Skoda Workshop Service and Repair Manuals

Installing the engine (Fabia II, Roomster, Rapid) Special tools and workshop equipment required t  Grease -G 000 100- for manual gearbox Precondition l  Fit engine and gearbox using engine mount to the engine/gearbox jack. Installation is performed in the reverse order, pay attention to the following points:   Note t  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. t  When undertaking assembly replace self-locking nuts and screws which have been tightened to a torquing angle. t  Always replace gasket rings and seals. t  All cable straps should be fastened again in the same place when installing. t  Secure all hose connections with corresponding hose clamps → Electronic Catalogue of Original Parts.   Caution When undertaking all installation work, particularly in the engine compartment due to its cramped construction, please observe the following: t  Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling fluid and refrigerant, brake fluid, vacuum) and electrical lines in such a way that the original line guide is re-established. t  In order to avoid damage to the cables, ensure that there is adequate free access to all moving or hot components.   Note t  Clean the serration of the drive shaft and if the clutch disc has been used clean the hub serration, remove corrosion and only apply a very thin layer of grease -G 000 100- on the serration. Subsequently move the clutch disc up and down on the drive shaft until the hub fits smoothly on the shaft. Always remove excess grease. t  After installing the coupling, check the centering of the clutch disc → Gearbox; Rep. gr.30. t  Check the clutch release bearing for wear. Replace release bearing if worn → Gearbox; Rep. gr.30. –  Check whether the dowel sleeves for centering the engine/gearbox are present in the cylinder block; insert if necessary.

–  Ensure that the intermediate plate has been inserted on the sealing flange and is pushed onto the dowel sleeves -arrows-. –  Screw on gearbox to engine → Gearbox; Rep. gr.34. –  Insert engine with gearbox into the body. For vehicles Fabia II, Roomster

–  Successively screw in screws for engine mounting -arrows- by hand. For vehicles Rapid

–  Successively screw in screws for engine mounting -arrows- by hand. Continued for all vehicles

–  Successively screw in by hand the screws for gearbox mount -arrows-. –  Remove engine mount -T10012- from engine. For vehicles Fabia II, Roomster –  Install pre-exhaust pipe with diesel particle filter → Chapter. For vehicles Rapid –  Install exhaust pipe with catalytic converter → Chapter. Continued for all vehicles

–  First tighten pendulum support with new screws -2- and -3- at gearbox and then tighten with new screw -1- at assembly carrier. –  Install the left as well as the right drive shaft → Chassis; Rep. gr.40. –  Install the slave cylinder, if necessary bleed the clutch control → Gearbox; Rep. gr.30. –  Attach shift mechanism to gearbox and adjust → Gearbox; Rep. gr.34. –  Install AC compressor at the bracket for auxiliary units → Chapter. –  Install alternator → Electrical System; Rep. gr.27. –  Install the V-ribbed belt → Chapter. –  Connect all hoses to the engine. –  Connect electrical connections and attach cables → Current flow diagrams, Electrical fault finding and Fitting locations. –  Carry out cohesive work when reconnecting the battery → Electrical System; Rep. gr.27. –  Top up coolant → Chapter. –  Checking the oil level: t  → BookletFabia II. t  → BookletRoomster. t  → BookletRapid. –  Install the left and right wheelhouse liner → Body Work; Rep. gr.66. –  Install the noise insulation → Body Work; Rep. gr.50. –  Filling and bleeding the fuel system. For this purpose, connect the vehicle diagnosis, measurement and information system -VAS 505x- and carry out the targeted function „bleeding the fuel system“. During this function, the fuel pump is actuated for 180 seconds. –  Check fuel system for tightness → Chapter. –  Perform a test drive. –  Interrogate all fault memories, if necessary rectify any faults existing and erase the fault memory → Vehicle diagnostic tester.   Note After deleting the fault memory of the engine control unit the readiness code must be re-generated. Tightening torques

Component		Nm
Screws or nuts	M6	10
	M7	15
	M8	20
	M10	40
	M12	70
Engine/gearbox connecting screws → Gearbox; Rep. gr.34