Skoda Workshop Service and Repair Manuals

Removing   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 fitted again in the same location when the engine is installed again. t  The hose connections are secured with screw-type clips, spring-type clips or clamp-type clips. t  Always replace clamp-type clips with screw-type clips or spring-type clips. t  Fuel lines on the engine must always be secured with spring-type clips. The use of clamp-type or screw-type clips is not allowed. t  Use pliers for spring strap clips to remove and fit the spring strap clips. t  Pay attention to correct assignment of the corresponding connectors, if necessary mark. Procedure –  On models fitted with a coded radio set, pay attention to the coding; determine if necessary. –  Switch off the ignition and disconnect the battery earth strap. For vehicles ► 07.97 –  Unhook throttle cable on the throttle valve control unit and at the support at induction pipe (do not remove connector catch). –  Unclip throttle cable and ignition leads from the ignition cable guide.

–  Remove plastic cover -arrows-. For vehicles 08.97 ►

–  Remove plastic cover -arrows-. –  Unhook throttle cable on the throttle valve control unit and at the support at induction pipe (do not remove connector catch). –  Unclip throttle cable and ignition leads from the ignition cable guide. For all vehicles –  Raise vehicle with a lift platform, pay attention to the following points:

The arms of the lift platform must be positioned under the frame side rail.   WARNING Under no circumstances may the arms of the lift platform be positioned under the sill, the front or rear axles. Both jacking up points at front are located on both front frame side rails at the height of the marking on the sill.   WARNING Never start the engine or engage a gear when the vehicle is raised, while even one driving wheel is still in contact with the ground.

Both rear jacking up points are located on both front frame side rails at the height of the marking on the sill.

–  Remove noise insulation -arrows-.

–  Open the cap of the coolant expansion reservoir. –  Position drip tray (e.g.-V.A.G 1306-) under the engine.

–  Turn the drain valve -arrow- on the radiator to the left, if necessary fit auxiliary hose onto connection.

–  In addition, detach coolant hose at bottom of oil cooler -arrow- and allow remaining coolant to drain.

–  Unbolt cable -1- on the terminal 30/B+ from alternator. –  Unplug connector -2- of terminal D+. –  Unbolt cable straps -3-. Vehicles with air conditioning –  Remove connector at the AC compressor. –  Unplug connector from control switch for coolant temperature too hot -F14-. All vehicles

–  Unplug connector from camshaft adjustment valve 1 - N205--1- and from coolant temperature sender -G2/G62--2- .

–  Disconnect the plug from the Hall sender -G40 --arrow-.

–  Disconnect plug from intake air temperature sender -G42--1-. –  Remove the connecting hose -2- to the intake hose -5-. –  Disconnect the vacuum line -3- from the brake servo unit to the throttle valve control unit -J338-. –  Release ventilation hose -4- to the activated charcoal filter system. –  Disconnect the connecting hose -6-. –  Remove intake hose -5- between air filter and throttle valve control unit -J338-.

–  Unplug connector -1- from the air mass meter -G70-. –  Release fixing screws -2- and remove air filter housing -3-.

–  Remove the earth strap -1- from the engine/gearbox connecting screw. –  Separate plug connection -2- and pull out of fixture. –  Detach cables -3- and -4- at starter. –  Detach cables from fixture at starter and place down to the side, remove fixture.

–  Remove fuel feed line -1- and fuel feed line -2- (press the release buttons).   WARNING The fuel feed line is pressurized! Place cleaning cloths around the connection point before detaching hose connections. Reduce pressure by carefully removing the hose.

–  Disconnect the following plug connections: 1 -  Knock sensor I -G61- (black) 2 -  Knock sensor II -G66- (brown). 3 -  Engine speed sender -G28- (grey). –  Disconnect the following plug connections: t  Plug connections to the injection valves -N30 ... 33-. t  Plug connection at oil pressure switch -F1-. t  Plug connection to the ignition coil with power output stage -N70-. t  Plug connection to the throttle valve control unit -J338-. t  Plug connection at vehicle speed sender -G68 -. t  On vehicles as of 08.97 disconnect the plug connection at PAS pressure switch -F88-. –  Detach wiring loom for the fixtures and run out to the side. Vehicles fitted with a manual gearbox

–  Mark fitting position of shift cable -B- to gearbox shift lever. –  Remove balancing weight -A- and shift cable -B- of gearbox shift lever. –  Disconnect selector cable from the driver/relay lever -C-, to do so raise the peg in the direction of the arrow. –  Unclip hose line of slave cylinder at cable support.

