Skoda Workshop Service and Repair Manuals

Removing engine Special tools and workshop equipment required t  Catch pan, e.g. -VAS 6208- t  Engine/gearbox jack, e.g. -V.A.G 1383 A- t  Engine mount -T10012- t  Pliers for spring strap clamps t  Double ladder t  Assembly stand -MP 9-101- t  Engine mount -MP 1-202- t  Cap -MP 1-202/10- t  Bushing -T30010 (VW540/1B)- t  Workshop crane, e.g. -V.A.S 6100- t  Lifting device -MP9-201 (2024 A)- t  Wire   Note t  The engine is removed downwards together with the gearbox. t  All cable straps that have been loosened or cut open when the engine was removed must be attached again in the same location when the engine is installed again. t  Collect drained coolant in a clean container for proper disposal or reuse. –  Observe all safety measures, notes and rules for cleanliness → Chapter. –  Remove engine cover → Chapter.   WARNING Observe measures when disconnecting the battery → Electrical System; Rep. gr.27. –  Remove battery and battery tray → Electrical System; Rep. gr.27. –  Remove air filter with intake hose and hose to turbocharger → Chapter.

–  Remove charge-air pipe at the top -1- with connecting hose -2--arrows-. –  Remove the sound dampening system → Body Work; Rep. gr.50. –  Detach the right front wheel → Chassis; Rep. gr.44. –  Removing the right wheel-well inner panel → Body Work; Rep. gr.66.   WARNING Hot steam or hot coolant may escape when the compensation bottle is opened. Cover the cap with a cloth and open carefully. –  Drain coolant → Chapter. For engine with engine code BNM, BNV

–  Release screw -3- and remove bottom charge air pipe -1- with connecting hose -2--arrows-. For engine with engine identification characters BMS –  Remove charge air pipe from exhaust turbocharger to charge air cooler. For all vehicles

–  Unscrew screws -arrows- for left steering joint → Chassis; Rep. gr.40.   Note After installing the screws carry out the axial measurement → Chassis; Rep. gr.44. –  Remove right drive shaft from the gearbox. Then swivel out drive shaft and secure below front bumper with wire, outside the engine compartment → Chassis; Rep. gr.40. –  Remove left drive shaft from gearbox and secure with wire → Chassis; Rep. gr.40. For engine with engine code BNM, BNV –  Remove pre-exhaust pipe with catalytic converter → Chapter. For engine with engine identification characters BMS –  Remove pre-exhaust pipe with diesel particle filter → Chapter. For all vehicles

–  Unscrew the pendulum support -arrows-. –  Remove holder for electric installation at the bottom from the gearbox.   Note Mark the direction of rotation with chalk or a felt-tip pen before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it. –  Remove V-ribbed belt → Chapter, → Chapter. –  Remove fan shroud from radiator → Chapter. –  Remove alternator → Electrical System; Rep. gr.27. On vehicles with air conditioning:   WARNING Do not open the refrigerant circuit of the air conditioning system.   Note In order to avoid damage to the AC compressor as well as to the refrigerant lines and hoses, ensure that the lines and hoses are not over-tensioned, kinked or bent. –  Remove the AC compressor from the bracket for auxiliary units → Heating, Air Conditioning; Rep. gr.87.

–  Attach AC compressor -3- e.g. to radiator grill in accordance with the figure. As protection put a sheet of cardbord -1- on the radiator wall.   Note Avoid damage to the radiator. Continued for all vehicles:

–  Disconnect the coolant hose -1- from the cylinder head. –  Disconnect the fuel-intake hose -3- and the fuel-return hose -2- from the pipes. –  Seal the lines in order to prevent any dirt from penetrating into the fuel system.

–  Remove the coolant feed hose -3- from the supports -4-. –  Remove the coolant return hose -2- from the heat exchanger connection fittings -1-. –  Pull off vacuum hose -6- from tandem pump -5-. –  Unclamp all remaining connecting, coolant, vacuum and suction hoses from the engine. –  Remove/unclamp all electrical lines from the engine, generator, starter and gearbox and uncover them.

–  Remove Bowden cable support -arrows-. –  Pull out slave cylinder line -A- from the holder on the gearbox. –  Remove shift mechanism from gearbox → Gearbox; Rep. gr.34. –  Remove the clutch slave cylinder from the gearbox → Gearbox; Rep. gr.30.   WARNING After removing the slave cylinder, do not operate the clutch pedal. Adapt engine mount -T10012-

–  Make additional hole -a- according to the given dimensions at the height of the already existing holes, if these do not yet exist. –  Insert engine mount -T10012- into engine/gearbox jack (e.g. -V.A.G 1383 A-).

–  Screw guide pin -1- with a washer and guide pin -2- with two washers -arrows- into engine mount -T10012-; use washers A13 x 24 x 2.5. –  Slacken the guide tube for the oil dipstick. On vehicles with air conditioning –  Screw engine mount -T10012- to the cylinder block with fixing nut -3- and bolt -5-. Tighten bolt (M10x50) to approx. 40 Nm. (If necessary place two washers A10.5 x 21 x 2 between engine mount -T10012- and engine block in such a way that they are positioned close to each other). On vehicles without air conditioning –  Screw engine mount -T10012- to the cylinder block with fixing nut -3- and bolt -5-. Tighten bolt (M10x50) to approx. 40 Nm. (If necessary place a nut (M12) -4- between engine mount -T10012- and engine block in such a way that they are positioned close to each other). For all vehicles   Note Use double ladder to release the screws for the assembly bracket.

–  Release the screws which connect the engine mount with the engine support -arrows-.

–  Unscrew the gearbox mount from the gearbox support -arrows-.   Note t  Check whether all hose and line connections between engine, gearbox and body are released. t  When lowering carefully guide the engine/gearbox jack unit, in order to avoid damage. t  The engine and gearbox unit must be carefully guided during withdrawal. Ensure adequate clearance to other components. Particularly from the AC compressor. –  First of all slightly lower the engine/gearbox unit. Then push engine/gearbox unit forwards to the radiator and only then lower further.