Sump Replacement 1

2/16/2011

DIY Oil Pan / Sump Replacement 1.8T Q…

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Audi Forum - Audi Forums for the A4, S4, TT, A3, A6 and more! > Audi Parts - Tuning - Technical > General D.I.Y. - Do It Yourself > A4 - B5, B6, B7, B8

DIY Oil Pan / Sump Replacement 1.8T Quattro

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A4 - B5, B6, B7, B8 DIY for A4 - B5, B6, B7, B8

LinkBack 02-10-2010, 06:28 PM

hosickjg Audi Forum Posts like an A1 Join Date: Jan 2010 Location: Peterborough Posts: 8 Feedback: 0 / 0% Audi Details Year: 2002 Model: A4 Transmission: Manual C olor: Grey

Thread Tools #1 (permalink)

DIY Oil Pan / Sump Replacement 1.8T Quattro

First off, thanks hosickjg! I had to remove my oil pan this week and I was shocked to find that there is no DIY for how to remove a sump, but lots of people seem to be looking for information about this job. I took photos of my experience so here goes: Before I start, this is a difficult job. If you have never replaced a transmission, engine or clutch in a front wheel drive car, DON'T ATTEMPT! I rate this a 7.5/10 First Step: Take the car to an air conditioning specialist and have the air conditioning system discharged. Second step: Unhook battery Third step: Put this front clip in the service position . This just means taking weight off the front end. After doing this remove all the bottom covers to expose the oil pan. This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

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Fourth step: Support the transmission using a jack and wood so you don't damage the transmission. Remove the lower A/C line off the compressor. This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

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DIY Oil Pan / Sump Replacement 1.8T Q…

This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

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DIY Oil Pan / Sump Replacement 1.8T Q… Fifth Step: Loosen the rear bolts (one on each side) for the front sub-frame. Do NOT take them out. Loosen them so about 1 inch is sticking out. This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

Next: Drain the oil from the engine. Remove the oil pan engine mount and turbo return line. This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

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Next: Remove the bottom engine mount bolts on the left and right side engine mounts. This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

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This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

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DIY Oil Pan / Sump Replacement 1.8T Q… Next: This step is optional. I found it easier to access some of the oil pan bolts at the back of the pan but you can do this job without this step. I removed the coolant reservoir and throttle body. This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

Next: Place another jack under the front of the sub-frame. Remove the front sub-frame bolts (there are 3 on each side). Lower the sub-frame using the jack. The sub-frame should drop about 8 inches. This drop w ill allow you to access the rear oil pan bolts. Next: Undo all the oil pan bolts. You will need a 16mm socket and a 10mm socket. Unhook the oil level sensor. Now is the tricky part. I wish I had a guide to tell me about the 2 hidden bolts. There are 2 windows between the transmission and oil pan. Inside these windows you will see the fly wheel. Turn the fly wheel until you see a gap in the fly-wheel and through that gap you see a bolt. You will need a LONG 5mm hex-key to get both these bolts out. Good luck finding one. I found one at Brafasco. I then modified the end with a grinder so it was a flat end and less likely to damage the hex-key bolt. REMEMBER: If you damage this hex-key bolt you will have to remove the transmission and flywheel to get the oil pan off!!!!

This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

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This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

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Next: Using a 2x4, pry the sub-frame down enough to remove the oil pan. This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

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Next: Remove the oil pan. Inspect and clean. This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

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This im a ge ha s be e n re size d. C lick this bar to vie w the full im a ge. The origina l im a ge is size d 800x600.

audiforum.ca/…/53442-diy-oil-pan-sum…

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DIY Oil Pan / Sump Replacement 1.8T Q… Next: Apply a thin bead of silicone (buy from Audi!) to the mating surface of the oil pan. REMEMBER: if you over-do the silicone and it gets into the engine that can spell the end of your 1.8 Turbo. They have small oil journals that can be easily clogged. Next: Allow the silicone to set for 20 to 30 minutes before installing the oil pan. You want it to start to get tacky. Pry down the sub-frame and install the oil pan. Snug one bolt and each side to start to hold the pan in place. Next: Locate the transmission windows and re-install the 2 bolts behind the flywheel. REMEMEBER: These don’t have to be very tight. If you damage them the next person to have to remove this pan is going to be VERY angry. Next: Follow all steps in reverse. Fill with oil and anti-freeze. Clean up and enjoy the satisfaction of a job well done.

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02-13-2010, 07:38 PM

johnny quattro Audi Forum - Posts like an A1 Join Date: Jan 2010 Location: Barrie Posts: 46 Feedback: 0 / 0%

#2 (permalink) Re: DIY Oil Pan / Sump Replacement 1.8T Quattro

Everyone! This is a first class DIY, well documented with great pics! Kudos and thanks to hosickjg!

Audi Details Year: 2004 Model: A4 1.8T Transmission: Tiptronic C olor: Black

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02-13-2010, 08:30 PM

1move

#3 (permalink) Re: DIY Oil Pan / Sump Replacement 1.8T Quattro

I edited your post, now it has all the info on there, let me know if anything was missed and thank you for the great writeup.

Join Date: Nov 2007 Location: .... Posts: 2,175 Feedback: 0 / 0% Audi Details

02-13-2010, 08:36 PM

hosickjg Audi Forum - Posts like an A1 Join Date: Jan 2010 Location: Peterborough Posts: 8 Feedback: 0 / 0%

#4 (permalink) Re: DIY Oil Pan / Sump Replacement 1.8T Quattro

Wow, looks great. Thanks for allowing that to be posted "1move". Jon

Audi Details Year: 2002 Model: A4 Transmission: Manual C olor: Grey

02-14-2010, 02:38 PM

GT awd pwns!

#5 (permalink) Re: DIY Oil Pan / Sump Replacement 1.8T Quattro

Great write up, images are now local

Join Date: Nov 2006 Posts: 923 Feedback: 0 / 0% Audi Details Year: 2001 Model: A4 Transmission: Manual C olor: Silver

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Images: 5

05-25-2010, 07:33 PM

#6 (permalink) Re: DIY Oil Pan / Sump Replacement 1.8T Quattro

yashart_A4 Audi Forum - Posts like an A1 Join Date: May 2010 Location: NJ Posts: 1 Feedback: 0 / 0%

Who-ever decided to place those two hidden bolts inside the bell housing should be shot. I w as able to remove one of the tw o, but the bolt in the closer to the center has been fighting me for the last 3 hours. I simply cannot get this bolt out The car is automatic, and i have placed it in neutral (with the e-brake on) however spinning the flywheel is nearly impossible. Does anyone know of the best way to gain access to flywheel, without dropping the entire subframe/engine/transmission!??!

Audi Details Year: 04 Model: A4 Transmission: Tiptronic C olor: grey

Thanks in advance for the assistance. Stupid sludge got the best of me

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