3-cylinder TDI unit injector engine (1.4 ltr. 2-valve), mechanics — Installing engine — AUDI

🧭 Before you start

Prepare the clutch side, check the dowel sleeves and intermediate plate, and join the gearbox to the engine. Lower the assembly into the body, fit the engine and gearbox mounting bolts hand-tight using new securing bolts, and remove the engine support. Refit the ancillaries and drivetrain parts, set the selector mechanism and install the mountings free of stress. Finish with wiring, the battery reconnection procedures, the wiper arm, an oil level check and filling the cooling system.

Fits: Audi A2 (8Z)

• Opens: coolant
• Renewed: securing bolts

Don't miss

• Grease input shaft splines only very thinly, and do not lubricate the guide sleeve.
• Never press the clutch pedal before the slave cylinder is installed.
• Use new securing bolts on the assembly mountings and align the mountings free of stress.
• Do not use a battery charger to boost starting; control units can be damaged.
• Reuse drained coolant only if the original head and block go back in, and never if contaminated.
• Torque values assume lightly oiled bolts; avoid lubricant containing graphite.

Written for this job from the workshop steps below · TorqFix editorial.

🔧 Engine codes this applies to

📐 46 workshop diagrams for AMF

Real factory drawings for this job — timing marks, bolt locations and routing. Locked in the free view.

📋 Procedure

1. Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines to the splines. Do not lubricate guide sleeve 30.
2. Check that clutch plate is correctly centred 30.
3. Check clutch release bearing for wear, renew if necessary 30.
4. Check whether dowel sleeves for centring the engine and the gearbox are fitted in the cylinder block; install missing dowel sleeves.
5. Ensure that the intermediate plate is engaged on the sealing flange and pushed onto the dowel sleeves (arrows).

6. Bolt gearbox to engine. [Note: Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.Additional lubricant such as engine oil or gearbox oil may be used, but do not use lubricant containing graphite.Do not use degreased parts.Tolerance for tightening torques: ± 15 %.]
7. Guide engine/gearbox assembly into the body.
8. Tighten bolts (1 and 2) of assembly mounting for engine initially hand-tight. [Note: Disregard (item 3).]
9. Tighten bolts of assembly mounting for gearbox (arrows) initially hand-tight.
10. Use new securing bolts.
11. Remove engine support T40076 from engine.
12. Install drive shafts 40.
13. Install swivel joint 40.
14. Install catalytic converter .
15. Install pendulum support .
16. Install air conditioner compressor 87.
17. Install starter 27.
18. Install poly V-belt .
19. ⚠ The clutch pedal must not be operated before installing slave cylinder. — Install clutch slave cylinder 30.
20. Attach and adjust selector mechanism at gearbox 34.
21. Install transverse support 34.
22. Install air pipes/hoses with plug-in connectors .
23. Install assembly mountings so they are free of stress and 34.
24. Electrical connections and routing .
25. Observe notes on procedures required after connecting battery 27.
26. Install windscreen wiper arm 92.
27. Check oil level .
28. ⚠ Do not use a battery charger to boost starting. There is danger of damaging the vehicle's control units. — Fill cooling system . [Note: Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed.Contaminated or dirty coolant must not be used again.]

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