Skoda Workshop Service and Repair Manuals

Removing engine Special tools and workshop equipment required t  Removal tool for inner lining of the door panel -MP8-602/1- t  Engine mount -T10012- t  Engine/gearbox jack, e.g. -V.A.G 1383 A- t  Catch pan, e.g. -VAS 6208- t  Double ladder, e. g. -VAS 5085- t  Pliers for spring strap clamps   Note t  If the partial engine must be replaced after the engine was removed, check whether the clamping claws for the injection units on the new partial engine were tightened. Tightening torque: Position 7 → Chapter. t  The engine is removed downwards together with the gearbox. t  All cable straps that have been loosened or cut open when the engine was removed must be attached again in the same location when the engine is installed again. t  Leave the ignition key in the ignition lock so that the steering lock does not click into place. t  Collect drained coolant in a clean container for proper disposal or reuse.   Caution When undertaking all installation work, particularly in the engine compartment because of its cramped construction, please observe the following: t  Lay lines of all kinds (e.g. for fuel, hydraulic fluid, cooling fluid and refrigerant, brake fluid, vacuum) and electrical lines in such a way that the original line guide is re-established. t  Ensure that there is adequate free access to all moving or hot components. Observe all safety measures and notes for assembly work on the fuel supply and injection system, at the charge air system and observe as well the rules for cleanliness → Chapter. –  If present, take the adapter for the anti-theft wheel bolts out of the luggage compartment. –  Disconnect the battery-earth strap with the ignition off → Electrical System; Rep. gr.27. –  Remove engine cover → Chapter. –  Remove air filter, air mass meter -G70- and intake hose → Chapter. –  Remove the battery with the battery tray → Electrical System; Rep. gr.27. Engines with identification characters CFFB, CFGB, CFHA, CFHC, CFHF, CFJA

–  Unplug the following plug connections at the bulkhead: 2 -  Exhaust gas temperature sender 4 -G648- (orange) 3 -  Exhaust gas temperature sender 1 -G235- (Temperature sender upstream turbocharger -G507 -) (black) 4 -  Lambda probe -G39- (black) 6 -  Exhaust gas temperature sender 3 -G495- (braun) Continued for all engines –  Pull off the vacuum hose -5- from the charge pressure control solenoid valve -N75 -. –  Drain coolant → Chapter.

–  Disconnect plug -1- at the oil level and oil temperature sender -G266-. –  Remove bracket -2- for the wiring harness of the oil level and oil temperature sender -G266- from the assembly carrier. Vehicles with front-wheel-drive

–  If present, unscrew heat shield for right drive shaft -arrows-. Continued for all vehicles –  Unscrew left front wheel. –  Remove the right and left wheelhouse liner → Body Work; Rep. gr.66. –  Unscrew the left drive shaft from the flange shaft of the gearbox. –  Remove pre-exhaust pipe: t  Engine identification characters CFFB, CFGB, CFHA, CFHC, CFHF, CFJA → Chapter t  Engine identification characters CLCA, CLCB, CLJA → Chapter Vehicles with four-wheel drive –  Unscrew propshaft from angle gearbox → Gearbox; Rep. gr.39. Continued for all vehicles

–  Unscrew the nut from the left coupling rod -2- and press off the coupling rod from the anti-roll bar. –  Unscrew the nuts for the left steering joint -3- and press the steering joint out of the suspension arm.

–  Unscrew the nut -2- from the left track control arm if the front left vehicle level sensor -G78- is present. –  Turn steering to full left lock. –  Swivel the steering joint outwards and secure the drive shaft -1- with a band -A- in the wheelhouse. The assembly carrier is already removed. –  Insert a pin screw in the suspension arm in order to stabilise the steering joint. –  Remove radiator → Chapter.

–  Release screws -arrows-. –  Expose coolant hose -1-. –  Loosen hose clamp -3-. –  Disconnect plug -2- at the charge pressure sender -G31- and remove the right charge air pipe.

–  Unscrew screw -arrow- and push the coolant recirculation pump 2 -V178- to the side.

–  Remove vacuum hose -2- from vacuum setting element of exhaust turbocharger. –  Disconnect vacuum hose -3-.

