sump replacement 1

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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

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02-10-2010,

06:28 PM #1 (permalink)

hosickjgAudi Forum -Posts like anA1 Join Date:Jan 2010Location:PeterboroughPosts: 8Feedback: 0 /0%

Audi DetailsYear: 2002Model: A4Transmission:ManualColor: Grey

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 toremove a sump, but lots of people seem to be looking for information about this job. I took photos ofmy experience so here goes:

Before I start, this is a difficult job. If you have never replaced a transmission, engine or clutch in afront 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 doingthis remove all the bottom covers to expose the oil pan.

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Fourth step:Support the transmission using a jack and wood so you don't damage the transmission. Remove thelower A/C line off the compressor.




Fifth Step:Loosen the rear bolts (one on each side) for the front sub-frame. Do NOT take them out. Loosenthem so about 1 inch is sticking out.


Next:Drain the oil from the engine. Remove the oil pan engine mount and turbo return line.




Next:Remove the bottom engine mount bolts on the left and right side engine mounts.




Next:This step is optional. I found it easier to access some of the oil pan bolts at the back of the pan butyou can do this job without this step. I removed the coolant reservoir and throttle body.


Next:Place another jack under the front of the sub-frame. Remove the front sub-frame bolts (there are 3on each side). Lower the sub-frame using the jack. The sub-frame should drop about 8 inches. Thisdrop will 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 levelsensor. Now is the tricky part. I wish I had a guide to tell me about the 2 hidden bolts. There are 2windows 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 willneed a LONG 5mm hex-key to get both these bolts out. Good luck finding one. I found one atBrafasco. I then modified the end with a grinder so it was a flat end and less likely to damage thehex-key bolt. REMEMBER: If you damage this hex-key bolt you will have to remove the transmissionand flywheel to get the oil pan off!!!!




Next:Using a 2x4, pry the sub-frame down enough to remove the oil pan.




Next:Remove the oil pan. Inspect and clean.




Next:Apply a thin bead of silicone (buy from Audi!) to the mating surface of the oil pan. REMEMBER: if youover-do the silicone and it gets into the engine that can spell the end of your 1.8 Turbo. They havesmall 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 gettacky. Pry down the sub-frame and install the oil pan. Snug one bolt and each side to start to holdthe pan in place.

Next:Locate the transmission windows and re-install the 2 bolts behind the flywheel. REMEMEBER: Thesedon’t have to be very tight. If you damage them the next person to have to remove this pan is goingto be VERY angry.

Next: Follow all steps in reverse. Fill with oil and anti-freeze. Clean up and enjoy the satisfaction of a jobwell done.



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02-13-2010, 07:38 PM #2 (permalink)

johnny quattroAudi Forum - Posts like an A1 Join Date: Jan 2010Location: BarriePosts: 46Feedback: 0 / 0%

Audi DetailsYear: 2004Model: A4 1.8TTransmission: TiptronicColor: Black

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!



02-13-2010, 08:30 PM #3 (permalink)

1move

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

Audi Details


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

02-13-2010, 08:36 PM #4 (permalink)

hosickjgAudi Forum - Posts like an A1 Join Date: Jan 2010Location: PeterboroughPosts: 8Feedback: 0 / 0%

Audi DetailsYear: 2002Model: A4Transmission: ManualColor: Grey


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

Jon

02-14-2010, 02:38 PM #5 (permalink)

GTawd pwns!

Join Date: Nov 2006Posts: 923Feedback: 0 / 0%

Audi DetailsYear: 2001Model: A4Transmission: ManualColor: Silver


Great write up, images are now local



Images: 5

05-25-2010, 07:33 PM #6 (permalink)

yashart_A4Audi Forum - Posts like an A1 Join Date: May 2010Location: NJPosts: 1Feedback: 0 / 0%

Audi DetailsYear: 04Model: A4Transmission: TiptronicColor: grey


Who-ever decided to place those two hidden bolts inside the bell housing should beshot. I was able to remove one of the two, but the bolt in the closer to the centerhas 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) howeverspinning the flywheel is nearly impossible. Does anyone know of the best way togain access to flywheel, without dropping the entiresubframe/engine/transmission!??!

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

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