Skoda Workshop Service and Repair Manuals

Removing   Note t  The engine is removed towards the front together with the gearbox. t  All cable straps that have been loosened or cut open when the engine was removed must be fitted again in the same location when the engine is installed again. t  The hose connections are secured with screw-type clips, spring-type clips or clamp-type clips. t  Always replace clamp-type clips with spring-type clips. t  Fuel hoses at the engine must only be secured with spring-type clips. The use of clamp-type or screw-type clips is not allowed. t  Use pliers for spring strap clips to fit the spring strap clips. t  Pay attention to the correct assignment of the plug connectors, if necessary mark. Procedure –  Remove front bonnet on the hinges: → Body Work; Rep. Gr.55. –  On models fitted with a coded radio set, pay attention to the coding; determine if necessary. –  Remove the battery: → Electrical System; Rep. Gr.27.

–  Remove battery tray -arrows-. –  Raise vehicle with a lift platform, pay attention to the following points:

The arms of the lift platform must be positioned under the frame side rail.   WARNING Under no circumstances may the arms of the lift platform be positioned under the sills, the front or rear axles.

Both jacking up points at front are located on both front frame side rails at the height of the marking on the sill.   WARNING Never start the engine or engage a gear when the vehicle is raised, while even one driving wheel is still in contact with the ground.

Both rear jacking up points are located on both front frame side rails at the height of the marking on the sill.

–  Remove noise insulation -arrows-. –  Open the cap of the coolant expansion reservoir. –  Position drip tray (e.g. -V.A.G 1306-) under the engine.

–  Turn the drain plug -arrow- on the radiator to the left and pull to the rear, if necessary fit auxiliary hose onto connection.

–  Remove engine cover -1-. –  Remove air filter -2-.   Note Do not use electric or air screwdrivers! –  Detach vent hose for crankcase at air filter. –  Detach air guide hose at hot air collector (manifold).

–  Disconnect plug from connector for the speedometer sender -G22--1- and from the reversing light switch -F4--2-.

–  Lever off front shift rod -1- from shift lever -2- with screwdriver, remove lock washer -3- and remove console -4- upwards. –  Separate console -4- by turning 90° to the right from the shift rod with mass damper -5-. Swing shift rod with mass damper to the top and remove from bracket -6-.

–  Use a screwdriver to lever off the long coupling rods from the selector lever -arrows-. Unscrew front shift lever -1- at gearbox. –  Release screws -2- and remove control console -3- with coupling rods and front shift lever from gearbox.

–  Remove the earth strap from the top engine/gearbox connecting screw -1-. –  Unscrew cable clip -3- at top starter -arrow-.

–  Pull out coolant hoses from the connections -1...6- of the coolant regulator housing (spring strap clamps). –  Pull out plug connector at the coolant temperature sender -G62--7-. –  Pull out plug connector at hall sender -G40-/ignition distributor. –  Remove plug connector at knock sensor 1 -G61- below the coolant pipe. –  Disconnect the vacuum hose to brake servo unit from intake manifold (warm-type clamp). –  Loosen coolant hose at top radiator (quick coupling).

–  Unplug plug connector -arrows- of the injectors (-N30 až N33-). –  Detach plug connector -1- for intake air temperature sender -G42- and intake manifold pressure sender -G71- –  Unplug plug connector -2- for throttle valve control unit -J338-. –  Unplug plug connector -4- for oil pressure switch -F22-. –  Unclip cable guide -3- with cables of fuel distributor. –  Remove throttle control cable at throttle valve control unit.   WARNING The fuel system is under pressure! Before opening the system lay cleaning cloths around the connection point. Reduce pressure by carefully releasing the connection point.

–  Remove fuel feed line -1- and fuel return line -2-, to do so press release buttons at the separation point. Lines and connectors are colour-coded. –  Detach hose -3- at the ACF tank. –  Unscrew the coolant expansion bottle and place outside (the coolant hoses remain attached).   Note Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation direction of an already used belt may destroy it. Pay attention to the correct position of the V-ribbed belt in the belt pulley when installing it.

–  To slacken the V-ribbed belt turn the tensioning element in the direction of the arrow. –  Remove the V-ribbed belt. –  Unbolt 2 brackets for the pressure line of power-assisted steering (on left at gearbox and below starter). –  Unbolt belt pulley of hydraulic pump for power-assisted steering. –  Unbolt the vane pump of power-assisted steering and tie up to the front of the vehicle. The hoses remain connected. –  Remove crankshaft belt pulley.

–  Unbolt cable -1- of terminal 30/B+ at alternator. –  Unplug connector -2- of terminal D+. –  Unscrew cable clamp -3-. –  Remove the cable from the guide tube (at the exhaust manifold).

–  Release cable from starter -1- and disconnect plug -2-. Vehicles with air conditioning   WARNING Do not open the refrigerant circuit of the air conditioning system. –  Unscrew the holder for refrigerant hoses.

–  Unscrew compressor of air conditioning system, lower together with the connected refrigerant hoses and tie up with wire to the towing lug on the inside of the bumper -arrow-.   Note Protect the bumper with soft base from damage due to the wire. –  Remove AC generator. All vehicles

–  Unscrew clutch slave cylinder from the gearbox -arrows-, lay aside and secure with wire. Do not open line system.   Note Do not depress the clutch pedal.

–  Unbolt the pendulum support -arrows-. –  Unscrew the drive shafts from the gearbox flanges. –  Lay right drive shaft to the rear and secure with wire to the assembly carrier, allow left drive shaft to hang down.

–  Separate front exhaust pipe from exhaust manifold, to do so unscrew nuts -arrows-.

–  Release double clamp -A- and separate the exhaust system. –  Lay return pipe of the catalytic converter as far upwards as possible (e.g. foam material between pipe and double clamp), so that the front exhaust pipe lies as far downwards as possible and does not obstruct the removal of the engine. –  Lay aside coolant hoses and electrical cables and secure.

–  Hook on the suspension fixture -MP 9-201- as follows and raise slightly with the workshop crane: On the belt pulley side: 2. Hole of the perforated bar in position 1 (if necessary unscrew bracket for engine cover) On the flywheel side: 2. Hole of the perforated bar in position 5   WARNING Use securing pins on the hooks and rig pins.   Note t  The rig positions on the supporting bracket marked 1 … 4 point towards the belt pulley. t  The holes in the perforated bars are counted from the hook.

–  Remove engine mount -A- and gearbox mount -B-. Release screws -1...3- Before removing the engine mount, unscrew power steering fluid reservoir. –  Turn unit slightly to the left (engine to the front, gearbox to the rear) and lift it out upwards.   Note When lifting up the unit, the assembly block must be guided by a second mechanic, in order to avoid damage to the body due to the low clearance.

–  Screws -1 ... 8- release at engine/gearbox flange. Screw -7- holds a small cover plate. –  Separate engine and gearbox.