Skoda Workshop Service and Repair Manuals

Removing and installing camshafts Special tools and workshop equipment required t  Counterholder -T10051- t  Extractor -T10052- t  Camshaft-insertion tool -T40094- t  Camshaft-insertion tool -T40095- t  Tensioning tool -T40096/1- t  Silicone sealant -D 176 501 A1- t  Sealant remover gasket stripper (bearing code GST, bearing article no. R 34402), manufacturer Retech s.r.o. t  Cleaning and degreasing agent, e.g. -D 009 401 04- t  Protective goggles and gloves Removing l  Cylinder head fitted. –  Pull toothed belt off camshaft sprocket and from toothed belt gear on the high pressure pump → Chapter. –  Remove cylinder head cover → Chapter.

–  Screw out the fixing screws -1- of the camshaft sprocket. –  Remove camshaft sprocket from the hub.

–  Slacken screw -1- for the hub of the camshaft, to do so counterhold with counterholder -T10051-. –  Release screw by about 2 turns.

–  Position the extractor -T10052- at the hub of the camshaft and screw the screws -1- into the hub. –  Slacken the hub of the toothed belt sprocket from the camshaft cone by uniformly tightening the screw of the extractor -2-.   Note While doing so, hold the extractor firmly using a wrench SW 30. –  Remove hub of toothed belt sprocket from cone of camshaft. –  Remove vacuum pump → Chapter.

–  Loosen the screws for the bearing frame in the sequence -20...1-. –  Unscrew screws and carefully separate the bearing frame from the cylinder head. –  Mark the camshafts for reinstalling and remove. Install   WARNING Wear protective gloves when working with sealant and grease remover! –  Remove residual sealant on the bearing frame and cylinder head using a chemical sealant remover. –  Clean sealing surfaces, they must be free of oil and grease. –  Oil contact surfaces of camshafts.   Caution The camshafts must only be installed using the camshaft-insertion tool -T40094- as described below. Otherwise the axial bearing in the bearing frame can be destroyed and the cylinder head must be replaced. Set up the camshaft-insertion tool -T40094- as follows:

–  Remove the supports -T40094/3-, -T40094/4- and -T40094/5- from the base plate. The screws are located at the bottom.   Note If the components of the camshaft-insertion tool -T40094- are not yet marked, they must be marked for the subsequent refitting. For this use e.g. blow counts.

–  Tighten the supports -T40094/9- and -T40094/12- (with detent bracket -T40094/11-) to the base plate as shown in the illustration.

–  Place the support -T40094/2- on the position -A- and the support -T40094/1- on the position -D-. –  Insert the inlet camshaft in the supports -T40094/1- and -T40094/2-.

l  The recess -arrow- for the cylinder head screw must point to the outside. –  Fit on a feeler gauge of 0.50 mm and slide the support -T40094/8- into the groove of the inlet camshaft. –  Insert the outlet camshaft in the supports -T40094/9- and -T40094/12- and lock with serration of detent bracket -T40094/11- l  The peg on the detent bracket -T40094/11- must engage in the groove of the camshaft.

–  Position the tensioning tool -T40096/1- on the pinions of the outlet camshaft in such a way that each clamping arm engages in a pinion. l  The wider clamping arm must engage in the wider pinion. –  Tension the tensioning tool -T40096/1- with the knurled wheel until the tooth flanks of both wheels are aligned. –  Slide the outlet camshaft to the inlet camshaft until the serrations are in mesh.

–  Position the bearing frames onto the camshafts. l  All of the camshaft bearings must rest on the camshafts. –  Position the camshaft-insertion tool -T40095-, as shown in the figure, and fix the camshafts in the bearing frame. –  Remove the detent bracket -T40094/11- and pull the support -T40094/8- out of the groove of the inlet camshaft.   Note

Pay attention to the use by date on sealant. –  Cut off nozzle tube at the front marking (Ø of nozzle approx. 2 mm).   Caution Risk of contamination of the camshaft bearings through excess sealant. Do not apply thicker sealant beads than indicated.

–  Apply sealant onto the clean sealing surface of the cylinder head as shown in the illustration. l  Thickness of the sealant beads: 2…3 mm l  Pay attention that the oil supply hole for the bearing frame is not closed through excess sealant.   Note The bearing frame with camshafts must be installed within 5 minutes after applying the silicone sealant. –  Remove the camshafts together with the bearing frame, the camshaft-insertion tool -T40095- and the tensioning tool -T40096/1- from the camshaft-insertion tool -T40094- and carefully insert into the bearings in the cylinder head.

–  Insert the screws of the bearing frame and first tighten in the sequence -1 … 20- by hand. l  The ladder frame must rest on the cylinder head with its complete contact surface. –  Tighten the screws of the bearing frame in the sequence -1…20-.    Tightening torque: 10 Nm –  Remove the camshaft-insertion tool -T40095- and the tensioning tool -T40096/1-. The further assembly is carried out in the reverse order, while paying attention to the following: –  Drive the new screw cap ( → Chapter, Pos. 17) into the cylinder head until flush. –  Replacing camshaft gasket ring → Chapter.

–  Install the hub for the camshaft timing gear and tighten the screw -1- to 100 Nm. To do so, counterhold with counterholder -T10051-.

–  Push camshaft sprocket onto the hub.   Note While doing so, the arrow on the camshaft sprocket must be close to the »12 o'clock« position. –  Screw in screws -1- by hand.

–  Lock hub with locking pin -3359-. –  Installing the timing belt → Chapter. –  Install vacuum pump → Chapter. –  Install cylinder head cover → Chapter.   Note t  After installing the camshafts, the engine must not be cranked or started for about 30 minutes. The hydraulic clearance compensation elements must settle (otherwise the valves would strike the pistons). t  After carrying out work on the valve gear, carefully crank engine at least 2 revolutions to ensure that no valve touches the piston when the engine is started.