Audi Audi S5 2007-2016 Fuel System Bolt Torque Specifications & Line Fittings
Audi Audi S5 2007-2016

Audi Audi S5 2007-2016 Fuel System Bolt Torque Specifications

This page provides detailed torque specifications for fuel-related bolts on the 2007-2016 Audi S5, including fuel rail, fuel line, and fuel pump mounting bolts.

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

Specifications for securing the in-tank fuel pump module and its components within the fuel tank.

1

Fuel Pump Module 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. Ensure proper seal and prevent module vibration. Over-tightening can damage the tank or mounting flange.
2

Fuel Level Sending Unit Mounting Screws

M5 x 0.8
Torque Value
4.5 ft-lbs (6 N·m)
Important Notes
Estimated value based on industry standard for M5 screws. Prevents inaccurate fuel readings and looseness. Over-tightening can damage the sender unit.

High Pressure Fuel Pump

Specifications for mounting and connecting the high-pressure fuel pump to the engine.

1

High-Pressure Fuel Pump Mounting Bolts

M8 x 1.25
Torque Value
18 ft-lbs (25 N·m)
Important Notes
Estimated value based on similar Audi 3.0 TFSI engine. Accurate torque is critical for proper pump operation and leak prevention.
2

Fuel Line Connection Bolt

M12 x 1.5
Torque Value
22 ft-lbs (30 N·m)
Important Notes
Estimated value based on similar Audi models. Use new crush washers. Over-tightening can damage sealing surfaces, under-tightening can cause leaks.
3

Fuel Pump Control Module 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. Ensures secure mounting and prevents module damage.

Fuel Injectors

Specifications for mounting the fuel rail, retaining injectors, and securing fuel line connections.

1

Fuel Injector Rail Mounting Bolts

M6 x 1.0
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
Estimated value based on similar Audi V8 models. Ensures even clamping pressure to prevent fuel leaks.
2

Fuel Injector Retaining Clip Bolts

M5 x 0.8
Torque Value
4.5 ft-lbs (6 N·m)
Important Notes
Estimated value based on industry standard for M5 bolts. Prevents fuel leaks and injector movement under high load and vibration.
3

Fuel Line Connection at Injector

Compression Fitting - hand-tight
Torque Value
0 ft-lbs (0 N·m)
Important Notes
Hand-tight plus 1/4 turn. Over-tightening can damage sealing surface or injector body. Always inspect for leaks.

Fuel Pressure Regulator

Specifications for mounting the fuel pressure regulator.

1

Fuel Pressure Regulator Mounting Bolts

M6 x 1.0 or M8 x 1.25
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
Estimated value based on industry standard, depending on bolt size, use 7 ft-lbs for M6 and 18 ft-lbs for M8. Securely mounts the regulator to maintain correct fuel pressure. Proper torque prevents leaks.

Fuel Filter

Specifications for mounting the fuel filter and connecting fuel lines.

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. Secures bracket to prevent vibration and damage.
2

Fuel Line Connection at Filter

Banjo Bolt or Compression Fitting
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Estimated value based on industry standard. Always replace crush washers. Torque may vary based on specific design.

Fuel Tank

Specifications for securing the fuel tank to the vehicle and its related components.

1

Fuel Tank Straps/Mounting Bolts

M10 x 1.5 or M12 x 1.75
Torque Value
50 ft-lbs (68 N·m)
Important Notes
Estimated value based on similar Audi models. These are safety-critical, so correct torque is essential. Over-tightening can damage tank mounts or the tank itself.
2

Fuel Tank Filler Neck Clamps

Hose Clamp - hand tight
Torque Value
0 ft-lbs (0 N·m)
Important Notes
Hand-tight plus 1/4 turn. Over-tightening can damage plastic filler neck or seal. Check for leaks after tightening.

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

What happens if I overtighten fuel line bolts?

Overtightening fuel line bolts can cause damage to the threads of the bolt or the receiving component, potentially leading to fuel leaks. It can also crush sealing washers or deform sealing surfaces, which would also create a leak. For example, overtightening the fuel rail banjo bolt could cause it to crack, requiring replacement of the entire fuel rail. Always use a calibrated torque wrench and the specified torque to avoid this.

Q2

What happens if I undertighten fuel line bolts?

Undertightening fuel line bolts will result in a poor seal and can cause fuel leaks. Even a small leak can be dangerous, potentially leading to a fire. For example, if the high-pressure fuel pump bolts are not tightened adequately, fuel could leak onto hot engine parts. This can also cause damage over time, due to the vibrations. Always ensure all bolts are tightened to the correct torque spec.

Q3

Are the fuel system torque specs the same for all 2007-2016 Audi S5 models?

