Removal and installation the engine (Audi A2)

Table of contents: Removal ↓ Engine installation ↓ Tightening torques ↓

Removal

Instructions. The engine is removed together with the gearbox in the forward direction. When installing, install all the binders removed or cut off during removal in their original places. Observe safety precautions when disconnecting the battery ground. The battery is located in a special compartment in the trunk.

Turn off the ignition and remove the key from the ignition switch. Disconnect the ground cable "arrow" from the battery. Remove the engine hood.

Caution! When opening the cap, hot steam or hot coolant may come out of the expansion tank, wrap the cap in a rag and carefully open the tank.

Open the "arrow" cap of the expansion tank.

Instructions: To release and remove the clips, release the pins "1" in the mounting clips by approx. 4 mm. Do not insert the pins all the way.

Loosen the fastening clips on the bumper cover. Unscrew bolts "3" and "4".

Remove the front wheels. Remove the noise insulation screen "arrows".

Place a tray for the VAS 6208 service cranes under the engine. Remove the lower coolant hose from the "arrow" radiator and drain the coolant.

Remove the air duct from the "arrow" intercooler.

Loosen the fastening clips on the mudguard. Unscrew bolt "3". Remove the front part of the left and right mudguards.

Remove the "arrow" bolts from the bumper trim. Mark the position of the bolts for reinstallation.

Press the bumper cover "arrow" out of the groove starting from the bottom. Disconnect the upper part from the inside "2". Remove the bumper cover. Disconnect the plug connectors of the fog lights (if available). Place the bumper cover on a soft surface.

Disconnect the "arrow" connector of the radiator fan thermal switch "F18".

Disconnect the "arrow" connector of the radiator fan "V7".

Disconnect plug connector "2". Remove water hose "1" from the washer pump and plug the fitting with a suitable plug.

Unscrew the lower wiring harness from the radiator frame "arrows".

To remove the wiring harness fasteners, use the "80-200" lever. To facilitate removal, use a silicone-free spray if necessary.

Disconnect the horn plug connector. Loosen 2 bolts "3" on the left and right and remove the reinforcement bar. Pry off and remove the lock washers "2". Loosen bolts "1" on the left and right and remove the bumper safety bar.

Unscrew the mounting bolts "arrows" of the radiator frame on the left and right.

Disconnect the "arrow" connector of the outside temperature sensor "G17". Disconnect the connector of the windshield washer fluid level warning sensor "F77". Disconnect the wiring harness from the left air duct; to remove the fasteners, use the "80-200" lever.

Remove the engine cover "arrows". Remove the noise insulation screen located below, for which disconnect the crankcase ventilation hose.

Disconnect vacuum hose "1". Disconnect air duct "2" from air flow meter "G70".

Disconnect the plug connector "1" of the intake manifold pressure sensor "G71" and release the wiring. Remove the air hose "2" connecting the intercooler and the intake manifold.

Disconnect the "arrow" plug connector of the headlights on the left and right sides of the car. Remove the wire binders leading to the right headlight from the radiator frame. Use the "80-200" lever to remove the fasteners.

Unscrew the "arrow" bolts and remove the hood cable.

Disconnect the plug connector "3" of the bonnet limit switch "F266". Release the wiring harness on the radiator frame, use the lever "80-200" to remove the fasteners. Remove the oil dipstick from the guide tube. Remove the guide tube "4" of the oil dipstick: radiator frame. Remove the oil filler tube "5" from the oil tank. Disregard pos. "1" and "2".

Remove drain hose "2" from water tank "1".

Remove the upper left coolant hose from the coolant pipe at the point marked with the number "1". Ignore item "2".

Unscrew the "arrow" bolt on the left and right.

Remove the radiator frame and secure it in a stable position. Using a screwdriver, remove caps "3" and "4" from the windshield wiper arms. Loosen the nuts on both arms a few turns. Release arms "1" and "2" by slightly tilting them on all windshield wipers. Loosen the nuts completely and remove the windshield wiper arms.

