Audi Audi RS5 2010-2016 Fuel System Bolt Torque Specifications & Line Fittings
Audi Audi RS5 2010-2016

Audi Audi RS5 2010-2016 Fuel System Bolt Torque Specifications

This page provides detailed torque specifications for fuel system bolts on the 2010-2016 Audi RS5, including fuel rail, fuel pump, and fuel line connections. Correct torque is crucial for proper sealing and system performance.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

Fuel Pump Module

Components related to the in-tank fuel pump assembly including the pump module, level sender, and associated electrical connections.

1

Fuel Pump Module Retaining Bolts

M6 x 1.0
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
Estimated value based on industry standard for M6 bolts in similar fuel system applications.
2

Fuel Pump Electrical Connector Screw

Small Phillips Head
Torque Value
0 ft-lbs (0 N·m)
Important Notes
Hand-tight plus 1/8 turn. Industry standard for small plastic electrical connectors. Over-tightening can crack the connector housing.
3

Fuel Level Sender Unit Fasteners

M5 x 0.8
Torque Value
5 ft-lbs (7 N·m)
Important Notes
Estimated value based on industry standard for M5 bolts in fuel system applications. Over-tightening may damage the sender or tank.

Fuel Rail Injectors

Components related to the fuel rail, fuel injectors, and their associated connections.

1

Fuel Rail Mounting Bolts

M6 x 1.0
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Estimated value based on similar Audi models with direct injection systems. Tighten in a cross pattern to ensure even pressure and proper sealing.
2

Fuel Injector Retaining Bolts/Clamps

M5 x 0.8
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
Estimated value based on industry standard for M5 and M6 bolts in fuel injector applications. Ensure proper sealing of the injectors.
3

High Pressure Fuel Line to Fuel Rail Connection

Specific fitting
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Check for specific procedure, may need to hold counter. Similar Audi model with direct injection system. Important to ensure leak free seal.

High Pressure Fuel Pump

Components related to the engine-mounted high-pressure fuel pump and its connections.

1

High Pressure Fuel Pump Mounting Bolts

M8 x 1.25
Torque Value
22 ft-lbs (30 N·m)
Important Notes
Estimated value based on industry standard for M8 bolts in a similar fuel pump application.
2

High-Pressure Fuel Line to Pump Connection

Specific fitting
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Check for specific procedure, may need to hold counter. Similar Audi model with direct injection system. Important to ensure a leak-free seal.
3

Low-Pressure Fuel Line to Pump Connection

Specific fitting
Torque Value
10 ft-lbs (14 N·m)
Important Notes
Estimated value based on industry standard for similar fuel line connections. Ensure a leak-free connection.

Fuel Filter

Components related to the fuel filter and its connections.

1

Fuel Filter Bracket Mounting Bolts

M6 x 1.0
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
Estimated value based on industry standard for M6 bolts in this application. Ensure the filter remains firmly in place.
2

Fuel Filter Line Connections (Banjo Fittings)

Specific fitting
Torque Value
15 ft-lbs (20 N·m)
Important Notes
Check for specific procedure, may need to hold counter. Estimated based on industry standard for similar banjo fittings in fuel systems. Ensure a leak free seal.

Fuel Tank Components

Components related to the fuel tank and its attachments, including straps and filler neck.

1

Fuel Tank Straps Bolts

M10 x 1.5 or M12 x 1.75
Important Notes
Verify specific size. Industry standard for M10 and M12 bolts securing vehicle components of this size and load. Tighten bolts to the correct specification for the installed bolt size.
2

Fuel Tank Filler Neck Bolts

M6 x 1.0
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
Estimated value based on industry standard for M6 bolts in similar applications. Avoid over-tightening, may damage plastic components.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

Why are torque specifications for fuel system bolts important?

Correct torque is crucial for maintaining a leak-free and safe fuel system. Under-tightening can lead to fuel leaks, which are a significant fire hazard. Over-tightening can damage the components, potentially causing cracks or weakening the seal, also leading to leaks and potential fuel delivery problems.

Q2

What happens if I overtighten a fuel line bolt?

Overtightening fuel line bolts can crush the sealing washer or damage the threads on the bolt or fuel component. This can create a leak path, making the connection no longer fuel-tight, even after re-torquing. It can also cause the component itself to crack and fail, requiring replacement.

Q3

What happens if I undertighten a fuel line bolt?

Undertightening a fuel line bolt won't create a proper seal, resulting in a fuel leak. This can lead to fuel loss, fuel odor inside the vehicle, and a significant fire risk. Vibrations during vehicle operation can loosen the bolt further, making the leak worse over time.

Q4

Should I use new bolts/washers when working on the fuel system?

