#ZedShed Zedshed Bus build (Audi A2)

Lee

Zorg Guru (V)
British Zeds
M Power
#ZedShed
Joined
Mar 26, 2014
Points
193
Location
Basingstoke
Model of Z
Z4 Coupe 3.0si
Not a BMW this time round. Thought I would do a little thread on the Zedshed bus. I bought this A2 a few years ago to replace the last A2 that reached 200k miles. This one is fast approaching 170k so decided it was time for some tlc.

First up was removing the EGR valve, 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. These normally have a duel mass but someone in the past changed it for a single mass flywheel. Difference in price in price is mega. £170 for a single mass and £495 for a duel mass.

There’s not many cars can transport engines in easy. Or hold 4 grown men and still manage over 50mpg with £30 a year tax.


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Dirty leaking EGR
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compact engine bay, 3 Cyl turbo Diesel.
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Next was the gearbox. This took 3 hours, first ever FWD box I’ve done.
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strange how some bolts reach the engine oil jacket.
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strangly someone had already done the single mass conversion in the past.
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you can see the oil path from the leaking EGR
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now waiting on bits to arrive. Once this side is done it will be the timing belt and water pump on the other side. Should give this little shed bus some extra years.
 

t-tony

Zorg Expert (II)
Supporter
British Zeds
#ZedShed
Joined
Dec 31, 2013
Points
226
Location
Torksey Lock,Lincoln, England
Model of Z
E89 Z4 23i Auto
Now you see how the belly bolts were covered in oil. Guess the engine support bar came in handy? That’s how I did FWD on my 4 post lift when I had my garage.

Tony.
 
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Reactions: Lee

Jjim

Zorg Guru (IV)
British Zeds
Joined
Jul 21, 2017
Points
168
Location
Mansfield
Model of Z
1.9 Roadster
Fancy doing some work on my X5 😂
 

Jjim

Zorg Guru (IV)
British Zeds
Joined
Jul 21, 2017
Points
168
Location
Mansfield
Model of Z
1.9 Roadster

Lee

Zorg Guru (V)
British Zeds
M Power
#ZedShed
Joined
Mar 26, 2014
Points
193
Location
Basingstoke
Model of Z
Z4 Coupe 3.0si
So finally got the clutch and flywheel kit. Really annoyed that took over two weeks. Stopping me doing Zed stuff.

So the new flywheel and clutch assembly went on no issues. The clutch disc was an odd one as my alignment tool wouldn’t work, then when I looked closer the pressure plate centralised it anyway, never seen that before.

gearbox was a right faff to fit, it clashes on everything but after the best part of half a day we got there in the end.

Flywheel on.
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Clutch assembly followed
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old vs new flywheel.
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EGR valves bypass in, I’ve already had this mapped out the ECU so should make her run better.
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New clutch disc vs the old one. Huge difference in size. This kit was from a 1.9 golf so I’m not surprised.
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I also did a video of it running. The A2 following is huge just like the Z3 community, they told me this swap can’t be done on this type of engine. So a little video to back up my swap.

Only a couple of bits to sort now. Then I can carry on with zeds again.

View: https://youtu.be/6XTpnB3x3Rk
 
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