Disconnect the windshield washer fluid tube "3". Disconnect the plug connectors "4" and "5" of the heated washer nozzles. Release the hose clamp "6" using hose clamp pliers "V.A.G. 1921" and remove the drain hose from the fairing grille. Remove the rubber seal "1" of the fairing grille. Remove the fairing grille "2". Release the windshield washer fluid tube.

Unscrew the bolts and nuts of the "arrows". Remove the fresh air intake duct and hang it on the right side of the car.

Disconnect the plug connector of the oil level and temperature sensor "G266".

Cut off the binder "2" and remove the cover "3" from the electromagnetic switch "1" in an upward direction.

Remove cover "3". Disconnect plug connector of terminal 50 "pos. 2" of electromagnetic switch. Unscrew nut "4" and remove positive wires. Observe stopper "1".

Unscrew the nuts and remove the "ground" wire. Disconnect the plug connector "2" of the reversing light switch "F4" and release the electrical wiring.

Disconnect the plug connector of the D+ terminal "pos. 1" of the generator. Disconnect the plug connectors "2" of the glow plugs. Remove the pin and loosen the nut with a notch "3" on the central plug connector of the unit injectors. Disconnect the plug connector of the Hall sensor "G40" "pos. 4" and the engine speed sensor "G28" pos. "5". Disconnect the plug connector "6" of the oil pressure sensor "F1" and release the wiring.

Remove the coolant hoses from the expansion tank "arrows".

Disconnect vacuum hose "1" from the tandem pump on the brake booster. Disconnect plug connector "2" of fuel temperature sensor "G81" and release the wiring. Disconnect plug connector "3" of coolant temperature indicator sensor "C2" / coolant temperature sensor "G62".

Disconnect vacuum hose "1" from mechanical EGR valve. Remove vacuum hose "2" from throttle control valve "N₂11".

Disconnect plug connector "1" of air flow meter "G70". Unscrew nut "2".

Disconnect the vacuum hose "arrow" from the vacuum pressure regulator, boost.

Warning! The temperature of the fuel lines or fuel on vehicles equipped with a unit-injector engine can reach 100°C. Allow the fuel to cool before disconnecting the fuel lines. Otherwise, severe burns may occur.

Mark and disconnect the fuel pressure line "2" and the fuel return line "1".

Mark the position of the supply hose "1" and the drain hose "2" in relation to the heater heat exchanger and remove the hoses from the front wall of the body.

Unscrew the wiring harness bracket from the Strelka gearbox.

Loosen the nuts of the "arrow" threaded connection of the pre-catalyst with the turbocharger.

Loosen bolt "1" on the gear shift heat shield.

Instructions: The heat shield is secured with 2 additional bolts from below, they will be removed later.

Disconnect the plug connector "2" of the speedometer sensor "G22".

Disconnect the "arrow" plug connector of the gearbox speed sensor "G38".

Loosen lock nut "B" and adjusting nut on clutch cable. Remove clutch cable from drive lever.

Instructions: Do not open the hydraulic hose of the clutch slave cylinder.

Release the connecting clamp with the wire in the place indicated by the "arrow" and remove the clutch slave cylinder from the stop "A". Put the clutch slave cylinder aside, do not open the line system.

Unscrew bolts "1" and "3" and remove the engine support. Ignore item "2".

Unscrew the heat shield "arrow" of the right drive shaft.

Loosen bolt "1" securing the connecting rod to the support arm "2"

1. 5mm Allen key, handle shortened by 10mm.
2. Device for installing rings.
3. Torque wrench "V.A.G 1331".

Hold the support arm nut with a 5 mm Allen key and loosen it.

Install the joint puller "3287 A" "pos. 1" as shown in the figure and push out the support arm.

Instructions: When installing the joint puller, make sure that the corrugated cover of the drive shaft is not damaged.

For reinstallation, mark the mounting position of the drive shaft to the flanged axle shaft on the gearbox. On the gearbox side of the dust cover, loosen the hose clamp using pliers "3340".

