Withdrawal
To remove the 1.4 liter engine on the Audi A2, the following preparatory steps must be performed: the soundproofing casing has been removed.
Make a 6.5 mm hole in the center of the lug of the cylinder block -arrow- and cut the thread. Make a 12 mm hole in the engine bracket -arrow-.
Distance -a- = 12 mm. Dimension -b- = 73 mm.
Instruction. Remove engine together with gearbox downwards. When reassembling, install all binders in the places where they were originally installed. Risk of damage to electronic components when disconnecting battery terminals. Follow the instructions for disconnecting the battery terminals. The battery is located in a special compartment in the trunk.
Switch off the ignition and remove the ignition key. Loosen the nut a few turns and remove the pole piece -arrow- of the earth cable from the battery terminal.
Remove the engine hood.
Attention! Risk of burns from hot steam and hot coolant. When the engine is warm, the cooling system is under overpressure. To relieve excess pressure, cover the coolant expansion tank cap with a cloth and open it carefully.
Open cap -arrow- of coolant expansion tank. Remove front wheels. Remove acoustic cover, to do this loosen fasteners -arrows-.
Place a pallet for service cranes -VAS 6208- under the engine. Unplug electrical connector -1- for coolant sender at radiator outlet -C-83-. Detach lower coolant hose -arrow- from radiator by lifting clip; drain coolant.
Remove nuts -2- and -4- to protect starter motor -3-. Disconnect connector -1-.
Remove canister solenoid valve 1 -N80- -pos. 2- with bracket. Disconnect connector -3-, remove hose and lay loosely -1-.
Remove air duct, to do this loosen spring clips with hose clip pliers -VAG 1921- -arrows-.
Remove fuel supply hose -arrow-.
Mark coolant supply hose -1- and return hose -2- to heater heat exchanger and remove from engine shield.
Remove the oil dipstick from the guide tube. Remove guide tube -1- of dipstick; to do this, press the release buttons. Remove oil filler pipe -2- from oil filler container.
Detach intake air preheating hose from heat shield -arrow-.
Unscrew water trap -1- and lay to one side with connected drain hose -2-.
Unplug connector -3- at radiator fan control unit J293-. Remove bolt -2- and remove radiator fan control unit -J293-. Unscrew locking screw -1-. Turn circlip counterclockwise -arrow- and remove radiator fan -V7- together with circlip.
Detach coolant hose -2-. Detach coolant hose -1- from radiator by lifting retaining clip.
Detach coolant hoses -arrows- from coolant expansion tank and lay coolant hose loosely at top.
Unplug electrical connector -1- for low coolant level indicator sender -F66-. Remove nut -arrow- and remove coolant expansion tank.
Carefully! Risk of damage to cable locks. Do not remove the cable locks from the shift lever and intermediate lever. Removed cable locks must be replaced.
Remove cap -3- above lock washer. Remove lock washer -2- from intermediate lever. Unlock the selector and shift cable lock as follows: Pull the safety mechanism on the shift cable -arrow A- forward as far as it will go. Turn movable sleeve -arrow B- as far as it will go and secure. Remove nut -4- and remove selector lever -1-. Unscrew nut -arrow- and lay ground wire loosely.
Unscrew nut -arrow- and remove starter protection cover upwards.
Unscrew the nut -2- while holding the wires of the traction relay to protect against damage. Remove wire B+. Remove anti-rotation stop -3-.
Lay wire B+ loosely on holder -1-. Lay engine wiring harness -2- loosely on support -arrow-.
Remove bolts -arrows- and remove selector rod support from gearbox.
Unscrew bolts -arrows-, remove clutch slave cylinder and lay to one side; do not open pipe system.
Carefully! Risk of damage to the clutch slave cylinder. With the clutch slave cylinder removed, do not depress the clutch pedal.
Disconnect vacuum line -arrow- from brake booster.
Instruction. Loosen nut -3- only after replacing engine mounting.
Loosen bolts -1- and -2- by approx. 2 turns.
Unscrew bolts -2- on gearbox mounting by approx. 2 turns. Raise footwell carpet on driver's side and remove trim -arrows-.
