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Home >> Audi >> 2016 >> S5 Prestige, 2D Convertible >> Repair and Diagnosis >> External Pages >> Different car >> Section 1252 (Diesel Fuel Injection [CATA]) >> 23 Diesel Fuel Injection >> Diesel Direct Injection System >> Overview - Fuel System

Overview - Fuel System

WARNING: This page is about a different car, the 2012 Volkswagen Touareg and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
Fig 1: Exploded View Of Fuel System
GWWA23-10288Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Fuel Return Line
    • To the fuel tank
    • The fuel return line must not be bent, damaged or plugged
  2. Fuel Supply Line
    • Coming from the fuel filter
  3. Fuel Return Line Banjo Fitting
    • 25 Nm
  4. Fuel Temperature Sensor -G81-
  5. Bolt
    • 9 Nm
  6. Bracket
  7. Fuel Pressure Regulator Valve -N276-
  8. Bolt
    • 9 Nm
  9. Bracket
  10. High Pressure Fuel Line
    • 28 Nm
    • Between the high pressure pump and rail element
  11. High Pressure Fuel Line
    • 28 Nm
    • Between the rail element cylinder bank 1 and rail element cylinder bank 2
    • Before reusing the "fuel high pressure line" , check the sealing cones for damage such as scratches or corrosion. Replace if damaged.
    • If the high pressure line is not OK, always replace the high pressure line
  12. Fuel High Pressure Pump
  13. Leak Lines (Fuel Return Lines)
    • Do not disassemble the fuel return lines. Replace them completely with the pressure retention valve.
    • Run the engine at idle for approximately two minutes after replacing to bleed the fuel system and then check the fuel return lines for leaks.
  14. Bolt
    • 5.5 Nm
    • Injector unit cover to cylinder head cover
  15. Injection Unit Cover
  16. Tension Clamp
    • Injectors and tensioning brackets that have been removed and are being reinstalled may only be installed in the same cylinder.
    • If the injector unit (injector) is being replaced, then the tension bracket must also be replaced.
  17. Hex Shoulder Nut
    • 10 Nm
    • For the tension clamp
  18. Bolt
    • 22 Nm
    • For cylinder bank 2 rail element (high pressure reservoir)
  19. Fuel Pressure Sensor -G247-
  20. Seal
    • Replace
  21. Fuel High Pressure Lines
    • 28 Nm
    • For cylinder bank 2
  22. Rail Element (High Pressure Reservoir)
    • For cylinder bank 2
  23. Seals
    • Replace
  24. Hex Shoulder Nut
    • 10 Nm
    • For the tension clamp
  25. Injection Unit (Piezo Injector)
    • The following components, seals and O-rings must be replaced each time a fuel injector is removed, and installed or replaced: "copper washer" , "O-ring for the fuel injector shaft" and the "O-ring for the fuel injector return" .
    • The following components and seals and/or O-rings must be replaced whenever an injector is replaced: "tensioning claw" , "copper washer" , "injector shaft O-ring" and "injector return O-ring" .
    • Before reusing the "high pressure line" , check the sealing cones for damage such as scratches or corrosion. Replace if damaged.
    • If any injector units (injectors), high pressure lines and tensioning brackets, which were removed, are being installed, then they must be installed on the same cylinder.
    • Removing and installing. Refer to PIEZO INJECTORS, REMOVING AND INSTALLING .
  26. Bolt
    • 5.5 Nm
    • Injector unit cover to cylinder head cover
  27. Injection Unit Cover
  28. Seal
    • Replace
  29. Fuel High Pressure Lines
    • 28 Nm
    • For cylinder bank 1
  30. Bolt
    • 22 Nm
    • For cylinder bank 1 rail element (high pressure reservoir)
  31. Leak Lines (Fuel Return Lines)
    • Do not disassemble the fuel return lines. Replace them completely with the pressure retention valve.
    • Run the engine at idle for approximately two minutes after replacing to bleed the fuel system and then check the fuel return lines for leaks.
  32. Restrictor
    • In the overflow lines from cylinder banks 1 and 2
    • The function of the restrictor in the fuel return lines is to constantly guarantee some residual pressure (control quantity).
    • The Piezo injectors need this control quantity to function correctly.
    • Always replace the entire restrictor at the same time the fuel return lines are replaced.
    • The engine must run at idle for approximately two minutes after replacing to bleed the fuel system.
    • Checking. Refer to RESTRICTOR IN THE FUEL RETURN LINE, CHECKING .
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