Skoda Workshop Service and Repair Manuals

Removing

–  Remove engine cover. To do so pull the front and rear engine cover upwards with a sudden motion. –  Remove the fuel lines from the injection pump.   Note Use the ring spanner, e.g. -3035-, for removing the high-pressure lines. –  Cover the openings with a clean cloth. –  Remove top toothed belt guard and cylinder head cover. –  Remove vacuum pump and brake servo unit → Chapter. With the engine installed

–  Position crankshaft on TDC for cylinder 1. The marking on the flywheel -1- must be flush with the marking on the gearbox -2-. Here one must view from the marking on the flywheel -1- vertically (90°) to the milled surface on the gearbox -A-.   Note The valves for cylinder 1 must be closed and the valves for cylinder 4 must overlap. With the engine removed

–  Screw the adjusting device -MP1-313- into the threaded bore of the top starter screw. –  Set adjusting device to 120 mm -arrow A-. The left notch on the vernier is the reference point. –  Rotate crankshaft until the TDC marking on the flywheel corresponds with the tip of the adjusting device -arrow B-.   Note The valves for cylinder 1 must be closed and the valves for cylinder 4 must overlap. Continued

–  Lock the camshaft position with the camshaft straightedge -MP1-312-.   Note The valves for cylinder 1 must be closed and the valves for cylinder 4 must overlap -arrows-. –  Centre camshaft straightedge as follows:    Turn locked camshaft in such a way that one end of the camshaft straightedge strikes the cylinder head. Measure the resulting clearance at the other end of the camshaft straightedge with a feeler gauge. Insert feeler gauge with halved value between the camshaft straightedge and the cylinder head. Now turn the camshaft in such a way that the camshaft straightedge is positioned on the feeler gauge. Slide in the second feeler gauge with the same dimension at the other end between the camshaft straightedge and the cylinder head.

–  Install supporting device -MP9-200- and support engine in fitting position.

–  Remove engine mounting -arrows A and B-. –  Remove the noise insulation. –  Unscrew engine support bracket from cylinder block.   Note The engine with the supporting device must be slightly raised in order to remove the engine support bracket. The bottom bolt remains in the support. –  Unscrew nut for tensioning pulley. –  Slacken the toothed belt from the camshaft timing gear and remove it from the injection pump gear.

–  Unscrew the fixing screws -1- for the injection pump gear and remove the injection pump gear from the hub on the injection pump shaft.   Note The nut -2- for the hub must never be loosened. Basic setting up of the injection pump cannot be undertaken using normal workshop tools.

–  Disconnect plug connection -arrow- on the injection pump and pull out of the bracket.

–  Unscrew the fixing screws -1- of the bracket.

–  Unscrew the fixing screws of the rear support -arrow-. –  Remove the injection pump.