Skoda Workshop Service and Repair Manuals

Install   Note t  Carefully remove residual sealant from the cylinder head and cylinder block. Make sure this does not cause any extended scoring or scratching. t  There must not be any oil or coolant present in the blind holes for the cylinder head bolts. t  Replace cylinder head bolts. t  When undertaking assembly replace self-locking nuts and screws as well as gasket rings and gaskets which have been tightened to a torquing angle. t  Remove the new cylinder head gasket from its wrapping immediately before fitting. t  Treat the seal with the utmost care. Damage to the silicone layer and in the area of the bead results in leakages. t  When installing an exchange cylinder head with the camshaft installed, it is necessary to oil the contact surfaces between the bucket tappet and the cam track after installing the cylinder head. t  The plastic base for protecting the open valves should only be removed immediately before attaching the cylinder head. t  Secure all hose connections with corresponding hose clips.   WARNING Wear protective gloves and goggles when working with gasket remover and degreasing agent! –  Make sure that when cleaning the cylinder head and cylinder block no foreign bodies can get into the cylinder or into the oil and coolant galleries. –  Carefully remove old sealant residue from the cylinder head and cylinder block using a chemical sealant remover. –  Before fitting the cylinder head rotate the crankshaft so that all the pistons are almost evenly at the same height.

–  Pay attention to the identification of the cylinder head seal. t  Part number = -arrow 1- t  Control code = -arrow 2- (ignore) t  Bores = -arrow 3-   Note t  If the cylinder head gasket or cylinder head were replaced, install a new cylinder head gasket with the same identification marking. t  If parts of the crankshaft drive were replaced, then the new cylinder head gasket must be redefined by measuring the protrusion of the piston in TDC.

–  Fit on cylinder head gasket. l  Pay attention to dowel sleeves -arrows- in cylinder block. l  Observe the installed position of the cylinder head gasket, the marking “above” or the part number must point to the cylinder head. –  Insert the cylinder head.

–  Insert cylinder head bolts and tighten by hand. –  Tighten the cylinder head in four stages in the indicated tightening sequence:

Stage	Tighten
I	–  Pre-tighten with the torque wrench to 35 Nm.
II	–  Pre-tighten with the torque wrench to 60 Nm.
III	–  Using a rigid wrench torque a further 90° (1/4 turn).
IV	–  Using a rigid wrench torque a further 90° (1/4 turn).

–  Screw lifting eye of engine onto the front cylinder head.

–  Insert screws -2 ... 4- with spread on locking agent -D 000 600 A2- and tighten to 10 Nm. –  Install Hall sender -G40-, insert screws -3- with spread on locking agent -D 000 600 A2- and tighten to 10 Nm. –  Screw in the pin screw -1- and tighten to 15 Nm.

–  Position hub onto camshaft. –  Tighten screw -1- to 100 Nm, use counterholder -T10051- to hold.

–  First of all position camshaft and then also crankshaft on TDC for cylinder 1: l  For the camshaft, the cams of cylinder 1 must be pointing up evenly -arrows-...

l   ... and depending on the version, the crankshaft toothed belt sprocket must be interlocked with the crankshaft arrester -T10050- or crankshaft arrester -T10100-.   Note t  Markings on the toothed belt sprocket and on the crankshaft arrester must be in line with each other -arrow-. The stud on the crankshaft arrester must engage into the hole in the sealing flange. t  The crankshaft arrester can only be fitted onto the toothed belt sprocket from the front side of the serration.

–  Push camshaft sprocket onto the hub. l  The tooth segment -arrow- of the camshaft sprocket must be at the top. –  Slightly screw in plug -1-. –  Interlock hub with locking pin e.g. -3359-. –  install (set the timing) → Chapter. –  Install cylinder head cover → Chapter. Further installation occurs in reverse order, while paying attention to the following: –  Install exhaust system and align free of stress → Chapter. –  Checking the oil level → Octavia ll.   Note Change contaminated engine oil → Octavia ll. –  Top up or replace coolant → Chapter. –  Then interrogate the fault memory of the engine control unit and erase → Vehicle diagnosis, testing and information system VAS 5051.