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2.0L - Fuel Injection System - Engine Code(s): Bpy & Cdma (Roadster): Overview Audi TT 8J facelift

Fuel System 32 illustrations ~3087 words

DESCRIPTION AND OPERATION

Engine Codes BWA and BPY

Engine Code CDMA

All

COMPONENT LOCATION OVERVIEW

Components A through N are not depicted in the exploded view illustration.

Scheme 461

Scheme 461: COMPONENT LOCATION OVERVIEW
Scheme 461: COMPONENT LOCATION OVERVIEW
  1. Wastegate Bypass Regulator Valve -N75- Installed directly on turbocharger (Scheme 484)
  2. Turbocharger Recirculating Valve -N249- Installed directly on turbocharger (Scheme 484)
  3. Ignition Coils with Power Output Stages Removing and installing. Refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(ref-505790-S27073088802012100100000). Ignition Coil 1 with Power Output Stage -N70- Ignition Coil 2 with Power Output Stage -N127- Ignition Coil 3 with Power Output Stage -N291- Ignition Coil 4 with Power Output Stage -N292- The ignition coils must be pulled out of the cylinder head using the ignition coil puller T40039
  4. Heated Oxygen Sensor -G39- and Oxygen Sensor Heater -Z19- Component location (Scheme 481) Removing and installing, refer to «HEATED OXYGEN SENSOR AND OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER»(ref-505776-S37773772732012100100000)
  5. Engine Control Module -J623- Removing and installing, refer to «ENGINE CONTROL MODULE»(ref-505776-S14561219682012100100000)
  6. Single Piston High Pressure Pump Removing and installing, refer to «HIGH PRESSURE PUMP»(ref-505776-S37366092442012100100000)
  7. Fuel Pressure Regulator Valve -N276
  8. Camshaft Adjustment Valve 1 -N205- Removing and installing, refer to «Removal and Installation»(ref-505782-S06424841442012100100000)
  9. 6-Pin Harness Connector For Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- (black) (Scheme 480)
  10. Low Fuel Pressure Sensor -G410- 15 Nm
  11. Engine Coolant Temperature Sensor -G62- Component location (Scheme 466)
  12. Engine Speed Sensor -G28- Oil Pressure Sensor -G10- Electrical connectors on Knock Sensor (KS) 1 -G61- and Knock Sensor (KS) 2 -G66- Component location (Scheme 475)
  13. Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- The intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- after removing or replacing the fuel rail vehicle diagnosis, testing and information system VAS 5052 "Guided Function". Removing and installing, refer to «INTAKE FLAP MOTOR AND INTAKE MANIFOLD RUNNER POSITION SENSOR»(ref-505776-S31518485982012100100000)
  14. EVAP Canister Purge Regulator Valve 1 -N80
  15. Charge Air Pressure Sensor -G31- Component location (Scheme 477)
  16. Connector For Camshaft Position (CMP) Sensor -G40- and Fuel Pressure Sensor -G247- Component location (Scheme 476)
  17. Fuel Injector 8-Pin Harness Connector Component location (Scheme 476)
  18. Throttle Valve Control Module -J338-, Throttle Drive for Electronic Power Control -G186-, Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187- and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188- After replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- see vehicle diagnosis and service system VAS 5052 "Guided Function".
  19. Intake Air Temperature Sensor -G42
  20. Fuel Pressure Sensor -G247- 22 Nm Component location (Scheme 468) Removing and installing, refer to «FUEL PRESSURE SENSOR»(ref-505776-S31108989872012100100000)
  21. Camshaft Position Sensor -G40- Electrical harness connector (Scheme 469)
  22. A - Mass Air Flow Sensor -G70- In upper section of air filter (Scheme 470) Removing and installing, refer to «MASS AIR FLOW SENSOR»(ref-505776-S28861860402012100100000)
  23. B - Fuel Pump Control Module -J538- (Scheme 472) If Fuel Pump (FP) Control Module -J538- is replaced, a fuel pump adaptation must be performed. Basic setting measured values block 103. Refer to «Diagnosis and Testing»(ref-505762-S23958735842012100100000) or via Vehicle Diagnosis and Service System VAS 5052 "Guided Functions".
  24. C - Brake Light Switch - F- and Brake Pedal Switch -F63- Component location (Scheme 474) Removing and installing, refer to «Removal and Installation»(ref-505735-S03755968862012100100000)
  25. D - Throttle Position Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- Component location (Scheme 465) On accelerator pedal (both sensors are stored in one housing) If the accelerator pedal module or engine control module is replaced in vehicles with automatic transmission, the kick-down function must be adapted. Removing and installing, refer to «Removal and Installation»(ref-505762-S03136779692012100100000)
  26. E - Clutch Position Sensor -G476- Component location (Scheme 473) Remove and install.
  27. F - E-Box Relay and Fuse Carrier Relay and fuse assignment.
  28. G - Coolant Fan Control Module -J293- Component location (Scheme 478)
  29. H - Fuel Injector In fuel rail pipe Removing and installing, refer to «FUEL INJECTORS»(ref-505776-S03728529152012100100000) Cylinder 1 Fuel Injector -N30- Cylinder 2 Fuel Injector -N31- Cylinder 3 Fuel Injector -N32- Cylinder 4 Fuel Injector -N33- Fuel injectors referred to here are high pressure fuel injectors. They inject fuel directly into the cylinder under high pressure (max. approximately 110 bar).
  30. I - Oxygen Sensor After Catalytic Converter -G130- and Oxygen Sensor Heater 1 After Catalytic Converter -Z29- Component location (Scheme 483) Removing and installing, refer to «OXYGEN SENSOR AFTER CATALYTIC CONVERTER AND OXYGEN SENSOR 1 HEATER»(ref-505776-S02930451642012100100000)
  31. J - Knock Sensor I -G61- For cylinder 1 and 2 20 Nm Component location (Scheme 476)
  32. K - Knock Sensor 2 -G66- For cylinder 3 and 4 20 Nm Component location (Scheme 476)
  33. L - Oil Pressure Switch -F1- Component location (Scheme 476) Checking, removing and installing, refer to «Removal and Installation»(ref-505789-S02769218192012100100000)
  34. M - Engine Coolant Temperature Sensor (on Radiator) -G83- Component location (Scheme 467)
  35. N - After-Run Coolant Pump -V51- Component location (Scheme 479)