Remove fuse box -3- from relay box. Unscrew bolt and nut -arrows- and carefully pull out bracket for control unit. Carefully pull out the engine control unit -1-, to do this release the clips 4- as shown in the figure.
Instruction. The figure shows the control unit bracket, side view. To unlock the control unit, press the clips -in the direction of the arrow-.
Unplug connectors -1...4- and loosely lay wiring harness. Remove bolts -arrows- and lay relay carrier aside.
Disconnect connectors -2- and -3- from engine control unit. Release wiring harness.
Remove bolts -1- and -2-. Cut through cable tie -3-, release catches -arrows- and remove wiring harness. Route the engine wiring harness to the body.
Remove cable for lambda probe downstream of catalytic converter -G130- from rubber grommet -arrow to left- and unclip from heat shield arrow to right-. Unscrew the 2 screws for the heat shield and lay the wire for the lambda probe loosely after the catalytic converter -G130-.
Remove bolts -arrows- and remove heat shield at rear.
Loosen screw connections -arrows- for clamping sleeve.
Secure the detachable element against bending with locking pin -T40035-.
Remove bolts -arrows- for front exhaust pipe to exhaust manifold. Remove front exhaust pipe with catalytic converter and resonator from retaining cables and lay to one side.
Carefully! Risk of breakage due to reverse rotation of the used V-ribbed belt. Before removing the V-ribbed belt, mark the direction of rotation on it with chalk or a felt-tip pen.
To loosen the V-ribbed belt, turn the tensioning element clockwise with a ring spanner -arrow-. Lock poly V-belt tensioner with locking pin -T10060 A- and remove poly V-belt.
Unplug connector -1- for solenoid clutch at air conditioner compressor. Unscrew bolts -arrows- for air conditioner compressor.
Carefully! Risk of damage to hoses and lines of the cooling system. Do not twist, bend or deform lines and hoses of the refrigerant.
Tie up the air conditioner compressor with the refrigerant hoses connected to the radiator frame from above. Unscrew bolts -arrows- and remove heat shield for right drive shaft.
Unbolt left and right drive shafts from gearbox flange shafts.
Unscrew bolts -arrows- and remove lower power unit support.
Unscrew left and right nuts -arrows- for axle joint. If fitted, unscrew nut on bracket for front left vehicle level sender -G78-. Hang axle pivots from transverse arms.
Swing left spring strut outward and support with extension -2024 A- as shown in illustration. Secure ball joint with nut -1-.
Rotate the right drive shaft forward. by moving the power unit forward first. Attach drive shaft to longitudinal member -arrows-. When removing, take care not to damage the surface of the drive shaft.
Disconnect connector -2-. Remove the air duct hose -1-, to do this, press the release buttons. Remove bolts -arrows- and remove crankcase ventilation pressure relief valve from cylinder block. Remove bolt -3- for bracket.
Check whether engine bracket -T40075- and cylinder block are prepared for engine removal. Remove bolt -1- for support -T40075/1- on engine bracket -T40075-. Screw support -T40075/1- into new threaded hole. Position engine bracket -T40075- on engine as shown in illustration and screw together with bolt -1- to support -T40075/1-. Tighten engine bracket -T40075- at rear of engine with M10x25 bolt - with washer to 20 Nm at cylinder block. Push engine bracket -T40075- onto jack -VAG 1383 A-. Raise engine slightly with engine jack -VAG 1383 A-. Loosen nut -3- only after replacing engine mounting. Remove bolts -1- and -2-.
Unscrew bolts -2- on gearbox mounting.
Instruction. Check that all hoses and wires between the engine, body and gearbox are disconnected. Lower the power unit should be extremely careful to avoid damage. Pay particular attention to the shift cables and engine wiring harness.
Slowly lower engine/gearbox assembly with engine jack -VAG 1383 A-.
Installation/Torques
Instruction. The tightening torques given are valid for lightly oiled, phosphated or oxidized nuts and bolts. It is allowed to use additional lubricants, such as oils, except for those containing graphite. Do not use degreased parts. Torque tolerance is±15%.
MB | 10 |
M7 | 15 |
MV | 22 |
M10 | 40 |
M12 | 65 |
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