Skoda Workshop Service and Repair Manuals

Removing and installing timing belt   Note Before removing the timing belt, mark direction of running. Reversing the rotation direction of an already used belt may destroy it. Special tools and workshop equipment required t  Torque wrench t  Counterholder -MP 1-216- t  Locking pin -3359- t  Adjusting straightedge -MP 1-312- t  Wrench for timing belt-tensioning pulley (e. g. -Matra V159-, -Hazet 2587- or -Stahlwille 127-17 -) t  Supporting device -MP 9-200 - t  Feeler gauges t  Puller -T40001- with hook -T40001/2- and -T40001/3-

1 -	120 Nm + torque a further (90°) 1/4 turn

q	to release and tighten the counterholder -MP 1-310- or counterholder -T30004- use

q	always replace

q	thread and contact surface must be free of oil and grease.

q	tightening to 90° may occur in successive stages

2 -	40 Nm + torque a further (90°) 1/4 turn

q	always replace

q	tightening to 90° may occur in successive stages

3 -

15 Nm

4 -

23 Nm

5 -

22 Nm

q	for vehicles 03.00 ?

6 -	Bottom toothed belt guard

7 -

10 Nm

8 -	Middle toothed belt guard

9 -

45 Nm

10 -	Engine support bracket

11 -	Top toothed belt guard

12 -	Timing belt

q	before removing mark running direction

q	check for wear

q	do not kink

q	removing and installing → Anchor

13 -	Guide pulley

q	for vehicles 03.00 ?

14 -	20 Nm + torque a further (90°) 1/4 turn

q

replace

q	tightening to 90° may occur in successive stages

15 -

20 Nm

16 -	screw for guide pulley

q	17 Nm for console - → Item; spare part No. 038 903 143 E/F

q	20 Nm for console - → Item; spare part No. 038 903 143 A/B

17 -

45 Nm

q	hold camshaft sprocket with counterholder -MP 1-216 - for slackening and tightening

18 -	Camshaft sprocket

q	pull off from cone of camshaft with puller -T40001-

19 -	Semi-automatic tensioning pulley

q	inspecting semi-automatic timing belt tensioning pulley → Chapter

q	Fitting position → Fig.

20 -	Guide pulley

21 -

30 Nm

22 -	Rear timing belt guard

q	insert at the lower edge behind the front sealing flange

23 -	Injection pump gear

q	for vehicles 08.97 ?

24 -	Injection pump gear

q	for vehicles 07.97 ?

25 -	Coolant pump

q	removing and installing → Chapter

26 -	Guide pulley

q	to remove, unscrew the coolant pump

27 -	Timing belt gear - crankshaft

q	there must not be any oil present on contact surface between timing belt sprocket and the crankshaft

q	Fitting position: the flats on the timing belt gear and the crankshaft must correspond

28 -

Bush

29 -

Nut

q	insert in bush → Item

30 -	Injection pump

q	do not unscrew central nut -arrow-

q	removing and installing → 1.9 ltr./66 kW (TDI) Engine, Fuel Injection and Glow Plug System → Rep. Gr.23

31 -

45 Nm

32 -

Console

q	for vehicles without air conditioning

q	for injection pump, generator and vane pump

Fitting position of the semi-automatic tensioning pulley Holding claw -arrow- must lock into the recess on the rear timing belt cover. Removing toothed belt Engine installed in the vehicle –  Remove engine cover → Chapter. –  Release the washer reservoir and lay aside. –  Release the coolant expansion reservoir and lay aside. –  Release the PAS reservoir and lay aside. –  Release the fuel filter reservoir and lay aside. For all vehicles –  Remove upper timing belt cover and cylinder head cover. –  Remove vacuum pump for brake servo unit → Chapter. –  Remove the ribbed V-belt → Anchor. Engine installed in the vehicle –  Remove the cover for the inspection hole of flywheel.

