Skoda Workshop Service and Repair Manuals

Removing Conditions l  Engine temperature should not exceed 35°, because the cylinder head could be twisted when slackening the screws. l  The pistons must not be at TDC. –  Switch off ignition and withdraw ignition key. –  Remove engine cover. –  Remove the sound dampening system → Body Work → Rep. Gr.50. –  Removing the lock carrier → Body Work → Rep. Gr.50.   WARNING Hot steam or hot coolant may escape when the compensation bottle is opened. Cover the cap with a cloth and open carefully. –  Position the catch pan, e.g. -VAS 6208-, under the engine. –  Drain coolant → Chapter.

–  Unplug connector -1- from intake manifold pressure sender -G71- with intake manifold temperature sender - G72-. –  Unscrew screw -2- and remove air guide to induction pipe -arrows-. –  Detach the vacuum line to the brake servo unit at the bulkhead. –  Unplug connector from air mass meter -G70- and remove air filter → Chapter. –  Loosen hose clamp and detach air guide hose to turbocharger. Vehicles with engine identification characters AVB

–  Disconnect hose -1- from mechanical exhaust-gas recirculation valve, hose -2- from vacuum setting element of intake manifold flap and hose -3- from vacuum setting element for charge pressure control. Vehicles with engine identification characters BSV

–  Disconnect plug -1- from the exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212- and EGR control motor -V338- and plug -2- from intake manifold flap motor -V157-. –  Detach coolant hoses from exhaust gas recirculation radiator. –  Detach vacuum hose from vacuum setting element for charge pressure control at turbocharger. Continued for all vehicles   Note The decoupling element in the front part of the exhaust pipe should not be bent by more than 10° - danger of damaging it.

–  Slacken screws of clamping sleeve at exhaust pipe, unscrew nuts at turbocharger flange -arrows- and push catalytic converter with exhaust pipe to the rear → Chapter.

–  Remove air guide hose from exhaust turbocharger, to do so pull retaining clip -arrow-.

–  Release screws -2 and 3- and remove support for turbocharger. –  Remove the oil return line -3- from the cylinder block. –  Remove fuel filter with bracket and separate fuel feed and return-flow line from the tandem pump → Chapter. –  Before removing the cylinder head, extract all of the fuel using a hand-operated vacuum pump -V.A.G 1390 - with the bleeding bottle - V.A.G 1390/1- from the tandem pump → Chapter. –  Detach hoses and remove top coolant pipe → Chapter. –  Detach coolant hoses from connection fitting of cylinder head → Chapter. –  Unplug plug for glow plugs, central screw for unit injectors and plug for coolant temeprature sender -G62- → Chapter.

–  Unscrew the oil feed line to the turbocharger -arrow- from the oil filter holder → Chapter. –  Slacken timing belt tensioning pulley and take timing belt off camshaft sprocket → Chapter. –  Remove camshaft sprocket and hub → Chapter. –  Remove timing belt tensioning pulley → Chapter.

–  Remove screws -1...4-. Vehicles with engine identification characters BSV –  Remove intake manifold with exhaust gas recirculation radiator → Chapter. Continued for all vehicles –  Remove cylinder head cover → Chapter.

–  Follow the specified order for loosening cylinder head bolts. –  Remove cylinder head and place down on a soft surface with the sealing surface to the top.   Note t  Engines with ceramic pencil type glow plugs: the cylinder head with installed ceramic pencil type glow plugs must never be placed on the sealing surface, as ceramic pencil type glow plugs protrude a little and thus can be damaged. t  Handling the ceramic pencil type glow plugs → Chapter. t  Removing and installing metal glow plugs → Chapter t  Removing the ceramic pencil type glow plugs → Chapter.