A2 Sport TDI 90 Engine Refresh (SMF)

Joycey

Member
I bought this A2 a few years ago to replace my last A2 that reached 200k. This one is fast approaching 170k and with so many rattles now coming from up front it was time for some TLC. I bought this Sport TDI 90 cheap because it had next to no history with it, safe to say she's done me proud for the last 35k trouble free.

First up was removing the EGR valve, I'm guessing the diaphragm has ruptured inside allowing the oil to leak out, this has been doing this since I bought the car. Once that was out the way we pulled the gearbox off, not knowing the condition of the clutch it was wise to replace. I hear these normally have a duel mass but someone in the past changed it for a single mass flywheel.

Feel free to chuck in any advice, this is the first time I've pulled my Audi apart. The plan is to fit another single mass flywheel, new EGR and do the timing belt and water pump. If time allows I'll pull the turbo as its starting to really whistle loudly.

My Noble steed :)
5ADE105E-8968-4753-904B-CA634BB96A4B.jpeg

The offending EGR. I'm still hunting for one if anyone has one in good condition.
B4A10A20-0554-457A-BB6F-E1FB9BB75188.jpeg

Dirty dusty engine bay at 170,000 with the EGR removed at this point. What a pain to access.
3DA558A9-CEEC-4E63-9B3A-AD77CF2D2AEA.jpeg

Interesting to see some of the gearbox bolts in the oil jacket. Is this normal ?
3D9735CD-D0B8-49E9-A0B0-A142A3658218.jpeg

Next to remove was the gearbox. around 4 hours in with an hour removing the EGR.
27147771-18E5-4117-A3E2-25E266CBB7FA.jpeg

Oh look no duel mass fly here.
1D00396A-B551-452B-B5B4-F251EED422D5.jpeg

Also the mess the leaky EGR has made.
81A442B6-F74B-42A4-8A2C-6F40DE144B3D.jpeg

One solid mass flywheel. Must be said I didn't get any clutch judder or any abnormal vibrations, you do notice a slight noise when release the clutch a very subtle change in frequency.
79C0C8C0-4E6B-4CBF-9E20-6CF8B0DF735B.jpeg

The gearbox itself.
D35F15A9-9862-4FB8-A8D7-E8B8FBF40C1D.jpeg


As I said any advice would be helpful, other things worth changing etc. I have an Audi Dealer less than a mile away so parts shouldn't be a problem to get.

Once the gearbox is back in I can tackle the other side and do the belt with pump. Also some advice on removing the turbo if there's any.
 

depronman

Member
I can offer you a fully machined out egr valve
This effectively removes the egr system from the engine
It will also remove the oil leak

The machined out egr is offered on an exchange basis at a price of £50 plus £4.10 postage

Cheers. Paul


Sent from my iPhone using Tapatalk
 

Robin_Cox

Member
The AMF turbo replacement I just had they undid and removed the dogbone and driveshafts (the dogbone and one CV joint were needing to be replaced anyway), and loosened the upper engine mount bolts ; the entire engine / gearbox combo was then swung forwards at the bottom a few inches which gave enough room from below in front of the bulkhead to undo the exhaust & manifolds and turbo oil pipes and rotate the various pieces so that they would come out of the gap behind the subframe ; reassembly was the reverse of removal.

p.s. - is all the oil down the back of your engine from the EGR, or could any of it be from the rocker cover? That was more than half of the seepage down the back of mine.
 

Joycey

Member
I can offer you a fully machined out egr valve
This effectively removes the egr system from the engine
It will also remove the oil leak

The machined out egr is offered on an exchange basis at a price of £50 plus £4.10 postage

Cheers. Paul


Sent from my iPhone using Tapatalk

Cheers Paul, Where about's are you, do you have one in stock as I'm hoping to bolt everything back together in the next few days.
 

Joycey

Member
The AMF turbo replacement I just had they undid and removed the dogbone and driveshafts (the dogbone and one CV joint were needing to be replaced anyway), and loosened the upper engine mount bolts ; the entire engine / gearbox combo was then swung forwards at the bottom a few inches which gave enough room from below in front of the bulkhead to undo the exhaust & manifolds and turbo oil pipes and rotate the various pieces so that they would come out of the gap behind the subframe ; reassembly was the reverse of removal.

p.s. - is all the oil down the back of your engine from the EGR, or could any of it be from the rocker cover? That was more than half of the seepage down the back of mine.

It's been leaking since I've owned it. I'll have a closer look and check it's not the rocker.
 

noahsark6

Member
Another tdi 90 specific issue which might be worth keeping an eye on is the anti-shudder valve which is operated by a motor instead of a vacuum. Some people have reported success by cleaning it, but i changed it for another used one which is still fine.
A failed one results in a judder when turning off the engine.

