Skoda Workshop Service and Repair Manuals

Install Conditions: l  The pistons must not be in TDC. l  The crankshaft - toothed belt sprocket is secured to the crankshaft with fixing screw and two washers. l  Camshaft sprockets are fixed with camshaft lock -T10016- in the fit holes in the camshaft housing and secured against turning.   Note When turning the camshaft the valves may touch the piston in TDC. Work procedure

–  Position crankshaft on TDC for cylinder 1. The chamfered tooth must correspond with the marking on the sealing flange -arrow-. –  Fit on coupling drive - toothed belt. If the toothed belt has been used pay attention to the rotation direction. Install the coupling drive tensioning pulley as follows:

–  Turn the coupling drive tensioning pulley with Allan screw -1- clockwise in the direction of the marking window -arrow-, (tensioning pulley in released position). –  Push the bottom part of the coupling drive-toothed belt upwards using the tensioning pulley and screw in the fixing screw of the tensioning pulley. –  Tighten fixing screw manually. The peg of the base plate -2- must engage in the bore in the cylinder head.

–  Subsequently tension the toothed belt by turning the tensioning pulley with an Allan key Pos. -1- anti-clockwise until the pointer -2- is positioned above the peg of the base plate in the marking window -arrow-. –  Tighten the fixing screw on the tensioning pulley. Tightening torque: 20 Nm –  Remove camshaft lock -T10016-. –  Turn the crankshaft or toothed belt gear from TDC half a tooth anti-clockwise (approx 1.5 mm). –  Fit on main drive toothed belt. –  Fix the two camshaft sprockets with camshaft lock -T10016-. If the tensioning pulley has been removed beforehand, install tensioning pulley as follows:

–  Turn tensioning pulley with Allan key anti-clockwise in the marked position -arrow-.

–  Tighten fixing screw manually. The screw in the cylinder block -2- must lock in the recess on the base plate -1-. –  Subsequently tension the toothed belt in the direction of the arrow by turning the tensioning pulley until the pointer -3- is positioned over the notch in the base plate -arrow-. –  Tighten the fixing screw on the tensioning pulley. Tightening torque: 20 Nm –  Remove camshaft lock -T10016-.

–  Now rotate crankshaft two revolutions in direction of rotation of engine until it is again positioned on TDC for cylinder 1. The chamfered tooth must correspond with the marking on the sealing flange -arrow- in the fig. -A-. In this position both camshaft sprockets must lock with camshaft lock -T10016- fig. -B-. –  Then inspect the toothed belt setting and tensioning pulley setting again, if necessary repeat tensioning of the two toothed belts. –  Install bottom timing belt guard. –  Install crankshaft belt pulley. Pay attention to the following: t  The fixing screws for the belt pulley and toothed belt gear must be replaced. t  Pay attention to the toothed belt gear attachment when installing the belt pulley. t  The clamping surfaces of the belt pulley and the screw must be degreased. t  Tightening process for the new oiled screw: 150 Nm + torque a further 1/2 turn (180°). t  Counterhold crankshaft belt pulley with counterholder -T30004 (3415)- and replaceable bolt -T30004/1 (3415/1)-. –  Attach engine mount to cylinder head. Tightening torque 50 Nm –  Install engine assembly bracket. Tightening torques → Chapter. –  Install top toothed belt guard. Vehicles with air conditioning –  Install tensioning pulley for V-ribbed belt → Chapter. For all vehicles –  Install the V-ribbed belt → Chapter.   Note Pay attention to the correct position of the V-ribbed belt in the belt pulley when installing it. –  Install the front right wheelhouse liner: → Body Work; Rep. gr.66. –  Install the noise insulation. –  Screw on the coolant expansion reservoir. –  Install activated charcoal filter → Chapter. For engine with identification characters BCA –  Install engine cover with air filter → Chapter.