Removal and installation of the engine and powertrain supports (Skoda Superb B6)

Removal

Note: The engine is removed from under the engine compartment downwards together with the manual transmission.

1. Relieve the pressure in the fuel supply system and remove the air cleaner (see Chapter 4).

2. Remove the top engine cover. To do this, unscrew the bolts (1 on the accompanying illustration), unhook the coolant hoses (2) and pull the cover up.

Note: When installing, tighten the bolts to 8 Nm.

3. Remove the air cleaner (see Chapter 4).

4. Follow the steps described in paragraphs 2-6 of Section 5.

Note: The coolant should be drained from both the engine cooling system and the intercooler.

5. Disconnect the fuel supply line (1 on the accompanying illustration) and the hose (2) going to the EVAP canister by squeezing the retaining ring. Remove the hose (3) going to the canister from the canister purge solenoid valve #1. Lift the canister up and unscrew the bolts (arrows) from the bracket. Remove the coolant hoses (4).



6. Disconnect the coolant hose from the engine cooling system radiator, top left (see accompanying illustration).





7. Disconnect the coolant hoses (1 and 2 in the accompanying illustration) from the heater radiator.



8. Unscrew the bolts and remove the turbocharger heat shield (see accompanying illustration).



9. Release the nuts on the turbocharger (see accompanying illustration).





10. Remove the coolant pipe (2 on the accompanying illustration).



11. Disconnect the connector (1 in illustration 5.16) sensor "G266" of the engine oil level and temperature. Remove the bracket (2) of the electrical wiring of the sensor G266 from the support of the power unit.

12. On models with additional heating, loosen the clamp (1 in illustration 5.14), unscrew the bolt (2) and remove the outlet pipe of the additional heater. If necessary, disconnect the interfering connections of the coolant pipe.

13. Pull out the wiring (1 on the accompanying illustration) on the catalytic converter, disconnect the connector (2), loosen the nuts (3) and remove the gasket. Remove the catalytic converter downwards.





14. Give the nuts (2 and 3 in the accompanying illustration) and remove the gasket. Unscrew the bolts (1 and 5) and remove the exhaust pipe with the bracket (4).



15. Loosen the clamp bolts (see accompanying illustration) and pull the intermediate exhaust pipe back. Remove or free all wiring from the manual transmission, generator and starter, as well as other engine wiring. Remove the vacuum and vent hoses from the engine.



16. Disconnect the connector (1 on the accompanying illustration) thermal switch and radiator fan. Disconnect the engine wiring harness connector at the ECM (front connector).





17. Remove the wiring harness guide plate retainer (see accompanying illustration) and pull it up out of the bulkhead.



18. Open all the protection of the engine wiring harness on the side member (see illustration 5.23). Open the other connections of the engine wiring harness, remove it, place it on the engine and secure it with clamps.

19. Loosen the swing support fasteners in the following sequence: (1-3 in illustration 5.11) and take it off.

20. Remove the gear shift mechanism and the clutch hydraulic actuator cylinder from the manual transmission without opening the clutch hydraulic actuator circuit (see Chapter 6). Hang the slave cylinder to the side.

Note: After removing the clutch slave cylinder, do not depress the clutch pedal.

21. Set the hood lock holder to the service position (see Chapter 11).

22. Disconnect the connector (3 on the accompanying illustration) "V50" coolant circulation pump. Loosen the clamps (arrows) and disconnect the coolant hoses. Unscrew the bolt (2) and remove the pump from the bracket. Unscrew the bolts (1) of the pump bracket from the cylinder block.



23. Remove the drive belt (see section 16).

24. Disconnect the connector (1 in illustration 5.13a) compressor magnetic clutch and unscrew the bolts (arrows). Remove the air conditioning compressor without disconnecting the refrigerant lines from it and secure it to the hood lock holder with wire so that the refrigerant lines are not stretched or kinked.