All the best
 

terrywindy1

Member
Don't forget to replace oil pump chain ,sprockets and tensioner
 

nod

Member
I bought this A2 a few years ago to replace my last A2 that reached 200k. This one is fast approaching 170k and with so many rattles now coming from up front it was time for some TLC. I bought this Sport TDI 90 cheap because it had next to no history with it, safe to say she's done me proud for the last 35k trouble free.

First up was removing the EGR valve, I'm guessing the diaphragm has ruptured inside allowing the oil to leak out, this has been doing this since I bought the car. Once that was out the way we pulled the gearbox off, not knowing the condition of the clutch it was wise to replace. I hear these normally have a duel mass but someone in the past changed it for a single mass flywheel.

Feel free to chuck in any advice, this is the first time I've pulled my Audi apart. The plan is to fit another single mass flywheel, new EGR and do the timing belt and water pump. If time allows I'll pull the turbo as its starting to really whistle loudly.

My Noble steed :)
View attachment 74739
The offending EGR. I'm still hunting for one if anyone has one in good condition.
View attachment 74741
Dirty dusty engine bay at 170,000 with the EGR removed at this point. What a pain to access.
View attachment 74740
Interesting to see some of the gearbox bolts in the oil jacket. Is this normal ?
View attachment 74742
Next to remove was the gearbox. around 4 hours in with an hour removing the EGR.
View attachment 74743
Oh look no duel mass fly here.
View attachment 74744
Also the mess the leaky EGR has made.
View attachment 74745
One solid mass flywheel. Must be said I didn't get any clutch judder or any abnormal vibrations, you do notice a slight noise when release the clutch a very subtle change in frequency.
View attachment 74746
The gearbox itself.
View attachment 74747

As I said any advice would be helpful, other things worth changing etc. I have an Audi Dealer less than a mile away so parts shouldn't be a problem to get.

Once the gearbox is back in I can tackle the other side and do the belt with pump. Also some advice on removing the turbo if there's any.
Good work for 4 hours! I'd be interested in the details of the SMF you fit and feedback on whether you get any juddering when the new one is fitted. Is your 90 remapped? cheers nod.
 

Joycey

Member
Good work for 4 hours! I'd be interested in the details of the SMF you fit and feedback on whether you get any juddering when the new one is fitted. Is your 90 remapped? cheers nod.

Thanks Nod, I spend most of my waking hours building various old BMW's, same meat different gravy :)

This was the kit I've purchased: https://www.ebay.co.uk/itm/SOLID-MASS-FLYWHEEL-CLUTCH-KIT-BOLTS-AUDI-A2-1-4-TDI/372634582268?ssPageName=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649

Yeah I'm running a tweaked ECU for the last 10k.
 
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depronman

Member
Cheers Paul, Where about's are you, do you have one in stock as I'm hoping to bolt everything back together in the next few days.
I in St Annes Lancashire so not local
I have one in stock already machined so can post tomorrow by what ever you are willing to pay for to get it to you in time
the £4.10 ia royal mail second class signed for small parcel which is normaly two days, but could be longer if they are clearing backlog (xmas returns etc) There is a garanteed next day but I'm not sure how much that would be
I can find out tomorrow for you, but to save time wouls suggest that you agree a max for the postage then I will get the best deal at the post office
I do postage at cost so it makes no difference to me

Cheers,
Paul
 
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Joycey

Member
I in St Annes Lancashire so not local
I have one in stock already machined so can post tomorrow by what ever you are willing to pay for to get it to you in time
the £4.10 ia royal mail second class signed for small parcel which is normaly two days, but could be longer if they are clearing backlog (xmas returns etc) There is a garanteed next day but I'm not sure how much that would be
I can find out tomorrow for you, but to save time wouls suggest that you agree a max for the postage then I will get the best deal at the post office
I do postage at cost so it makes no difference to me

Cheers,
Paul

Cheers Paul, send it guaranteed next day just PM me the cost and I'll ping it over.
 

spike

Member
Thanks Nod, I spend most of my waking hours building various old BMW's, same meat different gravy :)

This was the kit I've purchased: https://www.ebay.co.uk/itm/SOLID-MASS-FLYWHEEL-CLUTCH-KIT-BOLTS-AUDI-A2-1-4-TDI/372634582268?ssPageName=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649

Yeah I'm running a tweaked ECU for the last 10k.

