Skoda Workshop Service and Repair Manuals

Installing cylinder head   Note t  There must not be any oil or coolant present in the blind holes for the cylinder head bolts. t  Replace cylinder head bolts. t  When performing installation work replace the self-locking nuts. t  Replace screws which have been tightened to a turning angle as well as gasket rings and seals. t  Remove the new cylinder head seal from its wrapping immediately before fitting. t  Treat the seal with the utmost care. Damage to the silicone layer and in the area of the bead results in leakages. t  When installing an exchange cylinder head with the camshafts installed, it is necessary to oil the contact surfaces between the roller arms and the cams after installing the cylinder head. t  The plastic base for protecting the open valves should only be removed immediately before attaching the cylinder head. t  Secure all hose connections with corresponding hose clips.   WARNING Wear protective gloves when working with sealant and grease remover! –  Make sure that when cleaning the cylinder head and cylinder block no impurities can get into the cylinder or into the oil and coolant galleries. –  Carefully remove old residual sealant from the cylinder head/cylinder block using a chemical sealant remover. –  Before fitting the cylinder head rotate the crankshaft so that all the pistons are almost evenly at TDC.

–  Pay attention to the identification of the cylinder head seal. t  Part number = -arrow 1- t  Control code = -arrow 2- (ignore) t  Bores = -arrow 3-   Note t  If the cylinder head gasket or cylinder head are replaced, then install a new cylinder head gasket with the same identification marking. t  If parts of the crankshaft drive were replaced then the new cylinder head gasket must be defined by measuring the protrusion of the pistons in TDC .

–  Position the new cylinder heads. l  Pay attention to dowel sleeves -arrows- in cylinder block. l  Observe the installed position of the cylinder head gasket, the marking “above” or the part number must point to the cylinder head.

–  Hook on lifting device -2024 A- at cylinder head.   WARNING Lifting hooks and pegging pins on the supporting device must be secured using insertion locking mechansims -arrows-. –  Slightly raise the cylinder head with workshop crane. –  Swivel the cylinder head with the pin screw for the timing belt tensioning pulley into the recess in the rear toothed belt guard and simultaneously fit on the tensioning pulley. –  Fit cylinder head onto cylinder block.

–  Insert new cylinder head bolts and tighten by hand. –  Tighten the cylinder head in four stages in the indicated tightening sequence:

Stage	Tighten
I	–  Pre-tighten with the torque wrench to 40 Nm.
II	–  Pre-tighten with the torque wrench to 60 Nm.
III	–  Using a rigid wrench torque a further 90° (1/4 turn).
IV	–  Using a rigid wrench torque a further 90° (1/4 turn).

Note Tightening up the cylinder head bolts after doing repair work is not necessary.

–  Before inserting the valve-lever shaft, check whether all the ball studs -1- and O-rings -2- are inserted in the unit injectors.

–  Screw on valve-lever shaft and bearing frame as follows: –  Replace screws -1 … 5-.

Sequence	Tighten
I	–  Tighten screws -2- and -4- alternately in stages, until the valve-lever shaft is positioned on the bearing frame.
II	–  Tighten screws -1-, -3- and -5- to 20 Nm and torque a further 90° (1/4 turn).
III	–  Tighten screws -2- and -4- to 20 Nm and torque a further 90° (1/4 turn).
IV	–  Tighten bearing frame screws -6…10- to 20 Nm.

–  Insert screws -2 … 5- with spread on locking agent -D 000 600 A2- and tighten to 10 Nm. –  Turn nut -1- for timing belt tensioning pulley onto the pin screw.

–  Position hub onto exhaust camshaft. –  Tighten screw -1- to 100 Nm, use counterholder -T10051- to hold. –  Fit the hub onto the inlet camshaft in the same way and tighten.

–  Push toothed belt sprockets of camshafts onto hubs. l  Both tooth segments -arrows- of the toothed belt sprockets must be facing up. –  Slightly screw in plug -1-. l  It must still be possible to turn the toothed belt sprockets of the camshafts on the hubs, however they must not hang loose. –  Lock hubs with locking pins -3359-. –  Rotate crankshaft to TDC for cylinder 1.

–  Lock the toothed belt sprocket of the crankshaft with the crankshaft arrester -T10100- (bottom illustration “B”).   Note t  The markings on the toothed belt sprocket and on the crankshaft arrester must be in line with each other -arrow-.

t  The stud of the crankshaft arrester -arrow- must engage at the same time in the hole of the sealing flange. t  The crankshaft arrester can only be fitted onto the toothed belt sprocket from the front side of the serration. –  install (set and check the timing) → Chapter. –  Install cylinder head cover → Chapter. Further installation occurs in reverse order to removal. Pay attention to the following: –  Always replace gasket rings and seals. –  Install diesel particle filter → Chapter. –  Checking the oil level → Octavia II.   Note Change contaminated engine oil → Octavia II. –  Top up or replace coolant → Chapter.