Gearbox removal & installation: 4-cylinder direct injection engine (1.6 ltr. 4-valve), mechanics — Removing engine — AUDI

🧭 Before you start

Fits: Audi A2 (8Z)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: T40075/1

Don't miss

• The engine is removed from underneath together with the gearbox.Fit cable ties in the original positions when installing.
• Collect drained coolant in a clean container for re-use or disposal.
• Risk of injury - fuel system operates under high pressure.Wrap a clean cloth around the connection and carefully loosen the connection to allow the residual pressure to dissipate. — Detach fuel hoses (1) and (3).
• Mark coolant supply hose (1) and return hose (2) going to and from heat exchanger and detach hoses at bulkhead.
• Remove nut (2). (To prevent damage to solenoid switch, make sure wiring is not twisted.)

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📐 27 workshop diagrams for BAD

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

📋 Procedure

1. Modify engine support T40075 by drilling a hole ∅ 12 mm (arrow) as shown. [Note: The engine is removed from underneath together with the gearbox.Fit cable ties in the original positions when installing.] [Note: The battery is located in the luggage compartment panel.]
2. ⚠ To prevent irreparable damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery 27. — Switch off ignition and take out ignition key.
3. Slacken nut a few turns and disconnect battery clamp on earth cable (arrow) from battery terminal.
4. Detach bonnet .
5. ⚠ Hot steam/hot coolant can escape - risk of scalding.The cooling system is under pressure when the engine is hot.To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. — Open filler cap (arrow) on coolant expansion tank.

6. Remove both front wheels.
7. Release fasteners (arrows) and remove noise insulation. [Note: Collect drained coolant in a clean container for re-use or disposal.]
8. Place drip tray for workshop hoistVAS 6208 beneath engine.
9. Unplug electrical connector (1) at radiator outlet coolant temperature sender G83.
10. Lift retaining clip, disconnect coolant hose (arrow) from radiator (bottom) and drain off coolant.
11. Remove nuts (2) and (4) for panel protecting starter (3).
12. Unplug electrical connector (1).
13. Press release tabs and detach resonator from air hose (arrow 1).
14. Use hose clip pliersV.A.G 1921 to loosen spring-type hose clips (arrows 2) and detach air duct.
15. Unplug electrical connector (arrow) at fuel metering valve N290.
16. ⚠ Risk of injury - fuel system operates under high pressure.Wrap a clean cloth around the connection and carefully loosen the connection to allow the residual pressure to dissipate. — Detach fuel hoses (1) and (3).
17. Detach hose from activated charcoal filter (2).
18. Mark coolant supply hose (1) and return hose (2) going to and from heat exchanger and detach hoses at bulkhead.
19. Pull oil dipstick out of guide tube.
20. Detach guide tube (1) for oil dipstick (press release tabs).
21. Detach oil filler pipe (2) from oil filler reservoir.
22. Detach water collector (1) and move clear to one side (drain hose (2) remains connected).
23. Unplug electrical connector (3) at radiator fan control unit J293.
24. Remove bolt (2) and detach radiator fan control unit J293.
25. Remove securing bolt (1).
26. Turn retaining ring anti-clockwise (arrow) and detach radiator fan V7 with retaining ring.
27. Detach coolant hose (2).
28. Disconnect coolant hose (1) from radiator (pull out retaining clip).
29. Disconnect coolant hoses (arrows) from coolant expansion tank and move coolant hose (top) clear.
30. Unplug electrical connector (1) at coolant shortage indicator switch F66.
31. Remove nut (arrow) and detach coolant expansion tank.
32. ⚠ Risk of damage to cable end-pieces.Do not detach cable end-pieces from selector shaft lever or gear selector relay lever. The cable end-pieces must always be renewed if they have been detached. — Pull locking device on gear selector cable forwards onto stop (arrow A).
33. Turn locking sleeve as far as stop (arrow B) and lock in position.
34. Disengage cables from cable end-pieces.
35. Detach cover cap (3) from securing clip.
36. Detach securing clip (2).
37. Pull relay lever to side.
38. Unscrew nut (4) and remove selector shaft lever (1).
39. Remove nut (arrow) and move earth wire clear.
40. Remove nut (arrow) and lift out panel protecting starter.
41. Remove nut (2). (To prevent damage to solenoid switch, make sure wiring is not twisted.)
42. Detach B+ wiring.
43. Detach locating element (3). [Note: Disregard item (1).]
44. Move B+ wire (1) clear at bracket.
45. Move engine wiring harness (2) clear at cable support bracket (arrow).
46. Remove bolts (arrows) and remove cable support bracket from gearbox.
47. Remove bolts (arrows), detach clutch slave cylinder and place to one side. Do not open pipes.
48. ⚠ Avoid damage to clutch slave cylinder.Do not operate clutch pedal with slave cylinder removed. — Detach vacuum line (arrow) for brake servo. [Note: Do not loosen nut (3) unless renewing engine mounting.]
49. Loosen bolts (1) and (2) approx. 2 turns.
50. Loosen bolts (2) at gearbox mounting approx. 2 turns. [Note: Disregard (items 1 and 3).]
51. Lift carpeting in driver's footwell and detach cover (arrows).
52. Unplug electrical connectors (1 ... 4) and move electrical wiring harness clear.
53. Remove bolts (arrows) and place relay carrier to one side.
54. Detach fuse holders (3) and (4) from relay carrier (1).
55. Detach relay socket (5) from relay carrier.
56. Release fasteners (arrows) and unscrew wire on underside (2) to detach relay carrier.
57. Remove bolt and nut (arrows) and carefully pull out control unit support. [Note: Disregard (items 2 and 3).]
58. Release retaining clips (4) as shown in illustration below and carefully pull out engine control unit (1). [Note: The illustration shows the control unit support as seen from the side. Press retaining clips in direction of (arrow) to release control unit.]
59. Unplug electrical connectors (2) and (3) from engine control unit.
60. Unplug electrical connector (1) for NOx sender G295.

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