Skoda Workshop Service and Repair Manuals

Removing engine   Note t  The engine is removed downwards together with the gearbox. t  The hose connections are secured with screw-type clips, spring-type clips or clamp-type clips. Always replace warm-type clamps with spring strap clips or screw clamps. 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 relevant connectors, if necessary mark. Procedure Before disconnecting the battery determine the code of radio sets fitted with anti-theft coding. Always switch off the ignition before disconnecting and re-connecting the battery. Otherwise the engine control unit may be damaged. If the battery is connected, carry out certain additional operations → Electrical System → Rep. Gr.27.

–  Remove engine cover -2-. Release nut -1- before removing, withdraw oil dipstick -3- and pull front cover upwards with a sudden motion -arrows-. –  Remove secondary air pump with bracket → Chapter. –  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 the noise insulation in the middle -arrows-. Remove air guide parts on outside first of all. –  Unbolt the heat shield for right drive shaft. –  Remove drive shafts → Chassis → Rep. Gr.40. –  Remove front exhaust pipe → Chapter.   Note Avoid a large deflection of the decoupling element at the front exhaust pipe (max. 10 °). For 4 x 4 vehicles –  Disconnect propshaft from gearbox → Gearbox → Rep. Gr.39. For all vehicles

–  Unscrew the protective cover -arrows- and disconnect the 4-pin plug connection (black) -1- to lambda probe upstream catalytic converter - G39-. –  Unclip the cable for lamba probe from the guides. –  Position drip tray (e.g. -VAS 6208-) under the engine. –  Open the cap of the coolant expansion reservoir.

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

–  Also remove the coolant hose on the oil cooler -arrow- and drain residual coolant. –  Remove air filter. –  Remove battery and battery tray → Electrical System → Rep. Gr.27. –  Remove the top part of the intake manifold as follows:

–  Remove intake hose -1--arrows-. Ventilation hose -2- remains attached. –  Remove throttle control cable, disconnect plug of the throttle valve control unit - J338-. –  Detach coolant hoses from the throttle valve control unit (straight connection to the quick coupling at heat exchanger). –  Detach vacuum hose for fuel pressure regulator. –  Release front screws of top part/bottom part of the intake manifold (tightening torque: 10 Nm).

–  Detach ventilation hose -1-. –  Release screws -2- at the intake manifold support (tightening torque: 25 Nm).   Note Seal the intake passages in the bottom part of the intake manifold with a clean cloth. –  Detach vacuum hose from combination valve. –  Remove following coolant hoses with pliers for spring strap clips:

1 - Coolant hose at bottom of coolant regulator housing 2 - Coolant hose to the expansion reservoir

1 - Coolant hose at the top of the radiator at distributor part 2 - Coolant hose to expansion reservoir at T-union, connection of cylinder head

–  Separate the quick couplings at connection of the heat exchanger -arrows-. Same fixing system as coolant connection; pull retaining clasp downwards up to the stop.   WARNING The fuel feed line is pressurized! Place cleaning cloths around the connection point before detaching hose connections. Reduce pressure by carefully removing the hose.

–  Detach the feed line -2- and the return-flow line -1- from fuel pressure regulator und collect the flowing out fuel in a vessel. –  Disconnect plugs -3- from hall sender -G40-. –  Disconnect plug -4- from the injection valves - N30- to N33-, unclip cable rail -5- and expose the wiring loom.

–  Unbolt cable -1- (terminal 30/B+) at alternator. –  Unplug connector -2- of terminal D+. –  Unscrew cable clamp -3-.

–  Disconnect plug 1 -  at knock sensor 1 -G61-, black 2 -  at knock sensor 2 -G66-, brown 3 -  for engine speed sender -G28- 4 -  at ignition module with power output stage -N122- 5 -  at oil pressure switch - F1-  -  at coolant temperature sender - G62- (at coolant flange, laterally at cylinder head) Vehicles fitted with a manual gearbox

–  Unscrew the Bowden cable support from the gearbox and unclip the hose line -arrows-.

–  Pull forward the locking mechanism at shift cable and at selector cable as far as the stop (-arrow 1-), then lock by turning to the left (-arrow 2-). –  Place down cables with Bowden cable support upwards. –  Disconnect plug: –  at vehicle speed sender -G68- –  at reversing light switch -F4 -

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

–  Use screwdriver to press off selector cable -1- at gearbox selector lever -4-, pull off securing clasp -3- at support bearing. –  Take off selector lever cable and place to the side.

–  Disconnect following plugs: 1 -  to the solenoid valves (10-pin plug) 2 -  to vehicle speed sender -G68 - 3 -  at the multifunction switch -F125- 4 -  at gearbox speed sender -G38- –  Remove bracket -5- for pressure line of power-assisted steering at gearbox support. –  Detach wiring loom for the fixture and run out to the side. Vehicles with air conditioning   WARNING Refrigerant circuit of the air conditioning system must not be opened. –  Remove connector at the AC compressor. –  Unplug connector from monitoring switch for coolant temperature sensor too hot -F14- (in coolant distributor part).

–  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. Continued for all vehicles

–  Remove the earth lead -1- from the engine/gearbox connecting screw. –  Separate plug connection -2- and pull out of fixture. –  Detach cables -3- and -4- at starter. –  Detach wiring loom from fixture at starter and place to the side. –  Remove the ribbed V-belt → Chapter.

–  Unscrew two brackets for pressure line of power-assisted steering -arrows- (the figure shows the vehicle with manual gearbox). –  Remove belt pulley of hydraulic pump for power-assisted steering (counterhold with screwdriver). –  Unscrew vane pump and attach to the body with wire. The lines on the vane pump remain connected up.

–  Remove pendulum support -arrows-. –  Insert engine mount -T10012- into engine/gearbox jack (e.g. -V.A.G 1383 A -).

–  Screw engine mount - T10012- to the cylinder block with fixing nuts and bolts M10 to 40 Nm. –  Slightly raise the engine and gearbox with the engine/gearbox jack (e.g. -V.A.G 1383 A -).

–  Unscrew the engine mounting from the engine support bracket from the top -arrows-.   Note Use the double ladder (e.g. -VAS 5085-) for removing the fixing bolts.

–  Unscrew the gearbox mount from the gearbox support bracket from the top -arrows-. –  Carefully lower the engine with gearbox. –  Run pressure line of power-assisted steering past the gearbox.   Note Engine with gearbox must be guided carefully, in order to avoid damaging the body.