Contents: Removal ⬇ Installation ⬇
1. Timing belt and engine bracket installation details are shown in the illustration.
36.1. Timing Belt Installation Details 1. Timing belt; 2. Gear wheel mounting bolt 3, subject to replacement, 120 Nm, then tighten to an angle of 90°; 3. Crankshaft gear; 4. Nut, 20 Nm; 5, 16. Intermediate roller; 6. Nut, 20 Nm, then tighten to an angle of 45°; 7. Tension roller; 8. Nut, 20 Nm, then tighten to an angle of 45°; 9. Camshaft gear wheel; 10. Bolt, 20 Nm; 11. Bolt, 100 Nm; 12. Wheel hub 9; 13. Rear timing belt cover; 14. Bolt, subject to replacement, 20 Nm, then tighten to an angle of 45°; 15. Bolt, subject to replacement, 9-12 Nm; 17. Bolt, subject to replacement, 50 Nm, then tighten to an angle of 90°; 18. Fuel injection pump hub; 19. Nut, 95 Nm; 20. Fuel injection pump gear; 21. Bolt, to be replaced, 20 Nm, then tighten to an angle of 90°; 22. Water pump; 23. Bolt, 15 Nm; 24. Upper timing belt cover; 25. Lower timing belt cover; 26. Bolt, 9 Nm, installed with fixing sealant D 000 600 A2; 27. Bolt, subject to replacement, 10 Nm, then tighten to an angle of 90°; 28. Crankshaft pulley; 29. Bolt, 5 Nm; 30. Protective plate; 31. Bolt, subject to replacement, 40 Nm, then tighten to an angle of 180°; 32. Engine bracket
Removal
2. Place the transmission in neutral to allow the crankshaft to turn and remove the key from the ignition.
3. Remove the top engine cover (see Section 34).
4. Remove the sound insulation under the engine compartment (see Chapter 11).
5. Disconnect the feed (2 in illustration 34.18) and return (1) fuel lines by squeezing the clamps.
6. On CFHC and CFJA engines, disconnect the connector (2 in the illustration) differential pressure sensor "G505", unscrew the bolt (3) and remove the bracket together with the sensor from the bracket of the additional fuel pump in the direction of the arrow. Place the bracket with the sensor back.
36.6. Differential pressure sensor and its bracket
Note: The "G505" sensor is very sensitive, so do not allow it to touch other parts.
7. Unscrew the bolt (1 in illustration 34.20) and push the neck (2) with the filling tube to the side.
Note: For clarity, the fuel filter is not shown in the illustration.
8. Release the fuel hose (2 in illustration 34.21) from the bracket, remove the fuel line bracket upward in the direction of the arrow and set it aside. Disconnect the connector (1) of the additional fuel pump "V393" and unscrew the bolts (3).
9. Loosen the bolt by two turns (1 in illustration 34.22), unscrew the bolt (2) and loosen the nut (3). Separate the coolant line bracket from the fuel filter. Place the expansion tank and fuel filter on the engine without disconnecting the hoses from them.
10. Disconnect the connector (3 in the illustration) sensor "G83" of coolant temperature at the radiator outlet. Loosen the nut (1), unscrew the bolt (2) and push aside the right coolant pipe with the hoses connected to it.
36.10. Right coolant pipe
11. Press the clamps (see illustration) and remove the upper timing belt cover. Remove the crankshaft pulley (see Section 35), without blocking the auxiliary drive belt tensioner.
36.11. Upper timing belt cover clamps
12. Unscrew the bolts and remove the lower timing belt cover (see illustration).
36.12. Fastening the lower timing belt cover
13. Turn the crankshaft clockwise to the TDC position of piston No. 1 and fix the crankshaft gear with the T10050 device (see illustration). When inserting the pin of the T10050 device into the hole in the front sealing flange, the marks on the toothed segment of the device (1) and on the crankshaft toothed wheel (2) must coincide, and the arrow on the camshaft toothed wheel must be in a position close to the "12 o'clock" position.
36.13. Fixing the crankshaft in BMT
14. If the belt being removed is intended to be reused, mark the direction of its movement on it. Loosen the bolts in sequence (1 in the illustration) camshaft gear fastenings and replace them, screwing in the new bolts not all the way (by hand).
36.14. Camshaft gear mounting bolts
15. Loosen the bolts in sequence (2 in the illustration) fastenings of the fuel injection pump gear and replace them, screwing in the new bolts not completely (by hand).
36.15. Fastening of coolant pipe (1) and fuel injection pump gear (2)
16. Loosen the nut (1 in the illustration) tension roller fastenings and turn its eccentric counterclockwise (arrow) with the T10264 Allen key until the T10265 locking device can be inserted. Lock the tension roller with the T10265 device.
36.16. Tensioner locking
17. Turn the tension roller eccentric clockwise (arrow on the illustration) until it stops and tighten the nut (1) by hand. Remove the timing belt first from the large idler roller, and then from the remaining rollers and gears.
(Information published on the website: «www.skodabook.ru»)
36.17. Removing the drive belt
Installation
Note: The timing belt tension should be adjusted on a cold engine, since the position of the tensioner indicator depends on the engine temperature.
