Contents: Removal ⬇ Installation ⬇
Removal
Note: The engine can only be removed from the vehicle together with the transmission. After which they can be separated. The engine/transmission assembly is lowered from the engine bay onto the floor.
1. Place the vehicle on a level surface, then remove the hood as described in Section 11.
2. If the engine needs to be disassembled, drain the oil and remove the oil filter (see Section 1). Clean the drain plug and replace it.
3. Apply the handbrake and loosen the front wheel bolts. Jack up the front of the car and secure it on axle stands. Remove both front wheels.
4. Drain the transmission oil as described in Section 1, then clean the drain plug and replace it.
5. Drain the cooling system as described in Section 1.
6. Remove the air cleaner assembly as described in Section 4.
7. Disconnect the negative cable from the battery and remove the generator.
8. Turn the clutch adjusting nut counterclockwise to create maximum play in the clutch cable. Disconnect the cable from the clutch release lever and release the cable housing from the bracket.
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9. Unscrew the knurled retaining ring and disconnect the speedometer drive cable from the rear of the transmission.
10. Slide the rubber insulating boot off the main terminal of the starter solenoid relay, then unscrew the nut and disconnect the battery wiring.
11. Disconnect the electrical connectors from the oil pressure sensor located on the front wall of the cylinder block and the reverse light switch installed on the back side of the transmission (see illustration).
12. Release the retaining clip, then disconnect the feed hose from the fuel lift pump/filter connection. Plug the end of the hose to minimize fuel loss.
13. Disconnect the following from the fuel system and intake manifold (see illustrations):
- a) Electrical wiring connector.
- b) Accelerator pedal cable.
- c) Brake booster unit hose.
- d) Cooling system hoses.
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14. Proceeding as described in Section 3, disconnect the wiring from the coolant temperature gauge sensor, and disconnect the upper radiator hose and the expansion tank hose from the thermostat housing. Loosen the retaining clips, and disconnect the lower radiator hose from the front and the heater hose from the rear of the metal coolant pipe (see illustrations).
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15. Trace the low voltage wiring from the distributor to the ignition module and disconnect the connectors. Disconnect the ignition coil high voltage wire from the center of the distributor and move it away from the engine.
16. Working under the vehicle, remove the mounting bolt and disconnect the transmission ground strap from the underbody of the vehicle.
17. Disconnect the shift linkage from the transmission. Disconnect the inner drive shaft CV joints from the transmission. Make sure the drive shaft and shift links will not interfere with engine/transmission removal.
18. On models equipped with an engine oil cooler, disconnect the cooler hoses from the block, see Chapter 8 of Section 2A.
19. Attach the lifting chains to the bracket on the rear of the cylinder head and lift the engine slightly with a winch. Make sure the chains do not contact surrounding components.
20. Remove the nut securing the rear engine/transmission mount rod to the subframe. Remove the bolt securing the rod to the engine support bracket and remove the rod from under the vehicle.
21. Loosen the right engine/transmission mount pinch bolt and remove the nut. To gain clearance for removing the bolt, knock out the plug on the right side member. The pinch bolt can now be removed through the hole under the wing (see illustrations).
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22. Loosen and remove the left hanger tie bolt and remove its square nut from the front of the bracket (see illustration). Please note that there is no need to disturb the left or right suspension brackets; they should be left in place as they are good adjustment points when the engine is raised into position during installation.
23. Once again, make sure that nothing is preventing the engine/transmission assembly from being removed from the vehicle. Note that it will be much easier to remove the assembly from underneath the vehicle if it is lowered onto a wheeled dolly.
24. Carefully lower the engine/transmission out of the engine bay. Then disconnect the chains and remove the unit from under the vehicle.
25. If it is necessary to separate the engine and transmission, first remove the starter. Remove the flywheel housing plate mounting bolts and lift the plate off the transmission. Loosen and remove the remaining bolts securing the transmission case to the engine, noting the location of the clutch cable bracket. Separate the transmission from the engine by freeing it from the mounting pins. If necessary, also remove the clutch.
Installation
26. Installation is carried out in reverse order, taking into account the following additional points:
- a) Before connecting the engine and transmission, adjust and lubricate the clutch components.
- b) Carefully lift the engine/transmission assembly into the engine bay, then insert the left and right suspension pinch bolts and tighten them by hand. Install the rear suspension bar by firmly tightening the mounting nut and bolt, then rock the engine/transmission assembly to adjust the suspension components. Finally, tighten both pinch bolts to the specified torque Specifications (see illustration).
- c) Tighten all nuts and bolts to the specified tightening torque Specifications, where given
- d) Make sure that all hoses and pipes are securely connected to their original places and secured with clamps. It is recommended to replace all old Skoda hose clamps with standard worm-type ones.
- e) Finally, fill the engine and transmission with the specified Specifications type and quantity of oil, and fill the cooling system as described in Section 1.