Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Extension -2024 A /1-

t	Engine and gearbox jack -V.A.G 1383 A-

t	Hose clip pliers -V.A.G 1921-

t	Stepladder -VAS 5085-

t	Drip tray for workshop hoist -VAS 6208-

t	Hose clip pliers -VAS 6340-

t  Locking pin -T10060 A-

t  Setting tool -T40035-

t  Engine support -T40075- t  Bolt M10x25 with washer t  Drill bit, Ø 6.5 mm t  Drill bit, Ø 12 mm t  Thread tap M8

Preparations Preparations for removal of the 1.4 ltr. engine on the Audi A2: l  Noise insulation is removed. 1.  Drill a Ø 6.5 mm hole in centre of cast projection on cylinder block -arrow- and cut an M8 thread.

2.  Modify engine support -T40075- by drilling a hole Ø 12 mm -arrow- as shown. l  Distance -a- = 12 mm. l  Distance -b- = 73 mm. Procedure   Note t  The engine is removed from underneath together with the gearbox. t  Fit cable ties in the original positions when installing.   Caution To prevent irreparable damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery → Rep. gr.27.   Note

The battery is located in the luggage compartment panel. –  Switch off ignition and take out ignition key. –  Slacken nut a few turns and disconnect battery clamp on earth cable -arrow- from battery terminal.

–  Detach bonnet → Chapter.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. –  Open filler cap -arrow- on coolant expansion tank.

–  Remove both front wheels. –  Release fasteners -arrows- and remove noise insulation.   Note

Collect drained coolant in a clean container for re-use or disposal. –  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Unplug electrical connector -1- at radiator outlet coolant temperature sender -G83-. –  Lift retaining clip, disconnect coolant hose -arrow- from radiator (bottom) and drain off coolant.

–  Remove nuts -2- and -4- for panel protecting starter -3-. –  Unplug electrical connector -1-.

–  Detach activated charcoal filter solenoid valve 1 -N80--item 2- with bracket from air duct. –  Unplug electrical connector -3-, detach hose -1- and move clear.

–  Use hose clip pliers -V.A.G 1921- to release spring-type hose clips -arrows- and detach air duct.

WARNING Risk of injury - fuel system operates under high pressure. Wrap a clean cloth around the connection and carefully loosen the connection to release the fuel pressure. –  Detach fuel supply hose -arrow-.

–  Mark coolant supply hose -1- and return hose -2- going to and from heat exchanger and detach hoses at bulkhead.

–  Pull oil dipstick out of guide tube. –  Detach guide tube -1- for oil dipstick (press release tabs). –  Detach oil filler pipe -2- from oil filler reservoir.

–  Detach intake air preheating hose from heat shield -arrow-.

–  Detach water collector -1- and move clear to one side (drain hose -2- remains connected).

–  Unplug electrical connector -3- at radiator fan control unit -J293-. –  Remove bolt -2- and detach radiator fan control unit -J293-. –  Remove securing bolt -1-. –  Turn retaining ring anti-clockwise -arrow- and detach radiator fan -V7- with retaining ring.

–  Detach coolant hose -2-. –  Disconnect coolant hose -1- from radiator (pull out retaining clip).

–  Disconnect coolant hoses -arrows- from coolant expansion tank and move coolant hose (top) clear.

–  Unplug electrical connector -1- at coolant shortage indicator switch -F66-. –  Remove nut -arrow- and detach coolant expansion tank.

Caution Risk of damage to cable end-pieces. Do not detach cable end-pieces from selector shaft lever or gear selector relay lever. The cable end-pieces must always be renewed if they have been detached. –  Detach cover cap -3- from securing clip. –  Detach securing clip -2-. Release cable end-pieces for gate selector cable and gear selector cable as follows: –  Pull locking device on gear selector cable forwards onto stop -arrow A-. –  Turn locking sleeve as far as stop -arrow B- and lock in position. –  Unscrew nut -4- and remove selector shaft lever -1-.

–  Remove nut -arrow- and move earth wire clear.

–  Remove nut -arrow- and lift out panel protecting starter.

–  Remove nut -2-. (To prevent damage to solenoid switch, make sure wiring is not twisted.) –  Detach B+ wiring. –  Detach locating element -3-.   Note Disregard item -1-.

–  Move B+ wire -1- clear at bracket. –  Move engine wiring harness -2- clear at cable support bracket -arrow-.

–  Remove bolts -arrows- and remove cable support bracket from gearbox.

–  Remove bolts -arrows-, detach clutch slave cylinder and place to one side. Do not open pipes.   Caution Avoid damage to clutch slave cylinder. Do not operate clutch pedal with slave cylinder removed.