Note: If the tensioner pulley needs to be replaced, the engine bracket must be removed.
18. Make sure that the tension roller is locked with the T10265 device and secured with a nut screwed all the way in (see illustration 36.17).
19. Make sure the crankshaft is locked with the T10050 tool (see illustration 36.13), and new bolts are screwed into the gear wheels of the camshaft and fuel injection pump. In this case, the bolts must be tightened so that the specified gear wheels can be turned, but without distortion.
20. If necessary, turn the camshaft hub using the T10172 counter support with T10172/4 adapters so that the hub can be locked. To do this, tighten at least one bolt by hand (1 in the illustration).
36.20. Turning the camshaft hub
21. Secure the camshaft hub by pushing the locking pin #3359 through the free oblong hole into the hole in the cylinder head (see illustration). After this, loosen the bolts, tightened by hand.
36.21. Fixing the camshaft hub
22. If necessary, turn the fuel injection pump hub using a screwdriver by the bolt heads (1 in the illustration) enough so that it could be fixed.
36.22. Turning the fuel injection pump hub
23. Secure the fuel injection pump hub by pushing the locking pin No. 3359 into the adjustment hole on the outside of the fuel injection pump gear (see illustration).
36.23. Fixing the fuel injection pump hub
24. Turn the camshaft and fuel injection pump gears in their oblong holes clockwise until they stop. Place the timing belt on the crankshaft sprocket (1 in the illustration), pass through the tension roller (2), the gear wheels of the camshaft (3), the water pump (4) and the fuel injection pump (5). Finally, pass the timing belt through the intermediate roller (6).
36.24. Timing belt routing diagram
25. Loosen the tension roller nut and pull out the T10265 tool (see illustration 36.17). Make sure the tensioner pulley is seated correctly in the rear timing belt cover (see illustration).
36.25. Position of the tension roller in the rear timing belt cover
26. Install the T10172 counter support with T10172/4 adapters on the camshaft gear and press it in the direction of the arrow (see illustration) and hold the camshaft timing gear in the pre-tension position. In this position, tighten the bolts (1) of the camshaft gear, and then the bolts of the injection pump gear with a force of 20 Nm.
36.26. Tightening the bolts for fastening the camshaft gears (1) and the high-pressure fuel pump (2)
Note: The bolts should be finally tightened after checking the correct installation of the timing phases (see below).
27. Carefully turn the tension roller eccentric clockwise with the T10264 angle screwdriver until the tension indicator (2 in the illustration) was located in the center of the gap in the base plate. Make sure that the nut (1) does not turn. While holding the tension roller in this position, tighten its fastening nut to 20 Nm, and then pull it to an angle of 45°.
36.27. Tensioning the timing belt
28. Remove locking pins No. 3359 of the camshaft and high-pressure fuel pump, as well as the crankshaft retainer T10050. Turn the crankshaft 2 turns clockwise, set it to the position just before TDC and install the T10050 crankshaft locking tool. Turn the crankshaft clockwise until the pin (arrow on the illustration) the T10050 retainer entered the hole in the sealing flange.
36.28. Pin of the T10050 device
29. When performing the following inspection procedure, only the camshaft and crankshaft must be clamped. Again, finding the mounting position of the fuel injection pump hub is quite difficult, but a small deviation (arrow on the illustration) does not affect engine operation.
36.29. Deviation from fuel injection pump adjustment
30. Check that the camshaft hub can be secured with locking pin No. 3359 and that the indicator (2 in the illustration) the tension roller is located in area (a) of the base plate.
36.30. Position of the indicator before checking the timing phases
31. If the camshaft hub cannot be locked, proceed as described in paragraphs 32-34. Otherwise, proceed to paragraph 35.
32. Pull out the crankshaft locking tool T10050 until the pin comes out of the hole. Turn the crankshaft counterclockwise a little past the TDC position, and then slowly turn it clockwise until the camshaft hub can be locked with locking pin #3359. Once locked, loosen the camshaft gear mounting bolts on the locked hub.
33. Check the position of the T10050 retainer pin relative to the hole in the sealing flange (see illustration 36.28). If the pin is to the left of the hole, slowly turn the crankshaft clockwise until the pin enters the hole. Tighten the camshaft timing gear mounting bolts to 20 Nm.
34. If the pin of the T10050 tool is to the right of the hole, turn the crankshaft slightly counterclockwise (so that the pin is to the left of the hole), and then clockwise until the pin enters the hole. Tighten the camshaft timing gear mounting bolts to 20 Nm.
35. Remove locking pin No. 3359 and crankshaft retainer T10050 and check the timing phases again (see paragraphs 28-31).
36. If the camshaft hub can be fixed, tighten the camshaft gear mounting bolts by an angle of 45', holding it from turning with the T10172 tool and T10172/4 adapters. Then tighten the fuel injection pump gear mounting bolts by an angle of 90', holding it from turning with the T10172 tool and T10172/8 adapters.
37. Further installation is carried out in reverse order.