Skoda Workshop Service and Repair Manuals

Removing   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 fitted again in the same location when it 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 screw or 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 correct assignment of the corresponding connectors, if necessary mark. Procedure –  On models fitted with a coded radio set, determine and note the coding. –  Switch off the ignition and disconnect the battery earth strap.

–  Remove engine cover: –  Pull out oil dipstick -1-. –  Remove plug -2- and slacken nuts -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 the rear frame side rails at the height of the marking on the sill.

–  Remove noise insulation panel in middle as well as on left and right -arrows-. –  Open the cap of the coolant expansion reservoir.

–  Turn the drain valve -arrow- on the radiator to the left, if necessary fit auxiliary hose onto connection.

–  In addition, detach coolant hose at bottom of oil cooler -arrow- and allow remaining coolant to drain.

–  Slacken hose clamp -2- and remove air guide hose -1-. –  Detach vent hose -3- and unplug connector for air mass meter -4-. –  Slacken fixing screws -5- and remove air filter cover -6-.

–  Remove battery and battery tray -arrows-.

–  Unbolt earth strap -1-. –  Detach cables -3- and -4- at starter. –  Disconnect plug connection -2- and pull out of bracket. –  Detach cables from bracket at starter, lay to the side and unscrew the bracket.

–  Unbolt cable -1- of terminal 30/B+ from generator. –  Detach plug connection -2- of terminal D+. –  Unscrew cable clamp -3-. Vehicles with air conditioning –  Disconnect plug connection at AC compressor. For all vehicles:

–  Disconnect wiring/plug: 1 -  Edge connector for glow plugs 2 -  Plug connection for needle lift sender -G80- (brown, connector black) 3 -  Plug connection for engine speed sender -G28- (black) 4 -  Plug connection for injection pump 5 -  Plug for electronic thermoswitch -F14- (black, only for air conditioning system) –  Disconnect connector for coolant temperature sender -G62- (black) at cylinder head flange. –  Disconnect plug for oil pressure switch -F1- at oil filter holder. –  Detach cable harness for the fixtures and run out to the side. –  Disconnect the plug connection at the throttle valve positioner. –  Remove shift mechanism: → 5-Speed Manual Gearbox 02K → Rep. Gr.34. –  Remove the clutch slave cylinder → 5-Speed Manual Gearbox 02K → Rep. Gr.34.

–  Remove fuel hoses -arrows- at the injection pump, close with clean plugs and lay aside. –  Remove following coolant hoses with pliers for spring strap clips:

1 - Coolant hose at bottom of coolant regulator housing and radiator (remove hose). 2 - Coolant hose to the expansion reservoir.

1 - Top coolant hose at branch piece 2 - Coolant hose to the expansion reservoir and heat exchanger 3 - Coolant hose to the heat exchanger 4 - Coolant hose from heat exchanger at coolant pipe –  Detach vacuum hose: t  on the vacuum pump t  on the mechanical exhaust gas recirculation valve   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. –  Position flat ring spanner SW 16 at hexagon of tensioning pulley.

–  Swing the the tensioning pulley in the direction of the arrow detension the V-ribbed belt. –  Remove the V-ribbed belt. –  Remove belt pulley of hydraulic pump for power-assisted steering. –  Unscrew the vane pump for the power-assisted steering. Vehicles with air conditioning   WARNING Do not open the refrigerant circuit of the air conditioning system.

–  Remove AC compressor and tie up together with the connected hoses with wire to the towing lug -arrow-.   Note Protect the shock absorber with suitable adhesive tape from scratches. All vehicles

–  Remove pendulum support -arrows-. –  Unscrew the drive shafts from the gearbox flanges → Chassis → Rep. Gr.40. –  Lay both drive shafts to the rear and secure with wire to the body. –  Remove front part of exhaust system → Chapter. Vehicles with increased cooling –  Remove right electric fan (smaller fan wheel diameter). All vehicles

–  Fix engine mount -T10012- to the cylinder block using fixing nuts and bolts M10 to 40 Nm. –  Slightly raise the engine and gearbox with the engine/gearbox jack.   Note Use the double ladder (e.g. -V.A.S 5085-) to remove the fixing screws of the engine and gearbox console. –  Remove screws from engine and gearbox mounts from above. –  Carefully lower the engine with gearbox.   Note Engine with gearbox must be guided carefully, in order to avoid damaging the body. –  Remove engine/gearbox connecting screws.