–  Detach vacuum line -arrow- for brake servo.   Note

Do not loosen nut -3- unless renewing engine mounting. –  Loosen bolts -1- and -2- approx. 2 turns.

–  Loosen bolts -2- at gearbox mounting approx. 2 turns.   Note Disregard -items 1 and 3-.

–  Lift carpeting in driver's footwell and detach cover -arrows-.

–  Detach fuse holder -3- from relay carrier. –  Remove bolt and nut -arrows- and carefully pull out control unit support.   Note Disregard item -2-. –  Release retaining clips -4- as shown in illustration below and carefully pull out engine control unit -1-.   Note

The illustration shows the control unit support as seen from the side. Press retaining clips in direction of -arrow- to release control unit.

–  Unplug electrical connectors -1 ... 4- and move electrical wiring harness clear. –  Remove bolts -arrows- and place relay carrier to one side.

–  Unplug electrical connectors -2- and -3- from engine control unit. –  Move electrical wiring clear.   Note Disregard item -1-.

–  Remove bolts -1- and -2-. –  Cut through cable tie -3-, release fasteners -arrows- and detach wiring guide. –  Guide out engine wiring harness through body.

–  Pull electrical wiring for Lambda probe after catalytic converter -G130- out of rubber grommet -left arrow- and unclip from heat shield -right arrow-. –  Remove 2 bolts for heat shield and move electrical wiring for Lambda probe after catalytic converter -G130- clear.

–  Remove bolts -arrows- and detach rear heat shield.

–  Loosen bolt connections -arrows- on clamp.

–  Use setting tool -T40035- to make sure flexible joint is not kinked.

–  Remove bolts -arrows- securing front exhaust pipe to exhaust manifold. –  Disengage front exhaust pipe with catalytic converter and centre silencer from rubber mountings and move clear.

Caution If a used belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen for re-installation. –  To slacken poly V-belt use ring spanner to turn tensioner in clockwise direction -arrow-. –  Use locking pin -T10060 A- to lock poly V-belt tensioner and detach poly V-belt.

–  Unplug electrical connector -1- for magnetic clutch on air conditioner compressor.   WARNING Risk of injury caused by refrigerant. The air conditioner refrigerant circuit must not be opened. –  Remove bolts -arrows- for air conditioner compressor.   Caution Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Tie up air conditioner compressor together with refrigerant hoses to lock carrier (refrigerant hoses remain connected).

–  Remove bolts -arrows- and detach heat shield for drive shaft (right-side). –  Unbolt drive shafts (left and right) from gearbox flange shafts.

–  Remove bolts -arrows- and detach pendulum support.

–  Remove nuts -arrows- for swivel joint on both sides. –  If fitted, loosen nut on bracket for front left vehicle level sender -G78-. –  Detach swivel joints from wishbones.

–  Swing suspension strut (left-side) outwards and support with support bracket -2024 A /1- as shown in illustration.   WARNING Accident risk from loose components of support bracket. Secure swivel joint with nut -1-.

–  Pivot drive shaft (right-side) forwards; to do so, push the engine/gearbox assembly slightly forwards. –  Tie up drive shaft to longitudinal member -arrow-.   Note Take care not to damage the surface coating of the drive shaft.

–  Unplug electrical connector -2-. –  Press release tabs and disconnect air hose -1-. –  Unscrew bolts -arrows- and remove pressure control valve for crankcase breather system from cylinder block. –  Remove bolt -3- securing bracket.

–  Make sure that preparations for removal of engine have been performed on engine support -T40075- and cylinder block → Anchor. –  Remove bolt -1- for support -T40075/1- on engine support -T40075- –  Screw support -T40075/1- into newly drilled threaded hole. –  Attach engine support -T40075- to engine as shown in illustration and secure with bolt -1- to support -T40075/1-. –  Securely fix engine support -T40075- to cylinder block at rear of engine with bolt M10x25 -2- and washer (tightening torque 20 Nm). –  Fit engine support -T40075- onto engine and gearbox jack -V.A.G 1383 A-. –  Raise engine slightly using engine and gearbox jack -V.A.G 1383 A-.   Note

Do not loosen nut -3- unless renewing engine mounting. –  Remove bolts -1- and -2-.

–  Remove bolts -2- at gearbox mounting.   Note Disregard -items 1 and 3-.   Note t  Check that all hoses, pipes and wiring connections between engine, gearbox and body have been detached. t  Carefully guide engine/gearbox assembly when lowering to avoid damage. t  Make sure there is sufficient clearance for gear selector cables and engine wiring harness. –  Lower engine and gearbox slowly using engine and gearbox jack -V.A.G 1383 A-.