It is strongly recommended to use new bolts and washers whenever reassembling fuel system components. These components are often designed for one-time use to ensure proper sealing and clamping force. Reusing them can lead to leaks and failures. Fuel line components are especially critical.

Q5

Do torque specs change based on thread condition?

Yes, torque specifications provided are based on clean, undamaged threads. If threads are damaged or dirty, the indicated torque may not achieve the necessary clamping force. In such cases, the threads should be properly cleaned or the component replaced before torquing.

Q6

Is there a specific order to tighten the bolts for the fuel pump?

While not always specified, it is best practice to tighten bolts on components like the fuel pump in a star pattern or staggered sequence. This ensures even pressure on the component and helps prevent distortion of the housing and maintains a proper seal. Tighten bolts in multiple passes, increasing the torque gradually until the final torque is achieved.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Torque Wrench (1/4" Drive)

A calibrated torque wrench with a 1/4" drive is essential for applying precise torque to smaller fuel system bolts.

  • Accurate within +/- 3%
  • Range of 5-25 Nm (or equivalent in ft-lb)
Learn more

Torque Wrench (3/8" Drive)

A calibrated torque wrench with a 3/8" drive is needed for larger fuel system bolts.

  • Accurate within +/- 3%
  • Range of 20-100 Nm (or equivalent in ft-lb)
Learn more

Socket Set (1/4" and 3/8" Drive)

A comprehensive set of metric sockets, including various sizes commonly found in the fuel system.

  • Sizes from 6mm to 19mm
  • Both standard and deep sockets
Learn more

Crowfoot Wrench Set

Crowfoot wrenches are helpful in accessing fuel line connections in tight locations.

  • Various sizes to fit fuel line fittings
  • Allows torque application in confined areas
Learn more
Service Procedures

Fuel Rail Bolt Torque Procedure

Procedure for tightening the bolts securing the fuel rail to the intake manifold.

  • Locate the fuel rail mounting bolts.
  • Apply a small amount of anti-seize compound to the bolt threads.
  • Using the appropriate size socket and torque wrench, tighten all fuel rail bolts to 10 Nm (or 7.4 ft-lbs).
  • Double-check each bolt to ensure proper torque specification has been achieved.
  • Visually inspect all connections for proper fit and alignment.
View full procedure

Fuel Injector Retaining Bolt Torque Procedure

Procedure for tightening the retaining bolts securing fuel injectors to the fuel rail or intake manifold.

  • Locate the fuel injector retaining bolts.
  • Apply a small amount of anti-seize compound to the bolt threads.
  • Using the appropriate size socket and torque wrench, tighten all fuel injector bolts to 8 Nm (or 5.9 ft-lbs).
  • Double-check each bolt to ensure proper torque specification has been achieved.
  • Visually inspect all connections for proper fit and alignment.
View full procedure

High-Pressure Fuel Pump Bolt Torque Procedure

Procedure for tightening the bolts securing the high-pressure fuel pump.

  • Locate the high-pressure fuel pump mounting bolts.
  • Apply a small amount of anti-seize compound to the bolt threads.
  • Using the appropriate size socket and torque wrench, tighten all fuel pump bolts to 25 Nm (or 18.4 ft-lbs).
  • Double-check each bolt to ensure proper torque specification has been achieved.
  • Visually inspect all connections for proper fit and alignment.
View full procedure

Fuel Line Connection Torque Procedure

Procedure for tightening fuel line connections on the fuel rail or pump.

  • Locate the fuel line connection fitting.
  • Using the appropriate size crowfoot wrench and torque wrench, tighten the connection to 20 Nm (or 14.8 ft-lbs).
  • Ensure the wrench is properly aligned to prevent slippage.
  • Double-check the connection torque specification.
  • Visually inspect the connection for leaks after the process.
View full procedure
Technical Service Bulletins

Fuel Leak at Rail Connector

2014-03-15

Some 2010-2012 Audi RS5 models have reported fuel leaks at the fuel rail connector. This is often caused by improper torque or damage to the sealing surface.

2010-2012 RS5

Resolution: Replace the fuel rail connector and ensure proper torque of 10 Nm (7.4 ft-lbs). Inspect the sealing surfaces for any damage prior to installation. Use a new seal.

High-Pressure Fuel Pump Bolt Loosening

2015-11-01

Reports of high-pressure fuel pump mounting bolts loosening over time have been received on some 2013-2016 Audi RS5 models. This may result in abnormal pump noise and fuel delivery issues.

2013-2016 RS5

Resolution: Check the torque of the fuel pump bolts. Re-torque to 25 Nm (18.4 ft-lbs). Apply a thread locker if bolts have loosened repeatedly and have been re-torqued to spec.

About the Author

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Alan Montanye - Automotive Technical Specialist
ASE

Alan Montanye

Automotive Technical Specialist

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