Removal and installation of the engine and powertrain supports (engine 1.8) (Skoda Superb B6)

Removal

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

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

2. Remove the PCV tube (1 on the accompanying illustration), unscrew the bolt (arrow) and remove the inlet pipe by loosening the clamp (2). Seal the turbocharger inlet port to prevent dirt from getting in.



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

4. Remove the front right wheel arch liner (see Chapter 11). On FWD models, remove the right drive shaft heat shield fastener (see accompanying illustration).



5. Remove the right drive shaft (see Chapter 8).



6. Loosen the left drive shaft fastener to the manual transmission/DSG flange shaft and tie up the drive shaft so that it does not hang down under its own weight.

7. Remove the exhaust pipe (see Section 4) and the propeller shaft (on AWD models, see Chapter 8).

8. Remove the radiator fan shroud and drain the coolant (see Chapter 3). Disconnect the coolant hoses from the radiator, heater radiator and expansion tank.

9. Disconnect the engine wiring harness connector from the ECM (see Chapter 5).

10. Remove the wiring harness guide plate retainer (see illustration 15.17) and pull it up. Pull the rear left engine wiring harness out of the bulkhead.

11. Open the wiring guide bracket (see illustration 5.23).

12. Disconnect the connector (1 on the accompanying illustration) and open the bracket (2) under the wiring guide. Release the engine wiring harness going to the ECM, disconnect all engine/body wiring harness connectors.



13. On models with DSG, remove the selector lever cable from it (see Chapter 7).

14. On models with a manual transmission, remove the gear selection and shift cables from it, remove the rack (1 on the accompanying illustration), remove the slave cylinder (arrows) of the clutch hydraulic drive and tie it to the side without opening the clutch hydraulic drive circuit.

Note: Do not depress the clutch pedal after removing the clutch slave cylinder.

15. Remove the clamp (arrow on the accompanying illustration) protective cap (if available), disconnect the ground wire (1), disconnect the connector (2), pull back the protective cap and disconnect the B+ wire from the starter solenoid valve bracket.



16. Loosen the clamp (2 on the accompanying illustration), unscrew the bolt (4), disconnect the connector (arrow) and pull out the wiring. Unscrew the bolt (1) and remove the pressure pipe by moving it downwards.



17. Remove the right pressure hose (see accompanying illustration).





18. On models with additional heating, loosen the clamp (1 in illustration 5.14), unscrew the bolt (2) and remove the additional heater muffler.

19. Disconnect the connector (2 on the accompanying illustration) sensor "G83" of coolant temperature at the radiator outlet and connection (1).



20. Remove the fuel supply line (2 on the accompanying illustration), pressing the retaining ring upwards, and collect the leaking fuel.



21. Loosen the bolts (see accompanying illustrations) brackets of the right and left engine mounts by no more than 1 turn.







22. Remove the drive belt (see section 24).

23. 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 side member holder (2 on the accompanying illustration) on the wire so that the refrigerant lines are not stretched or kinked.



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



25. Remove/release all remaining wiring from the engine and transmission; disconnect the coolant, vacuum and ventilation hoses from the engine.

26. Remove the bolt (2 on the accompanying illustration) on the bracket of the coolant circulation pump "V51".



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

28. Secure the T10359 support to the cylinder block by tightening the bolt (1 on the accompanying illustration) into the hole for fastening the "V51" circulation pump with a force of 20 Nm. Insert the VAG1383A transmission jack into the T10359 support and support the engine to relieve its supports.



29. Make sure all hoses and wiring between the engine, transmission and body are disconnected. Remove the bolts from the stepladder (see illustrations 23.21a-b) fastening the right and left brackets (on the engine and transmission).



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

31. Secure the engine to the mounting stand and separate the transmission from the engine (see Chapter 6 or 7).

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.

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

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

34. On models with manual transmission, 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 film 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).

35. On DSG models, replace the crankshaft needle bearing as described in Section 14. Note: Press the bearing to the depth (and in the illustration 14. Zb) - 2.0 mm.

36. Make sure the transmission centering bushings are inserted into the cylinder block. Secure the transmission to the engine (see Chapter 6 or 7).



37. Secure the power unit to the transmission jack using the T10359 support, move it into the engine compartment and screw in the new power unit bracket mounting bolts by hand. Adjust the brackets and tighten the mounting bolts (see subsection below).

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

39. Install the compressor and accessory drive belt.

40. On models with manual transmission, install the clutch slave cylinder and gearshift mechanism, then adjust it.

41. On models with DSG, secure the selector cable to it.

42. Place the engine wiring harness and connect it to the ECM.

43. Install the exhaust pipe.

44. On AWD models, install the driveshaft.

45. Connect the battery wiring.

46. Fill the engine cooling system (see Chapter 3).

47. Clear all fault codes from the ECM memory that occurred during engine removal/installation and verify that the ECM has generated a readiness code.

48. Perform a road check (see Chapter 1) and fix any errors found.

Checking and adjusting the powertrain supports

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



50. To check the installation of the bracket, make sure that the heads of both bolts (2 in illustration 23.21a) are parallel to the edge of the support arm (3), and the distance between the bracket (1) and the support (4) is 10-13 mm. If the engine or transmission hits the side member when turning and the distance (x) is not 10-13 mm, adjust the bracket as described below.

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

52. Install the MP9-200 support (No. 10-222A) with two MP9-200/10 spindles (No. 10-222A/1 0) (see illustration 15.45) and evenly unload the power unit supports by rotating both spindles.

53. Loosen the bolts (2 in illustration 23.21a) fastening the right bracket and slightly (no more than 1 turn) loosen the bolts (see illustration 23.21b) fastening the left bracket.

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

55. Move the power unit using a lever installed between the support lever (3 in illustration 23.21a) and support (1) so that the heads of the bolts (2) are parallel to the edge of the support arm and the distance (x) is 10 mm. Tighten the bolts of the right support (see illustration 23.49).

56. Make sure that on the transmission 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 bracket mounting bolts (see illustration 23.33).



57. Install the remaining parts.