0,037
53,75 – 0,022  
– 0,042
 47,55 – 0,022  
– 0,042
The second repair
53,50 – 0,017  
– 0,037
47,30 – 0,022  
– 0,037
53,50 – 0,022  
– 0,042
 47,30 – 0,022  
– 0,042
The third repair
53,25 – 0,017  
– 0,037
47,05 – 0,022  
– 0,037
53,25 – 0,022  
– 0,042
 47,05 – 0,022  
– 0,042