Table of contents: Removal ↓ Engine installation ↓
Removal
To remove the 1.6 l FSI engine on the Audi A2, the following preparatory operations must be performed: on the bracket for the "T40075" engine, make a hole with a diameter of 12 mm "arrow", as shown in the figure.
Distance "a" = 12 mm, size "b" = 73 mm.
Instructions. Remove the engine together with the gearbox downwards. When reassembling, install all the binders in the places where they were originally installed. Risk of damage to electronic components when disconnecting the battery terminals. The battery is located in a special compartment in the trunk.
Turn off the ignition and remove the ignition key. Loosen the nut a few turns and remove the pole tip "arrow" of the ground cable from the battery terminal. Remove the engine hood.
Warning! Risk of burns from hot steam and hot coolant. When the engine is warm, the cooling system is under excess pressure. To relieve excess pressure, place a rag around the coolant expansion tank cap and carefully open it.
Open the "arrow" cap of the coolant expansion tank. Remove the front wheels. Remove the noise-insulating casing, loosen the fasteners for this.
Install the tray for the service cranes "VAS 6208" under the engine. Disconnect the plug connector "1" of the coolant sensor at the radiator outlet "G83". Disconnect the lower coolant hose "arrow" from the radiator, for which lift the clamp; drain the coolant.
Unscrew nuts "2" and "4" to protect the starter "3". Disconnect connector "1" 1
Remove the resonator on the air duct hose "arrow 1" by pressing the locking buttons. Remove the air duct by loosening the spring clamps "arrow 2" with hose clamp pliers "V.A.G 1921".
Disconnect the "arrow" connector on the fuel metering valve "N₂90". When releasing the residual pressure, place a clean rag around the connection point and carefully disconnect. Remove fuel hoses "1" and "3". Remove the hose from the absorber.
Mark the coolant supply hose "1" and the return hose "2" to the heater heat exchanger and remove from the engine shield.
Remove the oil level dipstick guide tube. Remove the oil level dipstick guide tube "1"; to do this, press the locking buttons. Remove the oil filler tube "2" from the oil filler tank.
Unscrew the water collector "1" and put it aside together with the connected drain hose "2".
Disconnect connector "3" on radiator fan control unit "J293". Unscrew bolt "2" and remove radiator fan control unit "J293". Unscrew lock screw "1". Turn lock ring counterclockwise "arrow" and remove radiator fan "V7" together with lock ring.
Remove coolant hose "2". Remove coolant hose "1" from the radiator by lifting the clamping washer.
Remove the coolant hoses "arrows" from the coolant expansion tank and place the coolant hose freely on top.
Disconnect the plug connector "1" of the low coolant level indicator sensor "F66". Unscrew the nut "arrow" and remove the coolant expansion tank.
Caution! Risk of damage to cable locks. Do not remove cable locks from the shift rod lever and intermediate lever. Removed cable locks must be replaced.
Unlock the selector and shift cable lock as described below: Pull the safety mechanism on the shift drive cable "arrow A" forward as far as it will go. Turn the movable sleeve "arrow B" as far as it will go and lock it. Pull the selector cable out of the cable lock. Remove the cap "3" above the lock washer. Remove the lock washer "2" from the automatic transmission selector. Unscrew the nut "4" and remove the lever "1" of the gearshift rod. Unscrew the nut "arrow" and freely lay the ground wire.
Unscrew the "arrow" nut and lift up the starter protection cover.
Unscrew nut "2", holding the traction relay wires to protect them from damage. Remove wire B+. Remove anti-rotation stop "3".
Place the B+ wire loosely on the holder "1". Place the engine wiring harness "2" loosely on the support "arrow".
Unscrew the "arrow" bolts and remove the support for the shift rods from the gearbox.
Unscrew the "arrow" bolts, remove the clutch slave cylinder and put it aside, do not open the pipeline system.
Caution! Risk of damage to the clutch slave cylinder. Do not press the clutch pedal when the clutch slave cylinder is removed.
Remove the vacuum line "arrow" from the brake booster.
