Skoda Workshop Service and Repair Manuals

Removing and installing injection pump Special tools and workshop equipment required t  Adjusting straightedge -MP1-312 (3418)- t  Adjusting device for TDC point -MP1-313 (2068A)- t  Centering mandrel -3359- t  Counterholder -MP1-216 (3036)- t  Wrench for timing belt-tensioning pulley (e. g. -Matra V159-, -Hazet 2587-, -Stahlwille 127-17 -) t  Connection fitting (e.g. -V.A.G 1318/10-) t  Vacuum pump (e.g. -V.A.G 1390-) t  Ring spanner for injection lines (e.g. -3035 -) t  Puller -T40001- with hook -T40001/2- and -T40001/3- t  Feeler gauges t  If necessary steel straightedge (marking tool) t  Transparent fuel line Removing –  Remove engine cover. –  Remove all the fuel lines from the injection pump.   Note Use the open ring spanner (e.g. -3035-) for removing the high-pressure lines. –  Cover the openings with a clean cloth. –  Remove top toothed belt guard and cylinder head cover as well as vacuum pump → 1.9 ltr./50 kW (TDI) Engine, Mechanics → Rep. Gr.13. Engine installed in the vehicle –  Remove trim panel at the inspection opening of the flywheel.

–  Position crankshaft to TDC cylinder 1 -arrow-. Removed engine is on the working surface:

–  Screw in adjusting device for TDC point -MP1-313-, as shown in the fig. –  Set adjusting device to 90 mm (the left notch on the vernier -arrow A- is the reference point). –  Rotate crankshaft until the TDC marking on the flywheel corresponds with the edge of the adjusting device -arrow B-. Engine attached to engine and gearbox mount -MP1-202-

–  Position flexible steel straightedge (marking tool) at circumference of the flywheel. –  Measure exactly 100 mm from the TDC marking from -arrow A- and affix auxiliary marking -arrow B- with marking tool.

–  Screw in adjusting device for TDC point -MP1-313-, as shown in the fig. –  Set adjusting device to 104 mm (the left notch on the vernier -arrow A- is the reference point). –  Rotate crankshaft until the TDC marking on the flywheel corresponds with the edge of the adjusting device -arrow B-. For all vehicles

–  Lock the camshaft position with the adjusting straightedge -MP1-312-.   Note The valves of cylinder 1 must be closed and the valves of cylinder 4 must overlap -arrows-. –  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.

–  Loosen fixing bolts -1- of the injection pump gear.   Note t  Use rig pin -3359- to counterhold the injection pump gear → Anchor, fig A13-0052. t  Rig pin must be moistened with oil each time in use. It is recommended to use a mirror in order to facilitate the removal. t  If it is not possible to unlock the injection pump gear with the rig pin, the crankshaft must be turned in such a way that the bore holes for the rig pin are aligned. Then, loosen the screws of the injection pump gear and only then position the crankshaft to TDC. t  Never release 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. –  Unscrew nut for tensioning pulley. –  Remove toothed belt from the camshaft sprockets and the injection pump gear. –  Disconnect the plug connection for the electrical connections of the injection pump.

–  Unscrew fixing screws -1- from the console.   Note Never release 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.

–  Unscrew fixing screw from the rear bracket -arrow-. –  Remove injection pump. Installing –  Insert injection pump into the console and first of all fasten the screw to the rear support with cone nut. –  Insert front fixing screws and tighten to 25 Nm. –  Screw the injection pump gear with new bolts to the hub, so that the gear can still be turned.

–  Align the injection pump gear in middle position in the elongated holes -arrows-. –  Lock the injection pump gear with the rig pin -3359-. –  Loosen the fixing bolt on the camshaft timing gear by approx. 1/2 turn.   Note Once the camshaft sprocket is released and fitted, never use the adjusting straightedge as counterholder! Counterhold camshaft sprocket with counterholder - MP1-216 -.

–  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. –  Tighten fixing screw for camshaft sprocket sufficiently, so that the camshaft sprocket can be turned. –  Check whether the TDC marking on the flywheel is located opposite the reference mark. –  Place the toothed belt on the injection pump gear, camshaft sprocket and tensioning pulley.

–  Tighten the timing belt. Turn the wrench for timing belt-tensioning pulley (e. g. -Matra V159-) with positioning wedge to the right until the notch and lobe -arrows- are positioned opposite.   Note

Pay attention to correct positioning of the holding claw. –  Tighten fixing nut of the tensioning pulley to 20 Nm. –  Again check the TDC marking on the flywheel. –  Tighten new fixing screws of injection pump gear to 20 Nm.   Note The fixing bolts must be used once only as they are antifatigue bolts. –  Tighten fixing screw of camshaft sprocket to 45 Nm (counterhold with -MP1-216-). –  Remove the locking pin -3359-. –  Remove adjusting straightedge -MP1-312- from the camshaft. –  Turn the crankshaft 2 turns in the direction of running of the engine until the crankshaft is positioned again 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. –  Release fixing screws for injection pump gear. –  Turn the crankshaft until the TDC marking on the flywheel and reference mark is aligned. If the injection pump gear can be arrested: –  Tighten the fixing screws for injection pump gear to 20 Nm and then torque a further 1/4 turn (90°). –  Remove the locking pin -3359-. –  Connect injection lines, fuel feed line and electric cables.

–  Fill injection pump with clean diesel fuel as follows: –  Screw connection fitting -V.A.G 1318/10- into the return-flow opening of the injection pump. –  Connect vacuum pump (e. g. -V.A.G 1390-) with an approx. 1 m long transparent plastic line to the return-flow opening. –  Operate vacuum pump until fuel flows out of the return-flow opening. Do not draw fuel into the vacuum pump. –  Connect return-flow line. –  Install top toothed belt guard, vacuum pump and cylinder head cover. –  Install the engine cover. –  Check the injection begin point dynamically and adjust → Chapter.