Skoda Workshop Service and Repair Manuals

Removing Requirements l  Engine temperature should not exceed 35°, because the cylinder head could be twisted when slackening the screws. l  The pistons must not be in TDC.   WARNING Observe measures when disconnecting the battery → Electrical System; Rep. Gr.27. –  Disconnect the earth strap from the battery with the ignition off.

–  Lift the engine cover at the sides -arrows A- and pull out towards the front -arrow B-. –  Remove air filter with intake hose → 1.9/96 TDI Engine, Fuel Injection; Rep. Gr.23. –  Remove battery and battery tray → Electrical System; Rep. Gr.27. –  Removing rear charge-air pipe → Chapter. –  Unplug connector with glow plugs. –  Remove pre-exhaust pipe with catalytic converter → Chapter.

–  Release screws -1- and -2- and remove bracket for turbocharger. –  Remove the vacuum hose from the vacuum unit for charge pressure control.   Note Collect any engine oil which flows out with a cloth. –  Unscrew the oil return line -3- at the cylinder block. –  Unscrew oil feed line from exhaust turbocharger and from exhaust manifold and lay it to one side. –  Drain coolant → Chapter. –  Unscrew the induction pipe from the intake manifold and lay aside with the hoses connected → 1.9/96 TDI Engine - Fuel Injection; Rep. Gr.23. –  Use hand vacuum pump and bleeder tank to extract the fuel at the return-flow hose of the tandem pump → Chapter.

–  Remove fuel hoses -1- and -4-. –  Remove coolant hose -5-. –  Remove central plug connection -2- for pump-nozzle unit. –  Disconnect plug -3- at fuel temperature sender -G81-. –  Unscrew the oil feed line on the oil filter holder, the exhaust turbocharger and brackets.

–  Disconnect coolant hose -1- from T-piece and the coolant hoses -2- and -3- from the connection fittings. –  Disconnect plug -4- from coolant temperature sender -G62-.

–  Remove the coolant hose -3- from the support -4-. –  Pull off vacuum hose -6- from tandem pump -5-. –  Remove coolant pump → Chapter.

–  Install supporting device -MP 9-200- with positioned spindles as shown and support the engine with spindle -A-. –  Carefully raise the engine with spindle -A-. –  Removing toothed belt → Chapter. –  Remove camshaft sprocket and hub → Chapter. –  Remove timing belt tensioning pulley.

–  Screw out screw -3- and remove Hall sender -G40- from cylinder head. –  Release screws -2- and -4-.

–  Screw bracket -T10014 - into the threaded holes in the area of the coolant pump in the cylinder block. Tightening torque: 20 Nm. –  Support the engine and carefully raise with spindle -A- and through this release the spindle -B-. –  Remove spindle -B-. –  Remove cylinder head cover → Chapter.

–  Slacken cylinder head bolts in the specified order and unscrew. –  Raise cylinder head and remove sideways past the toothed belt guard.   Note The assistance of a second mechanic is required to remove and install the cylinder head.