audi Workshop Repair Guides

Audi Workshop Service and Repair Manuals

High-pressure pump > < Vacuum system
Intake manifold (bottom section), fuel rail and injectors - exploded view
   
Intake manifold (bottom section), fuel rail and injectors - exploded view
1 - Seals
q   Renew
2 - Intake manifold (bottom section)
q   Removing and installing → Chapter
3 - Seal
q   Renew if damaged
q   When renewing lever out with screwdriver
q   Press in by hand
4 - Bolt
q   2.5 Nm
5 - Intake manifold flap potentiometer
q   Cylinder bank 1 (right-side): intake manifold flap potentiometer -G336-
q   Cylinder bank 2 (left-side): intake manifold flap potentiometer 2 -G512-
q   Before removing, remove intake manifold (top section)
q   Adaption must be performed after this component has been renewed; use a vehicle diagnostic tester
6 - Bolt
q   2.5 Nm
7 - Vacuum unit
q   For intake manifold flaps
q   After renewing, check vacuum system for leaks → Chapter
8 - Screw plug
q   25 Nm
9 - Fuel rail
q   Removing and installing → Chapter „Removing and installing injectors“ → Chapter
10 - Sleeve
11 - Retaining clip
q   For fuel rail
12 - Bolt
q   Tightening torque and sequence → Fig.
13 - High-pressure pipe
  WARNING
The fuel system operates at extremely high pressure. This can cause injury.
The pressure in the high-pressure section of the injection system must be reduced to a residual pressure prior to opening the system.
q   Reducing fuel pressure in high-pressure section of injection system → Chapter
q   Connections must not be damaged
q   Do not alter shape
q   Removing and installing → Chapter
q   Lubricate thread lightly with engine oil
q   25 Nm
14 - Bolt
q   9 Nm
15 - Bolt
q   2.5 Nm
16 - Union nut
q   Lubricate thread lightly with engine oil
q   25 Nm
17 - Seals
q   Renew
18 - Support ring
q   Renew
q   Via this support ring, the fuel rail exerts the clamping force that holds the injector in the cylinder head
19 - O-ring
q   Renew
q   Lubricate lightly with clean engine oil
20 - Spacer ring
q   Renew if damaged
21 - Injector
q   Removing and installing → Chapter
22 - Sealing element
q   Renew
23 - Combustion chamber ring seal
q   Renew
q   Do not apply grease or use any other lubricants

   
Intake manifold (bottom section) - tightening torque and sequence
–  Tighten bolts -arrows- in stages and in diagonal sequence; final torque 9 Nm.
  A24-10725
Fuel pressure sender -G247- / -G624-
t  At front of fuel rail
t  Cylinder bank 1 (right-side): fuel pressure sender -G247--arrow-
t  Cylinder bank 2 (left-side): fuel pressure sender 2 -G624-
t  Removing and installing → Chapter
t  25 Nm
  A24-10727
Fuel pressure sender for low pressure -G410-
t  Behind oil filter housing -arrow-
t  15 Nm
  A24-10729

High-pressure pump > < Vacuum system