Our 3 cyl tdi engines uses a unique flywheel design where a fair chunk of metal is scalloped from the rim on the back face of the flywheel. This is to compensate for the small bobweights on the crankshaft.
Running a conventional flywheel will certainly increase engine vibration so it's worth checking the kit has a scalloped flywheel. Most don't although they claim to be compatible.

Cheers Spike
 

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Joycey

Member
Our 3 cyl tdi engines uses a unique flywheel design where a fair chunk of metal is scalloped from the rim on the back face of the flywheel. This is to compensate for the small bobweights on the crankshaft.
Running a conventional flywheel will certainly increase engine vibration so it's worth checking the kit has a scalloped flywheel. Most don't although they claim to be compatible.

Cheers Spike

Cheers Spike I'll be sure to check when it arrives.
 

Joycey

Member
So I’ve finally got my new clutch & flywheel kit. Been driving me mad, I’ve been waiting nearly 2 weeks.

This kit is quite a bit different to the one I took off. First thing that stood out was the size difference of the flywheel, the old one is lot thicker but weight wise not much heavier. I checked the fitment and there’s no issues or clashes with the engine. I also checked the flange ofset in relation to the starter ring and it’s in the same place. I’ll find out for sure when I fit it in the morning. Also worth noting is the size of the clutch disc and spring set on it, it’s huge and the disc itself is a good 5/10mm bigger, aswell as it’s depth/thi so this is a good sign to absorb vibrations.

I also quickly looked at the invoice which states 1.9VWGolf flywheel conversion kit, I’ve heard these kits are similar, I’m guessing you guys more about this.

Old on the left
5EE22567-785F-45B7-8E72-71E1C578E1B2.jpeg

New disc is the left
A56AA223-B38E-4818-8336-20E8A5633F31.jpeg

A4F1D869-4790-4A06-AB5B-E0BE47A19B52.jpeg

Pressure plate looking very similar
BCF1A529-BF96-44DC-8929-A81E878B50C9.jpeg

Stay tuned to find out if it works ok or not. I’ll be fitting it in the morning so I’ll grab some more photos of it all going together. If it does work for £140 you cant complain.
Lee
 

Weetank2

Member
So I’ve finally got my new clutch & flywheel kit. Been driving me mad, I’ve been waiting nearly 2 weeks.

This kit is quite a bit different to the one I took off. First thing that stood out was the size difference of the flywheel, the old one is lot thicker but weight wise not much heavier. I checked the fitment and there’s no issues or clashes with the engine. I also checked the flange ofset in relation to the starter ring and it’s in the same place. I’ll find out for sure when I fit it in the morning. Also worth noting is the size of the clutch disc and spring set on it, it’s huge and the disc itself is a good 5/10mm bigger, aswell as it’s depth/thi so this is a good sign to absorb vibrations.

I also quickly looked at the invoice which states 1.9VWGolf flywheel conversion kit, I’ve heard these kits are similar, I’m guessing you guys more about this.

Old on the left
View attachment 74880
New disc is the left
View attachment 74877
View attachment 74878
Pressure plate looking very similar
View attachment 74879
Stay tuned to find out if it works ok or not. I’ll be fitting it in the morning so I’ll grab some more photos of it all going together. If it does work for £140 you cant complain.
Lee
If possible a photo of the reverse side of flywheels please

Three pot one will have a cut out for a reason
 

Joycey

Member
If possible a photo of the reverse side of flywheels please

Three pot one will have a cut out for a reason
Just ran down and grabbed a photo. Looking at both they’re very similar. Also the SMF I took off my 90 has an Audi stamp on it.

E003CBEE-F59F-4854-8B8C-9F700C6C021C.jpeg
 

depronman

Member
This worries me as the flywheel for the 1.9 is for a 4 pot engine which is a self balancing engine. However the 3 pot 1.4 engine needs a balance shaft and also a specific crank shaft pulley and flywheel. These are all specific to the 3 pot engine

There will be major vibration issues is a 4 cyclometer flywheel is fitted to a 3 cylinder engine or indeed the other way around

Paul


Sent from my iPhone using Tapatalk
 

Joycey

Member
This worries me as the flywheel for the 1.9 is for a 4 pot engine which is a self balancing engine. However the 3 pot 1.4 engine needs a balance shaft and also a specific crank shaft pulley and flywheel. These are all specific to the 3 pot engine

There will be major vibration issues is a 4 cyclometer flywheel is fitted to a 3 cylinder engine or indeed the other way around

Paul


Sent from my iPhone using Tapatalk

What's your thoughts on the SMF I've just taken off, this has been fine the last 35k with no Vibration issues at all.
 
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