1.2tdi gear box hydraulic leaks and turbo

A

audia23l

Member
Since purchasing my 1.2 TDI I have had to top up the gearbox hydraulic oil. It has leaked about 1 litre in 40,000 km. I have just purchased new hydraulic pipes but have some concerns about fitting them. Access appears to be extremely difficult and I wonder has the hydraulic pump and reservoir to be removed to fit the pipes? Have the clutch and gear actuators to be bled after refitting new pipes and have the gear change and clutch to be calibrated electronically? If this is the case I will have to purchase a workshop manual, VAG COM software and a diagnostic cable.

I recently had to replace the turbocharger at 168k km. Is this a common fault on tdi A2’s? The original turbo was badly worn. I was lucky that no engine damage occurred as the turbo failed very suddenly. It started making a rubbing noise and the engine ran on uncontrollably on the engine oil. (loads of smoke and difficult to stop) I was extremely surprised by the turbo failure as my A2 has a full service history and has been filled with 507 00 engine oil. I always allow the turbo to cool by reducing speed and coasting before switching off. I wonder could the stop start system have contributed to the failure or is this a weakness on 1.2tdi’s.

I recently changed from winter tyres back to the Ecopia summer tyres. The Ecopia’s transform the 1.2tdi. Fuel consumption has returned to 2.8 l/100km (100 mpg) and coasting huge distances is again possible. Consumption had increased to approx 3.2 l/100 km (88 mpg) on the winter tyres.

The Ecopia’s will need replacing shortly. Has any one experience of Michelin Energy Savers on a 1.2 tdi? The 165/70x14T will fit.
 
The hoses have O ring seals at each end and are secured by metal clips. The clips wear and should be replaced and the O rings also require replacement. Unless damaged, replacement of the hoses is not strictly necessary. Be careful that the hoses are replaced correctly because it is apparently possible to write-off the actuator by incorrect connection. Access is not easy on the A2, unlike the Lupo 3L.

If you only replace the hoses, it is not strictly necessary to reset the clutch and gearbox, although this should be done periodically anyway.

From my experience with wider Ecopia's, don't expect better economy with the Michelin's!

RAB
 
I've just recently seen the depth of information and experience available on the German site with regard to 3L versions.
If you want assistance with dealing with the issues, then you really need to get over there. That particular thread was a mechanic with extensive experience looking for assistance :D

We simply have more of them.

Bret
 
1.2tdi gear box hydraulic leaks

Thank you both for the information. I didn't know that the clips should also be replaced. I am going to change the hoses as I remember reading somewhere that they are liable to split, leading to complete hydraulic oil loss. Do you know if the hydraulics have to be bled and if they are liable to get air locked after changing the hoses?

Rab, what tyres have you fitted to your 1.2tdi A2? I would be happy with the Michelin Energy savers if I can achieve the same economy as with the Ecopias.

Bret, I am having difficulty finding the thread and the German site. Could you please post a link for it. Thank you.

audia23l
 
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I have to go out right now, I will do some hunting for you later. I know one poster talked about the clips (and there's pics to show)... give me a few hours and I'll see what I can do.

Bret
 
audia23l said:
Thank you both for the information. I didn't know that the clips should also be replaced. I am going to change the hoses as I remember reading somewhere that they are liable to split, leading to complete hydraulic oil loss. Do you know if the hydraulics have to be bled and if they are liable to get air locked after changing the hoses?

Rab, what tyres have you fitted to your 1.2tdi A2? I would be happy with the Michelin Energy savers if I can achieve the same economy as with the Ecopias.

audia23l
Click to expand...

The clips are wire and wear because of hose movement. In 15 car/years ownership of A2 1.2Tdi/Lupo 3L, I have never had a split hose and one of those cars is 8.5 years old but of course it is possible.

There is no way of bleeding the system - the system is presumably self-bleeding. You should loosen the accumulator to allow the fluid to return to the reservoir before topping up.

I've changed from wider B391's (bought with the car and 145x80's not available then) to standard 145x80 B381's with a decrease in full consumption of something like at least 5%, if not more. You might get more grip with the Michelins but you'll be very lucky to improve fuel consumption as well.

RAB
 
1.2tdi gear box hydraulic leaks

Thank you for the information. I have ordered the clips, hoses and seals from my local Audi dealer.

It will be interesting to see if there is much wear on the clips.

Thanks Bret for the information. I registered on the German site. It will even translate the posts to English.

The clips on the photographs are on the gear actuators. My A2 is leaking where the hoses come out of the hydraulic pump unit. I will also replace the hose retaining plate on the hydraulic pump. Hopefully this will stop the leaks.

Regards

audi2a3l
 
audia23l said:
..//..
The Ecopia’s will need replacing shortly. Has any one experience of Michelin Energy Savers on a 1.2 tdi? The 165/70x14T will fit.
Click to expand...

If it is legal in your country, I would be tempted by the energy savers. The composition is surely better that that of the dated ecopias. My experience of 145/80x14 ecopias is that they are terrible in the wet. If you have power steering, then I cannot see any drawback to fitting the michelins. Safer braking, safer cornering, minor increase in fuel consumption. The 145 are really too close to the limit with 4 wheel slides possible in the dry. Mostly fun, sometimes scary.

Cheers

GA
 
Gaff,

Never had any problems with 145/80x14 Ecopia's in the dry or wet since fitting them about six months ago. I do drive in a rather relaxed manner though. My 1.2 was fitted with wider B391's when I bought it - not sure whether for more grip or the non-availability of B381's.

RAB
 
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