–  Disconnect cable support from gearbox -arrows- and lay aside.

–  Remove the slave cylinder -arrows- and lay aside, secure with wire, do not open the line system.   Note Do not depress the clutch pedal. Vehicles with automatic gearbox

–  Use screwdriver to press off selector cable -1- at gearbox selector lever -4-, pull off securing clasp -3- at support bearing. –  Take off selector cable and place to the side.

–  Disconnect the following plug connections: 1 -  Solenoid valve (10-pin plug) 2 -  Vehicle speed sender -G68 - 3 -  Multi-function switch -F125- 4 -  Gearbox speed sender -G38- –  Remove bracket -5- for pressure line of power-assisted steering at gearbox support. –  Detach wiring loom for the fixture and run out to the side. All vehicles –  Remove following coolant hoses with pliers for spring strap clips:

1 - bottom coolant hose at coolant regulator housing 2 - coolant hose to expansion reservoir

1 - top coolant hose at branch piece 2 - coolant hose to heat exchanger 3 - coolant hose from heat exchanger 4 - coolant hose to expansion reservoir 5 - coolant hose of the throttle valve control unit –  Remove the ribbed V-belt → Chapter.

–  Remove two fixtures for pressure line of power-assisted steering -arrows- (the figure shows the vehicle with manual gearbox). –  Remove belt pulley of hydraulic pump for power-assisted steering (counterhold with screwdriver). –  Remove hydraulic pump of power-assisted steering and tie up to the body. The lines on the vane pump remain connected up. Vehicles with air conditioning   WARNING Do not open the refrigerant circuit of the air conditioning system.

–  Remove AC compressor, lower together with connected cables and tie with wire to the towing lug -arrow-.   Note Protect the shock absorber with suitable adhesive tape against scratches. All vehicles –  Remove protective caps for drive shafts. –  Remove catalytic converter → Chapter.

–  Remove the pendulum support -arrows-. –  Remove drive shafts from the flanges of the gearbox. –  Place left drive shaft to the rear and secure with wire. –  Remove right drive shaft: → Chassis; Rep. Gr.40. –  Insert engine mount -T10012- in the engine/gearbox jack (e.g. -V.A.G 1383 A -).

–  Fix engine mount -T10012- to the cylinder block using fixing nuts and bolts M10 to 40 Nm. –  Slightly raise the engine and gearbox with the engine and gearbox jack (e.g. - V.A.G 1383 A -).

–  Unscrew fixing screws of right assembly bracket -arrows-.   Note Use double ladder (e. g. -V.A.S 5085-) to remove the screws for the assembly bracket.

–  Unscrew fixing screws of left assembly bracket -arrows-. –  Carefully lower the engine with gearbox.   Note When lowering, a second mechanic must guide the assembly block, in order to avoid damage to the body due to the low clearance. At the same time, pay attention to the drive shaft boots. Vehicles with automatic gearbox –  Detach coolant hoses at ATF radiator. –  Pull off plug in hole of torque converter cover plate.

–  Unscrew 3 nuts -arrow- from torque converter, rotate crankshaft each time 1/3 revolution for this step. –  After separating engine and gearbox, secure torque converter in gearbox to prevent it dropping out. All vehicles –  Remove cover plate for flywheel.

–  Release connecting screws -1...8- at engine/gearbox flange. –  Separate gearbox from engine.

–  Hook on the lifting device -MP 9-201- with bracket -MP 1-224- as follows and raise slightly with the workshop crane (e.g. -V.A.G 1202 A-). On the belt pulley side: 3. Hole of the perforated bar in position 1 On the flywheel side: 2. Hole of the perforated bar in position 6   WARNING Use securing pins on the hooks and rig pins to prevent release.   Note t  The rig positions on the supporting bracket marked 1...4 point towards the belt pulley. t  The holes in the perforated bars are counted from the hook.