25. To lower the power unit, prepare the T40075A support with adapters -/1, -/2 and -/3 (see accompanying illustration).



26. Screw the adapter T40075/1 into the cylinder block until it stops (see accompanying illustration).





27. Place the T40075A support with adapters -/2 and -/3 on the cylinder block and secure the adapter -/1 with a bolt (3 on the accompanying illustration). Between the cylinder block and the T40075A support, install two M10 nuts (2) and secure the support by screwing in the M8x35 bolt (1) by hand. Tighten all support mounting bolts with a force of 20 Nm, install the VAG1383A jack under the T10416 support and slightly lift the power unit on it to relieve its supports.



28. Make sure all hoses and wiring between the engine, transmission and body are disconnected. Remove the bolts from the stepladder (see illustration 5.28a and accompanying illustration) fastening the right and left brackets (on the engine and transmission).





29. With the help of an assistant, pull the power unit forward as far as possible and carefully lower it out of the engine compartment using a jack. Avoid damaging the power unit parts and engine compartment components.

30. Secure the engine to the mounting stand and separate the manual transmission from the engine (see Chapter 6).

Installation

Note: Place the hoses and wiring in the same position as they were before removal; install all clamps and ties in their original places. Tighten fasteners, depending on the thread, with the following forces: M6 - 9 Nm, M7 - 13 Nm, M8 - 20 Nm, M10 - 40 Nm, M12 - 70 Nm.

31. Installation is carried out in the reverse order. Please note the following features.

32. Use new self-locking nuts and bolts that require tightening to a certain angle. Use new seals and gaskets.

33. Clean the transmission input shaft splines and, if using an old clutch disc, its splines. Remove any traces of corrosion and apply a very thin coat of G000 100 grease to the input shaft splines. Move the clutch disc on the shaft until the disc moves smoothly, then wipe off excess grease. Check the clutch release bearing for wear; replace it if necessary. Make sure the clutch is centered (see Chapter 6).

34. Make sure that the centering bushings for the manual transmission are inserted into the cylinder block. Secure the manual transmission to the engine (see Chapter 6).

35. Secure the power unit to the transmission jack using the T40075A support, move it into the engine compartment and screw in the new power unit bracket mounting bolts by hand. Adjust the brackets and finally tighten the mounting bolts (see subsection below).

36. Install the rocker support (see subsection below) and drive shafts (see Chapter 8).

37. Install the compressor and accessory drive belt.

38. Install the clutch slave cylinder (see Chapter 6).

39. Install the gear shift mechanism and adjust it if necessary (see Chapter 6).

40. Perform the actions described in paragraphs 37-43 Section 5.

Checking and adjusting the powertrain supports

41. The details of the support fastenings are shown in the accompanying illustration.



42. To check the installation of the bracket, measure the distance (and in illustration 5.45) between the bracket and the support, - it should be 10-13 mm. The cast edge of the support (2) should be parallel to the support arm (1), and the distance (x) should be the same at the front and rear. If the engine or transmission hits the side member when turning and the distance (a) is not 10-13 mm, adjust the bracket as described below.

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43. Remove the battery and its holder (see Chapter 5).

44. Remove the front bonnet bumpers from the top sides of both front fenders. Insert the T10311 plates on the right (And in illustration 5.47) and left (B) sides in the direction of the arrows until they stop so that the arrows "R" and "L" on the plates point to the rear. These plates are needed to prevent damage to the wings.

45. Install the MP9-200 support with MP9-200/10 spindles (see accompanying illustration). The heel of the support should rest against the buffers. Evenly unload the power unit supports by rotating both spindles.



46. Loosen the bolts (arrows in illustration 5.28a) fastening the right bracket and slightly (less than 1 turn) loosen the bolts (2 in illustration 15.28) fastening the left bracket.

47. If the bracket bolts were not yet replaced when installing the engine, screw in the new bolts one by one.

48. Move the power unit using a lever installed between the support lever (1 in illustration 5.45) and support (2) so that the distance (a) is 10 mm and the distance (x) is the same at the front and rear. Tighten the bolts of the right bracket (see illustration 15.41).

49. Make sure that on the gearbox side the edges of the support (1 on the accompanying illustration) and its support arm (2) are parallel to each other. That is, the distance (x) should be the same on both sides of the support. Tighten the left bracket mounting bolts (see illustration 15.41).



50. Install the remaining parts.