Skoda Workshop Service and Repair Manuals

Removing

–  Remove engine cover. To do so pull the front and rear engine cover upwards with a sudden motion. –  Remove fuel lines from the injection pump.   Note To release the injection lines use an open ring spanner e.g. -3035- –  Cover the openings with a clean cloth. –  Remove top toothed belt shield and cylinder head cover. –  Removing vacuum pump for brake servo unit → 1.9/47 SDI Engine, Mechanics; Rep. Gr.15 With the engine installed

–  Position crankshaft on TDC cylinder 1. The marking on the flywheel -1- must be flush with the marking on the gearbox -2-. View from the milled surface on the gearbox -A- vertically (90°) to the marking on the flywheel -1-.   Note The valves of cylinder 1 must be closed and the valves of cylinder 4 must overlap. With the engine removed

–  Screw the adjusting device -MP 1-313- into the threaded hole of the top starter screw. –  Set adjusting device to 120 mm -arrow A-. The left notch on the vernier is the reference point. –  Rotate crankshaft until the TDC marking on the flywheel corresponds with the tip of the adjusting device -arrow B-.   Note The valves of cylinder 1 must be closed and the valves of cylinder 4 must overlap. Continued

–  Lock the camshaft with the adjusting straightedge -MP 1-312-.   Note The valves of cylinder 1 must be closed and the valves of cylinder 4 must overlap -arrows-. –  Centre adjusting straightedge as follows:    Turn locked camshaft in such a way that one end of the adjusting straightedge strikes the cylinder head. Measure the resulting play at the other end of the adjusting straightedge with a feeler gauge. Insert feeler gauge with halved play dimension between the adjusting straightedge and the cylinder head. Now turn the camshaft in such a way that the adjusting straightedge is positioned on the feeler gauge. Insert the second feeler gauge with the same dimension at the other end between the adjusting straightedge and the cylinder head.

–  Install supporting device -MP 9-200- and support engine in fitting position.

–  Remove engine mounting -arrows A and B-. –  Remove the noise insulation. –  Unscrew engine support bracket from cylinder block.   Note The engine with the supporting device must be slightly raised in order to remove the engine support bracket. The bottom bolt remains in the support. –  Unscrew the nut of the tensioning pulley. –  Slacken the toothed belt and remove it from the toothed belt gears of teh camshaft and injection pump.

–  Unscrew the fixing screws -1- of the injection pump gear and remove inejction pump gear from the injection pump shaft.   Note The nut -2- for the hub must never be loosened. This could result in a misadjustment of the basic setting of the injection pump which cannot be corrected with workshop tools.

–  Disconnect plug connection -arrow- from the injection pump and pull plug from holder.

–  Unscrew fixing screws -1- from holder.

–  Then unscrew the fixing screw from the rear bracket -arrow-. –  Take off the injection pump.