Skoda Workshop Service and Repair Manuals

Install cylinder head cover   Caution Before installing the cylinder head cover, screw in the pin screws (M 6 x 70) at the cylinder head. The pin screws guide the cylinder head cover and prevent the roller rocker arms sliding off from the balancing elements. Precondition l  The pistons must not be positioned at top dead centre.   WARNING Wear protective gloves when working with sealant and grease remover! –  Remove residual sealant from the sealing surfaces at the cylinder head cover and at the cylinder head with chemical sealant remover. –  Degrease the sealing surfaces.

–  Screw in two pin screws (M 6 x 70) -1- into the cylinder head before fitting on the cylinder head cover.   Caution The cylinder head cover is sealed with 2 different sealants!   Note The sealant must not be applied too thickly, as otherwise excess sealant may penetrate into the oil bores and possibly cause engine damage.

–  Apply sealant -D 189 500 A1 - on the sealing surface -1-.    The sealant bead must be 2…3 mm thick and must run past the area around the bolt holes on the inside. –  Apply a thin layer of sealant -D 154 103 A1 - evenly to the gridded sealing surfaces -2-. –  Check if the roller rocker arms rest on the balancing elements. –  Carefully fit the cylinder head cover over the pin screws and position the dowel pins onto the cylinder head.

–  Tighten the new fixing screws of the cylinder head cover in the specified order -1- to -12-. Tightening torque: 8 Nm + torque a further 90° (1/4 turn).   Caution The sealant for the cylinder head cover must absolutely be removed in the area of the -arrows-. In order to avoid leakage, the sealant for the cylinder head cover and the sealant for the timing case must not mix.

–  Remove excess sealant in the area of the -arrows-. –  Turn crankshaft up to the stop in direction of rotation of engine.

–  Lift up the timing chain with the assembly device -T10118-.

–  Check the correct position of the timing chain -1- on the crankshaft gear from below.

–  Place the timing chain -1- onto the chain sprocket -2-.   Note t  The timing chain must rest in the area of the sliding rail -3- and be slightly tensioned. t  The timing chain must run through the middle of the sliding rail -3-. –  Install fixing screw for camshaft sprocket and tighten by hand.

–  Tighten chain tensioner to 60 Nm.

–  Hold the camshaft sprocket with the counterholder -T10172- and tighten the fixing screw -1- of the camshaft sprocket to 50 Nm.   Note The fixing screw is only turned a further 90° (1/4 turn) after checking the timing at the end of the work procedure. –  Remove the fixing bolt -T10414 - from the camshaft. –  Release the fixing screw -T10340- from the cylinder block. –  Turn the crankshaft in direction of rotation of engine by 2 turns. –  Turn the fixing screw -T10340- up to the stop in the cylinder block. –  Turn crankshaft up to the stop in direction of rotation of engine. The timing is O.K., if the fixing bolt -T10414- can be inserted in the camshaft. If the timing is not O.K.: –  Repeat the setting of the timing → Chapter. If timing is o.k.:

–  Hold the camshaft sprocket with the counterholder -T10172- and torque the fixing screw -1- a further 90° (1/4 turn). –  Remove fixing bolt -T10414- and fixing screw -T10340-. –  Install top timing case → Chapter. –  Install exhaust turbocharger → Chapter. –  Installing the oil pan → Chapter. –  Install crankshaft belt pulley → Chapter. –  Install high pressure pump → Chapter. Further installation occurs in a similar way in reverse order to removal.