Oil pan (upper part), removing and installing: Installing

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, 2003 Audi A4, and 2002 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Installation is reverse of removal, noting the following:

NOTE: Replace gaskets and O-rings.

Fig 1: Cutting Tube Nozzle At Front Marking

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Cut tube nozzle at front marking (jet diameter approx. 1 mm).

Fig 2: Applying Silicon Sealant Bead To Clean Sealing Surfaces Of Oil Pan (Upper Part)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Apply silicon sealant bead to clean sealing surfaces of oil pan (upper part) as shown in illustration.

Thickness of sealant bead (arrows): approx. 1.5 mm

NOTE:

The oil pan (upper part) must be installed within 5 minutes after application of silicon sealant.
Sealant bead must not be thicker than specified, otherwise sealant could get into oil pan and clog the oil pump strainer.
Apply sealant bead in area of hole (arrow) in cylinder block with special care.

Install oil pan (upper part) and pre-tighten all bolts for oil pan (upper part)/cylinder block in diagonal sequence to 5 Nm.
Tighten bolts of oil pan (upper part)/transmission to 45 Nm.

Fig 3: Identifying Engine/Transmission Fasteners In Area Of Upper Part Of Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten diagonally bolts -1- to 16 Nm and bolts -2- to 22 Nm.
Install oil pump. Refer to Oil pump, removing and installing .
Install oil pan (lower part). Refer to Oil pan (lower part), removing and installing .
Replace O-ring at guide tube for oil dipstick and insert guide tube into hole in oil pan (upper part).

Install starter:

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Install generator. Refer to Ribbed belt for power steering pump, generator and A/C system .
Install subframe:

Refer to 40 - FRONT SUSPENSION

Install A/C compressor. Refer to Ribbed belt for power steering pump, generator and A/C system .
Install ribbed belt. Refer to Installing .
Install radiator support. Refer to Lock carrier, moving into service position .
Add engine oil and check oil level.

See Caution for connecting Telematics battery. Refer to Lubrication system components, removing and installing

Observe safety precautions after connecting the battery:

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Top up with coolant. Refer to Filling .

NOTE:

Only reuse drained coolant if cylinder head or engine block were not replaced.
Dirty coolant cannot be reused.