–  Position crankshaft to TDC cylinder 1 -arrow- (vehicles with manual gearbox).   Note Position crankshaft to TDC cylinder 1 on removed engine → Anchor. For all vehicles

–  Lock the camshaft position with the adjusting straightedge -MP 1-312 -.   Note The valves of cylinder 1 must be closed and the valves of cylinder 4 must overlap. –  Centre adjusting straightedge as follows:    Turn locked camshaft in such a way that one end of the adjusting straightedge strikes the cylinder head. Measure the resulting clearance at the other end of the adjusting straightedge with a feeler gauge. Insert feeler gauge with halved value between the adjusting straightedge and the cylinder head. Now turn the camshaft in such a way that the adjusting straightedge is positioned on the feeler gauge. Insert the second feeler gauge with the same value between the adjusting straightedge and the cylinder head. –  Lock injection pump gear with rig pin -3359-.   Note Rig pin must be moistened with oil each time in use. It is recommended to use a mirror, in order to facilitate the removal.

–  Slacken the fixing screws -1- of the injection pump gear and replace with new ones. –  Lightly tighten the bolts, so that the wheel should still be turnable.   Note Do not unscrew the central nut -2- of the injection pump gear. This could result in a misadjustment of the basic setting of the injection pump which can no longer be corrected with workshop tools. –  Slacken nut of the toothed belt tensioning pulley. –  Remove vibration damper/belt pulley.

–  Insert supporting device -MP 9-200- and support engine with gearbox in this position.

–  Unbolt engine support from engine mount and engine mount from body -arrows-. –  Unscrew engine support bracket from engine.   Note To slacken the front bolt of the engine support, raise engine slightly with spindle of supporting device -MP 9-200-. –  Remove belt pulley from the crankshaft. –  Remove middle and bottom timing belt guard. –  Mark the rotation direction of the timing belt. –  Remove timing belt. Installing the timing belt –  Check, if TDC marking on flywheel and reference mark must be aligned. –  Loosen the fixing bolt for the camshaft timing gear by 1/2 turn. Counterhold camshaft sprocket with counterholder -MP 1-216 -.   WARNING Once the camshaft sprocket is released and fitted, never use the adjusting straightedge as counterholder! Counterhold camshaft sprocket with counterholder - MP 1-216 -.

–  Insert puller -T40001- with hook -T40001/2 --A- and -T40001/3--B- into the camshaft sprocket. Use open-end wrench -C- as counterholder and slacken the camshaft sprocket from the cone of the camshaft. –  Lightly tighten fixing screw for camshaft sprocket sufficiently so that the camshaft sprocket can be turned. –  Align the injection pump gear in middle position in the elongated holes. –  Place toothed belt on toothed belt gear - crankshaft, guide pulley, injection pump gear and tensioning pulley (pay attention to running direction).

–  Turn tensioning pulley with nut wrench (e.g. -Matra V159-) to the right, until the notch and lobe -arrows- are positioned opposite. –  Tighten nut to the tensioning pulley to 20 Nm. –  Once again check, if TDC marking on flywheel and reference mark is aligned. –  Tighten the fixing bolt for the camshaft timing gear to 45 Nm. Counterhold camshaft sprocket with counterholder -MP 1-216-.

–  Tighten fixing screws for injection pump gear -arrows- to 20 Nm. –  Remove adjusting straightedge. –  Remove the locking pin -3359-. –  Turn crankshaft two turns further in the direction of running of the engine and again position on TDC for cylinder 1. –  Then check if the injection pump gear can be locked with the locking pin - 3359-. If the injection pump gear cannot be arrested: –  Turn the crankshaft until the locking pin -3359- can be inserted in the hub. –  Lock injection pump gear with rig pin. –  Release fixing screws for injection pump gear. –  Turn the crankshaft until the TDC marking on the flywheel and reference mark is aligned. –  Tighten the fixing screws for injection pump gear to 20 Nm and then torque a further 1/4 (90°). –  Remove the locking pin -3359-. If the injection pump gear can be arrested: –  Tighten the fixing screws for the injection pump gear 1/4 (90°). –  Install bottom and middle toothed belt guard. –  Install engine mount → Chapter –  Install engine console. Tightening torques → Chapter –  Remove supporting device -MP 9-200-. –  Install vacuum pump for brake servo unit → Chapter –  Install top toothed belt guard and cylinder head cover. –  Install tensioning pulley for V-ribbed belt. –  Install the V-ribbed belt → Anchor. –  Attach coolant reservoir, power steering and fuel filter. –  Install the engine cover. –  Dynamically test and set commencement of injection: → 1.9 ltr./50 kW (SDI) Engine, Fuel Injection and Glow Plug System → Rep. Gr.23.