Skoda Workshop Service and Repair Manuals

Removing and installing the timing case Special tools and workshop equipment required t  Supporting device -T30099- t  Base -T30099/1- t  Counterholder -T30004 (3415)- t  Bolt -T30004/1 (3415/1)- t  Sealant -D 176 501 A1- t  Sealant remover gasket stripper (bearing code GST, bearing article no. R 34402), manufacturer Retech s.r.o. t  Cleaning and degreasing agent, e.g. -D 000 401 04- Removing –  Remove engine cover → Chapter.

–  Release screw -1- for coolant line. –  Remove hose -2- for crankcase ventilation from the cover for timing chain, to do so press in the circlip.

–  Disconnect the vent line -1-. To do so press in the securing ring.

–  Detach the bleeder hose -1- to the intake manifold at the activated charcoal filter. –  Release the activated charcoal filter -arrow B- and remove the activated charcoal filter with bracket upwards -arrow A-.

–  Unbolt bracket -3- for activated charcoal filter. –  Release screw on filler neck -2- for windshield washer fluid reservoir. –  Disconnect plug from switch for coolant shortage warning light -F66- at coolant expansion reservoir and expose electrical wiring loom. –  Unscrew screws for coolant expansion reservoir -1-; place coolant expansion reservoir with connected hoses on the engine and if necessary fasten. –  Remove V-ribbed belt → Chapter. –  Remove belt pulley from the coolant pump → Chapter.

–  Disconnect plug -1- for regulating valve at AC compressor.   WARNING Risk of injury through refrigerant. Do not open the refrigerant circuit of the air conditioning system.   Caution Risk of damaging refrigerant lines and hoses. Do not twist and kink the refrigerant lines and hoses. –  Release screws -arrows- for AC compressor. –  Attach AC compressor to lock carrier. –  Remove the bracket for auxiliary units → Chapter.

–  Unscrew the hollow screw -2- of the oil feed line -1- for the exhaust gas turbocharger out of the timing case -3-.

–  Remove AC generator and guide pulley -2- → Electrical System; Rep. Gr.27. –  Rotate the crankshaft in direction of rotation of engine on TDC for cylinder 1 → Chapter. –  Remove crankshaft-belt pulley → Chapter.   Caution Risk of engine damage. In order to avoid that the chain sprocket on the crankshaft slides out of the driver, the crankshaft must not be turned when the V-ribbed belt pulley is released. –  Removing the oil pan → Chapter.   Note If the timing case is only removed in order to disassemble the cylinder head, the mounting of the engine as described in the following is not carried out, yet the mount described for the disassembly of the cylinder head is used.

–  Install the supporting device -T30099- as shown and support the engine in its installed position. –  Slightly pre-tension the engine.

–  Release screws -1...6- and remove engine mounting.

–  Release the Allen screws -1…6- of the timing case and the screws marked with the -arrows-. –  Remove timing case. To do so if necessary slightly raise engine.   Note Make sure that the bushing for the crankshaft remains in the timing case. –  Drive gasket ring for crankshaft out of the timing case. Install   Note Observe that the clamping surfaces of the belt pulley, the fixing screw, the bushing and the crankshaft chain sprocket are free of oil and grease.   WARNING Wear protective gloves when working with sealant and grease remover! –  Remove residual sealant on the sealing surfaces with chemical sealant remover. –  Degrease the sealing surfaces.

–  Insert new gasket rings -arrows- onto the reverse side of the timing case.   Note t  Furthermore, the timing case is sealed to the engine with a seal and additionally with the sealant D 176 501 A1.

t  The sealant D 176 501 A1 should prevent leaks between the timing case and the joints -1- and -2-. t  The sealant points must have a diameter of 10 mm and must be approx. 1 mm thick. t  Only apply the sealant immediately before installing the timing case. –  Apply the sealant D 176 501 A1 onto the joints of the camshaft housing/cylinder head -1- and the cylinder head/cylinder block -2-. –  Carefully place the new gasket onto the dowel pins. –  For better guidance, screw two studs - M6x80- into the cylinder head and the cylinder block. –  Position the timing case with bushing for crankshaft simultaneously onto the studs, the dowel pins and the crankshaft stud. –  Tighten diagonally and evenly the fixing screws of the timing case. Make sure that the timing case does not tilt. Tightening torques:    Screw M6 - 10 Nm    Screw M10 - 50 Nm –  Adjust engine mounting → Chapter. –  Install the gasket ring for the crankshaft - on the belt pulley side → Chapter. –  Install crankshaft belt pulley → Chapter. –  Attach the oil feed line for the exhaust gas turbocharger to the timing case → Chapter. Further installation occurs in a similar way in reverse order to removal.