Withdrawal
To remove the FSI of the 1.6l engine on the Audi A2, the following preparatory steps must be carried out: Make a hole with a diameter of 12 mm -arrow- on the engine bracket -T40075- as shown in the figure.
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. 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 pressure. To release excess pressure, cover the coolant expansion tank cap with a cloth and carefully open it.
Open cap -arrow- of coolant expansion tank. Remove front wheels. Remove the soundproofing cover, loosen the fasteners for this.
Place a pallet for service cranes -VAS 6208- under the engine. Unplug electrical connector -1- for coolant sender at radiator outlet -G83-. 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- 1
Remove the resonator on the air duct hose -arrow 1-; to do this, press the release buttons. Remove air duct, to do this loosen spring clips -arrows 2- with hose clip pliers -VAG 1921-.
Unplug connector -arrow- at fuel metering valve -N290-. When relieving residual pressure, place a clean cloth around the connection and carefully disconnect. Remove fuel hoses -1- and -3-. Remove the hose from the absorber.
Mark coolant supply hose -1- and return hose -2 - to heater heat exchanger and remove from engine shield.
Remove the dipstick to determine the oil level of 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.
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 clamping washer.
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.
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. Pull the selector cable out of the cable lock. Remove cap -3- above lock washer. Remove lock washer -2- from selector lever. 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- and remove the working one. clutch cylinder and set aside; 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-.
Unplug connectors -1...4- and loosely lay wiring harness. Remove bolts -arrows- and lay relay carrier aside.
Remove fuse box -3- and -4- from relay box -1-. Remove relay socket -5- from relay box. Remove the relay box by unlocking the catches -arrows- and unscrew the wire -2- on the underside.
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 following 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-.
Disconnect connectors -2- and -3- from engine control unit. Unplug connector -1- for NOx sender -G295-. Release wiring harness.
Remove screws -1- and -2-. Cut through cable tie -3-, release catches -arrows- and remove wiring harness. Route the engine wiring harness to the body.
Remove bolts -arrows- and secure main catalytic converter with cable ties.
Unscrew bolts -arrows- for air conditioner compressor.
Carefully! Risk of damage to hoses and lines of the cooling system. Do not kink, bend or deform lines and lines of the refrigerant.
Tie up the air conditioner compressor. installations with refrigerant hoses connected to the radiator frame. 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.
Attention! Risk of injury due to loose support parts.
Secure ball joint with nut -1-.
Rotate the right drive shaft forward by sliding 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.
Remove bolt -1-. Pos. -2, 3, 4- ignore.
Unscrew bolts -arrow- and remove support -1- for intake manifold.
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- is prepared for engine removal. Remove bolt -1- for support -T40075/1- on engine bracket -T40075-. Screw support -T40075/1- into free catalytic converter screw 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 -pos. 1- with washer -pos. 2- with a torque of 20 Nm on the cylinder block. Push engine bracket -T40075- onto jack -VAG 1383 A-. Raise engine slightly with engine jack -VAG 1383 A-.
Instruction. Loosen nut -3- only after replacing engine mounting.
Remove bolts -1- and -2-.
Unscrew bolts -2- on gearbox mounting. Pos. -1, 3- ignore.
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 using engine jack -VAG 1383 A-.
Engine installation
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 motor or transmission oils, except for those containing graphite. Do not use degreased parts. Torque tolerance is±15%.
Other tightening torques
MB | 10 Nm |
№7 | 15 Nm |
№8 | 22 Nm |
№10 | 40 Nm |
№12 | 65 Nm |
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