Caution! When removing the drive shaft, balls may fall out of the flanged axle shaft. Protect the balls from falling out with adhesive tape.

Tilt the shock absorber outward and remove the drive shaft from the flanged axle shaft. Repeat these operations on the opposite side of the vehicle. Tie both drive shafts to the side member. Make sure that the shaft surface protection is not damaged. Unscrew the lower bolts on the gearshift heat shield.

Instructions: Do not open the gear shift hydraulic lines.

Loosen bolt "1" a few turns. Remove pusher "A" from the gear shift fork rod. Loosen bolts "2" and "3". Tie the gear shifter to the body as high as possible.

Instructions: The detachable element between the pre-catalyst and main catalyst must not be bent…

Instructions: The detachable element between the pre-catalyst and main catalyst must not be bent more than 10°. Risk of damage!

Support the detachable element using the "T40035" fixing device.

Unscrew bolts "2" on the pre-catalyst bracket. Ignore pos. "1". Disconnect the pre-catalyst from the turbocharger. Tie the pre-catalyst to the body.

Screw the front right cargo eye "T40016" to the cylinder head.

Screw the rear left cargo eye "T40016/1" to the cylinder head.

Install 2 "10-222 A/12" earrings on the rear left cargo eye "T40016" on the cylinder head. Fasten the "2024 A" hanging device to the engine and to the "VAS 6100" service crane, as shown in the figure.

Instructions. To align the center of gravity of the power unit, the hook bars must be inserted as…

Instructions. To align the center of gravity of the power unit, the hook bars must be inserted as shown in the figure. The hooks and locking pins of the hanging device must be secured with cotter pins.

Raise the engine slightly using the VAS 6100 service crane.

Instructions: Unscrew nut "3" only after replacing the engine mount.

Unscrew bolts "1" and "2" and remove the bracket with the engine mount.

Loosen bolts "2" and move fuel unit "3" to the side. Ignore item "1".

Unscrew the bolts on the engine mount "arrows".

Remove the power unit forward. If necessary, disconnect the gearbox from the engine.

Engine installation

Installation is carried out in the reverse order, while observing the following: When installing, replace the self-locking nuts and bolts. Replace the bolts tightened to a certain angle, as well as the cuffs and gaskets. The hoses and pipes of the supercharger system must be cleaned of oil and grease before installation. Do not use lubricants under any circumstances. Use XCVs of the corresponding series to secure all hose connections. When assembling, install all binders in their original places. Clean the toothed ring of the input shaft and the toothed ring of the hub of the used clutch disc, remove traces of corrosion and apply a thin layer of plastic grease for the toothed ring of the hub of the clutch disc "G 000 100" to the toothed ring of the input shaft. Do not lubricate the guide sleeve. If necessary, check the centering of the driven clutch disc. Check the clutch release bearing for wear, replace if necessary. Check the presence of centering bushings for the power unit in the cylinder block; insert bushings if necessary.

Install the gasket on the centering bushings "arrows". When installing the power unit, take into account the availability of access to the gear shifter and pre-catalyst. Install the bracket with the engine mount. Install the gearbox fastening elements. Install the fuel unit. Install the engine mount. Install the pre-catalyst with the main catalytic converter. Install the clutch slave cylinder. Install the gear shifter. Install the drive shafts. Install the stabilizer connecting rods. Install the support arm. Install the bumper. Install the mudguards. Electrical connections and wiring. Observe safety precautions when disconnecting the battery terminals. Do not use a charger to start the engine. There is a risk of damaging the vehicle control units. Install and adjust the windshield wiper arms. Check the oil level. Fill with coolant. Perform basic adjustment of the manual transmission.

Tightening torques

Instructions. The tightening torques given are valid for lightly lubricated, phosphated or oxidized nuts and bolts. It is permissible to use additional lubricants, such as motor or transmission oils, except for graphite-containing ones. Do not use parts without lubrication. The tolerance of tightening torques is ±15%.