Instructions: Unscrew nut "3" only after replacing the engine mount.
Unscrew bolts "1" and "2" by approximately 2 turns.
Unscrew bolts "2" on the gearbox mount by approximately 2 turns.
Lift the carpet in the driver's side footwell and remove the "arrow" trim.
Disconnect connectors "1...4" and lay the wiring harness loosely. Unscrew the "arrow" bolts and put the relay unit aside.
Remove fuse block "3" and "4" from relay block "1". Remove relay base "5" from relay block. Remove relay block by unlocking "arrow" latches and unscrewing wire "2" on the bottom side.
Unscrew the bolt and nut "arrows" and carefully pull out the control unit bracket. Carefully pull out the engine control unit "1", to do this, unlock the clamps "4" as shown in the following figure.
Instructions. The figure shows the control unit bracket, side view. To unlock the control unit, press the clamps "in the direction of the arrow".
Disconnect connectors "2" and "3" from the engine control unit. Disconnect connector "1" for the NOx sensor "G295". Release the wiring harness.
Unscrew screws "1" and "2". Cut cable tie "3", unlock "arrow" clamps and remove wiring. Route engine wiring harness on body.
Unscrew the "arrow" bolts and secure the main catalyst with cable ties.
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Unscrew the air conditioning compressor "arrow" bolts.
Caution! Risk of damage to the cooling system hoses and lines. Do not twist, bend or deform the refrigerant lines and hoses.
Tie the air conditioning compressor with the refrigerant hoses connected to the radiator frame from above. Unscrew the left and right articulated shafts from the shafts with the gearbox flange. Unscrew the "arrow" bolts and remove the lower support of the power unit.
Unscrew the left and right "arrow" nuts of the axle joint. If present, unscrew the nut on the holder of the front left ground clearance sensor "G78". Hang the axle joints from the transverse levers.
Turn the left shock absorber strut outward and support it with the extension "2024 A" as shown in the figure.
Warning! Risk of injury due to loose support parts.
Secure the ball joint with nut "1".
Rotate the right cardan shaft forward by first sliding the power unit forward. Attach the cardan shaft to the "arrow" side member. When removing, be careful not to damage the surface of the cardan shaft.
Unscrew bolt "1". Ignore pos. "2, 3, 4".
Unscrew the bolts "arrow" and remove the support "1" for the intake manifold.
Disconnect connector "2". Remove air duct hose "1", to do this press the lock buttons. Unscrew bolts "arrows" remove the pressure reducing valve of the engine crankcase ventilation system from the cylinder block. Unscrew bolt "3" for the bracket.
Check if the T40075 engine bracket is prepared for removing the engine. Unscrew bolt "1" for support "T40075/1" on the T40075 engine bracket. Screw support "T40075/1" into the free threaded hole for the catalytic converter. Install the T40075 engine bracket on the engine, as shown in the figure, and screw together with bolt "1" with support "T40075/1". Tighten the T40075 engine bracket at the rear of the engine with bolt M10x25 "pos. 1" with washer "pos. 2" with a torque of 20 Nm on the cylinder block. Place the T40075 engine bracket on the "VAG 1383 A" tilter. Raise the engine slightly with the "VAG 1383 A" tilter.
Instructions: Unscrew nut "3" only after replacing the engine mount.
Unscrew bolts "1" and "2".
Unscrew bolts "2" on the gearbox mount. Ignore items "1, 3".
Check that all hoses and wires between the engine, body and gearbox are disconnected. The power unit should be lowered extremely carefully to avoid damage. Pay particular attention to the shift cables and engine wiring harness. Slowly lower the engine/gearbox unit using the "VAG 1383 A" tilting device.
Engine installation
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 degreased parts. The tolerance of tightening torques is ±15%.
Other tightening moments
| Mb | 10 Nm |
| №7 | 15 Nm |
| №8 | 22 Nm |
| №10 | 40 Nm |
| №12 | 65 Nm |
[A link to the original source is available on the website AUDIMANUAL]