Skoda Workshop Service and Repair Manuals

Removing engine Special tools and workshop equipment required t  Removal tool for inner lining of the door panel -MP8-602/1- t  Engine mount -T40076- t  Engine/gearbox jack, e.g. -V.A.G 1383 A- t  Catch pan, e.g. -VAS 6208- t  Double ladder, e. g. -VAS 5085- t  Pliers for spring strap clamps t  Bolt M10 x 50 t  Nut M12   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  Leave the ignition key in the ignition lock so that the steering lock does not click into place. t  Collect drained coolant in a clean container for proper disposal or reuse.   WARNING When undertaking all installation work, particularly in the engine compartment because of its cramped construction, please observe the following: t  Lay lines of all kinds in such a way that the original line guide is re-established. t  Ensure that there is adequate free access to all moving or hot components. Observe all safety measures and notes for assembly work on the fuel supply and injection system, at the charge air system and observe as well the rules for cleanliness → Chapter. Observe the instructions for the fuel hose in the engine compartment → Chapter. –  If present, take the adapter for the anti-theft wheel bolts out of the luggage compartment. –  Disconnect the battery-earth strap with the ignition off → Electrical System; Rep. gr.27. –  Only slacken the nut of the right drive shaft. –  Remove front wheels. –  Remove the right and left wheelhouse liner → Body Work; Rep. gr.66. –  Drain coolant → Chapter.

–  Unscrew the positive cable -1- at the positive terminal on the battery. –  Remove engine cover → Chapter. –  Remove air intake hose. –  Remove the battery with the battery tray → Electrical System; Rep. gr.27.

–  Remove vacuum lines with brackets -1- from air filter housing. –  Release plug -3- from charge pressure control solenoid valve -N75-. –  Unscrew bracket -2- with charge pressure control solenoid valve -N75-. –  Place the charge pressure control solenoid valve -N75- with vacuum lines on the engine. –  Remove air filter housing with air mass meter -G70- and intake hose → Chapter. –  Remove shift mechanism from gearbox → Gearbox; Rep. gr.34. –  Remove pressure line from breather/slave cylinder → Gearbox; Rep. gr.30.   Caution After separating the hydraulic line, do not operate the clutch pedal.

–  Unplug connector -arrow- from speedometer sender -G22- (if available). –  Remove vacuum line from the brake servo unit. –  Remove the engine control unit → Chapter. –  Unplug the plug of the engine wiring harness and disconnect from the engine control unit.

–  Disconnect plug connection -arrow-.

–  Carefully slacken the engine wiring harness on its fixing points -arrows-. –  Place the engine wiring harness on the engine.

–  Disconnect plug -arrow 1- from reversing light switch -F4-. –  Remove connector -arrow 2- and cable -arrow 3- from the starter. –  Expose cables. –  Disconnect the plug connection below the starter. –  Remove the coolant hoses at the top radiator and secure to the engine.

–  Pull off fuel hoses -1, 2, 5 and 6-. To do so, push the quick couplings onto the nozzles, press in the securing elements (hold pressed) and detach the quick couplings. Collect the fuel which flows out with a cleaning cloth. –  Unplug connector -4-. –  Unscrew expansion bottle -3-. –  Place the expansion bottle with connected coolant hoses and fuel hoses on the engine. –  Remove fan shroud with radiator fan -V7- → Chapter. –  Remove right charge air pipe to throttle valve control unit → Chapter. –  Remove drive shaft to the right → Chassis; Rep. gr.40. –  Unscrew left drive shaft from the flange shaft of the gearbox and tie up. Vehicles with air conditioning –  Remove V-ribbed belt → Chapter.   WARNING Risk of injury through refrigerant. Do not open the refrigerant circuit of the air conditioning system.   Caution Risk of damaging the condensor, the refrigerant lines and hoses. Do not over-tension or buckle refrigerant lines and hoses. –  Remove the AC compressor from the bracket for auxiliary units and secure it with connected refrigerant hoses to the body. Continued for all vehicles Vehicles with diesel particle filter –  Remove diesel particle filter: t  Left-hand drive → Chapter t  Right-hand drive → Chapter Vehicles without diesel particle filter –  Remove pre-exhaust pipe → Chapter. Continued for all vehicles

–  Disconnect plug connection for exhaust gas temperature sender 1 -G235-. –  Remove the coolant hoses at the heat exchanger and secure to the engine. –  Disconnect plug at oil level and oil temperature sender -G266-. –  Remove coolant temperature sender at radiator outlet -G83- ( → Chapter, Pos. 26).

–  Remove noise insulation -2- for oil pan. To do this:    - Release screws -1-. - Remove 2-part clips -arrows-. - Remove cable fixings at the noise insulation.

–  Release screw -6-.

–  Tighten engine mount -T40076- with nut -1- at the cylinder block to approx. 20 Nm. –  Place nut M12 -3- between engine mount -T40076- and cylinder block. –  Fix the engine mount -T40076- with a screw M10 x 50 -2- to the cylinder block. –  Insert engine/gearbox jack -V.A.G 1383 A- at engine mount -T40076- and slightly raise.   Note Use the double ladder to release the screws for the engine/gearbox mounting.

–  Successively release screws for engine mount -arrows-. l  The nut -2- must not be released.

–  Successively release screws for gearbox mount -arrows-.   Note t  Check whether all hose and line connections between engine, gearbox and body are released. t  When lowering carefully guide the engine with the gearbox, in order to avoid damage. –  Carefully lower engine with gearbox. During this procedure, turn or move the engine with the gearbox depending upon the constriction. –  Remove the gearbox from the engine.