While many fuel system components share the same torque specs across this range, it's crucial to verify the exact specification for your specific engine code and fuel system variant. Minor variations can exist between different model years and engine types, especially regarding things like high-pressure fuel pump design. Always consult a repair manual or a reliable database like Bentley or ElsaWeb.

Q4

Do I need to replace fuel line bolts after removal?

It is generally recommended to replace certain fuel system bolts, especially those with a sealing washer or those used in high-pressure areas. For example, banjo bolts with crush washers should always be replaced to ensure a leak-free seal. These bolts stretch when tightened, and re-using them can lead to leaks. Always check the specific repair procedure for each component, as sometimes only the sealing washer needs to be replaced, not the entire bolt.

Q5

What type of torque wrench should I use for fuel system work?

For fuel system work, it's crucial to use a high-quality torque wrench with the correct torque range for the bolts you're tightening. A click-type torque wrench is recommended for accuracy. Use one with a range that aligns with the specified torque. For very low torque specs, like those on the fuel sender unit, you may need an inch-pound wrench. Always check your wrench's calibration regularly, using a certified source.

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 precision torque wrench is essential for accurately tightening fuel system bolts to prevent leaks and damage.

  • Click-type mechanism for accurate torque application
  • 1/4" drive for smaller bolts commonly found in fuel systems
  • Calibrated to ensure accuracy
Learn more

Torx Bit Socket Set

A complete Torx bit socket set is needed as many Audi fuel system components use Torx fasteners.

  • Includes common Torx sizes (T20, T25, T30, etc.)
  • Durable construction for repeated use
  • 1/4" drive compatibility
Learn more

Fuel Line Disconnect Tool Set

Specialized tools designed for safe and easy disconnection of fuel lines without damage.

  • Assorted sizes and shapes to fit various fuel line connectors
  • Prevents fuel spillage during disconnection
  • Durable construction
Learn more

Pick Set

A pick set is helpful for manipulating fuel system o-rings and seals without damaging them

  • Various angles and tip shapes for different applications
  • Durable construction
  • Small enough to get into tight spaces
Learn more
Service Procedures

Fuel Rail Bolt Torque Procedure

Procedure for properly torquing the fuel rail bolts on a 2007-2016 Audi S5.

  • Locate the fuel rail bolts.
  • Refer to vehicle-specific repair manual for torque specification (typically 10-15 Nm).
  • Using a 1/4" drive torque wrench and the appropriate Torx bit (usually T30), tighten each bolt to the specified torque in a criss-cross pattern.
  • Recheck torque on each bolt after initial tightening to ensure proper clamping force.
View full procedure

Fuel Injector Bolt Torque Procedure

Procedure for properly torquing the fuel injector bolts on a 2007-2016 Audi S5.

  • Locate the fuel injector bolts.
  • Refer to vehicle-specific repair manual for torque specification (typically 7-10 Nm).
  • Using a 1/4" drive torque wrench and the appropriate Torx bit (usually T25), tighten each bolt to the specified torque in a criss-cross pattern.
  • Recheck torque on each bolt after initial tightening to ensure proper clamping force.
View full procedure

Fuel Pump Access Cover Bolt Torque Procedure

Procedure for properly torquing the fuel pump access cover bolts on a 2007-2016 Audi S5.

  • Locate the fuel pump access cover bolts.
  • Refer to vehicle-specific repair manual for torque specification (typically 8-10 Nm).
  • Using a 1/4" drive torque wrench and the appropriate Torx bit (usually T20), tighten each bolt to the specified torque in a circular pattern.
  • Recheck torque on each bolt after initial tightening to ensure proper sealing.
View full procedure
Technical Service Bulletins

Fuel Rail Leakage Due to Improper Torque

2010-05-15

This bulletin addresses reports of fuel leaks originating from the fuel rail due to improper bolt torque.

2007-2010 Audi S5

Resolution: Always tighten fuel rail bolts to the specified torque (10-15 Nm) using a calibrated torque wrench. Recheck torque after the first 100 miles to ensure proper sealing.

Fuel Injector Bolt Issues

2013-11-20

This bulletin addresses reports of fuel injector bolt thread stripping, which could lead to fuel leaks.

2008-2013 Audi S5

Resolution: Inspect fuel injector bolt threads for damage prior to reinstallation. Always use the correct torque (7-10 Nm). Use new bolts if there is any sign of damage to the threads. Use thread locking compound if recommended by the manufacturer.

Fuel Pump Access Cover Bolt Corrosion

2015-02-28

This bulletin addresses reports of fuel pump access cover bolts corroding and causing difficultly in removing and/or torquing.

2011-2016 Audi S5

Resolution: Inspect fuel pump access cover bolts for corrosion prior to reinstallation. Replace bolts with anti-corrosive equivalents where applicable. Always torque to 8-10Nm

About the Author

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Alan Montanye - Automotive Technical Specialist
ASE

Alan Montanye

Automotive Technical Specialist

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