–  Remove the vacuum hose -arrow- from the brake servo unit.

–  Separate fuel feed line -2- and fuel return-flow line -1-, to do so press in securing rings. Unlock the quick coupling and disconnect → Chapter.

–  Disconnect plug -4- at fuel temperature sender -G81-. –  Remove fuel feed line as well as fuel return-flow line, to do so loosen hose clamps -2 and 3-.

–  Release screw -1-. –  Push the filler tube with the filler neck -2- for the washer-fluid reservoir to the side.   Note For reasons of clarity the fuel filter is not shown.

–  Unhook the fuel hose -2- from the bracket. –  Remove the bracket for the fuel lines upwards in -direction of arrow- and place it to the side. –  Disconnect the plug -1- from the additional fuel pump -V393- or from the fuel pump 2 -V277-. t  –  Unscrew bolts -3-.

–  Loosen screw -1- by 2 turns. –  Release screw -2- and nut -3-. –  Loosen bracket for coolant line at fuel filter. –  Remove the fuel filter with the hoses connected and the bracket with the additional fuel pump -V393- or with the fuel pump 2 -V277-. Vehicles with air conditioning –  Remove V-ribbed belt → Chapter.   WARNING Risk of injury through refrigerant. Do not open the refrigerant circuit of the air conditioning system.   Note In order to avoid damage to the AC compressor as well as to the refrigerant lines and hoses, ensure that the lines and hoses are not over-tensioned, kinked or bent.

–  Remove the AC compressor from the bracket for auxiliary units, to protect the charge air cooler place cardboard -A- on it and secure the AC compressor with connected refrigerant hoses to the lock carrier. Continued for all vehicles –  Unlatch the fuse and disconnect the front plug from the engine control unit → Chapter.

–  Release duct for engine wiring harness -arrow- and pull out upwards.

–  Open the cable guides -arrows-, remove the engine wiring harness and place down to the side.

–  Expose the plug connection -1- and disconnect it. –  Open the bracket -2- lying below the cable guide. –  Remove the wiring loom to the engine control unit from the cable guide using the removal tool -MP8-602/1- and lay it on the engine.

–  Disconnect plug connection -arrow- at the bottom left frame side rail.   Note For purposes of presentation, the fitting position is shown from below.

–  Remove the cable strap for -arrow- protective collar if present. –  Unbolt earth strap -1-. –  Unplug connector -2-. –  Pull back the protective collar and unscrew the B+ cable from the bracket of the solenoid switch for the starter. –  Disconnect further necessary plug connections at the engine and gearbox or line connections to engine and gearbox.

–  Separate the quick couplings -arrows- at the heat exchanger. –  Pull off coolant hose at the top and bottom of the coolant expansion reservoir. Vehicles with auxiliary heating. –  Place a catch pan for coolant under the auxiliary heating. –  Detach the coolant hoses of the auxiliary heating. Vehicles fitted with a manual gearbox –  Remove shift mechanism from gearbox → Gearbox; Rep. gr.34. –  Remove pressure line from breather/slave cylinder → Gearbox; Rep. gr.30.   WARNING After separating the hydraulic line, do not operate the clutch pedal. Vehicles with automatic gearbox –  Remove shift mechanism from gearbox → Automatic Gearbox; Rep. gr.34. Continued for all vehicles –  Unclamp all remaining connecting, coolant, vacuum and suction hoses from the engine. –  Release all remaining plugs at engine and gearbox and lay aside the relevant lines.

–  Screw engine mount -T10012- to the cylinder block with nut -2- and screw -1- to 20 Nm. –  Insert engine/gearbox jack -V.A.G 1383 A- in the engine mount and slightly raise.   Note Use the double ladder to release the screws for the engine/gearbox mounting.

–  Successively release screws for engine mount -arrows-.

–  Successively unscrew screws for gearbox mount -arrows- at gearbox 02E or ...

–  ... or at gearbox 0A4 -arrows-.   Note t  Check whether all hose and line connections between engine, gearbox and body are released. t  When lowering carefully guide the engine with the gearbox, in order to avoid damage. –  Carefully lower engine with gearbox. During this procedure, turn or move the engine with the gearbox depending upon the constriction. –  Remove the gearbox from the engine.