DIY Oil Pan / Sump Replacement 1.8T Quattro

[hosickjg]

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. 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. 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. 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 but you 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 3 on each side). Lower the sub-frame using the jack. The sub-frame should drop about 8 inches. This drop 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 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!!!! 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 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.

[johnny quattro]

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

[1move]

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.

[hosickjg]

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

Jon

[GT-Rick]

Great write up, images are now local

[yashart_A4]

Who-ever decided to place those two hidden bolts inside the bell housing should be shot. I was able to remove one of the two, 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!??!

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