Scheme 462

Scheme 462: AIR FILTER AND ENGINE COVER ASSEMBLY OVERVIEW
Scheme 462: AIR FILTER AND ENGINE COVER ASSEMBLY OVERVIEW
  1. Mass Air Flow Sensor -G70- Removing and installing, refer to «MASS AIR FLOW SENSOR»(ref-505776-S28861860402012100100000)
  2. 3 Nm
  3. Upper Air Filter Housing/Engine Cover Clean air filter housing-upper section of salt residue, dirt and leaves
  4. Spring-Type Clip
  5. Intake Air Guide To air filter housing Clean dirt and leaves from intake air guide
  6. Filter Element Always use a genuine air filter element Removing and installing, refer to «ENGINE COVER WITH AIR FILTER»(ref-505776-S37372228492012100100000) Observe change intervals
  7. Lower Air Filter Housing Clean air filter housing-lower section of salt residue, dirt and leaves
  8. 3 Nm
  9. Heat Shield
  10. Rubber Boot Note installation marking
  11. Air Guide Hose Note installation marking To turbocharger Check air duct hose for dirt and leaves

Components A through L are not shown in the exploded view illustration.

Scheme 463

Scheme 463: COMPONENT LOCATION OVERVIEW
Scheme 463: COMPONENT LOCATION OVERVIEW
  1. Wastegate Bypass Regulator Valve -N75- Installed directly on turbocharger (Scheme 484)
  2. Ignition Coils with Power Output Stages Removing and installing, refer to «IGNITION COILS WITH POWER OUTPUT STAGES»(ref-505790-S27073088802012100100000) Ignition Coil 1 with Power Output Stage -N70- Ignition Coil 2 with Power Output Stage -N127- Ignition Coil 3 with Power Output Stage -N291- Ignition Coil 4 with Power Output Stage -N292- The ignition coils must be pulled out of the cylinder head using the ignition coil puller T40039
  3. Heated Oxygen Sensor -G39- and Oxygen Sensor Heater -Z19- Component location (Scheme 481) Removing and installing, refer to «HEATED OXYGEN SENSOR AND OXYGEN SENSOR HEATER BEFORE CATALYTIC CONVERTER»(ref-505776-S37773772732012100100000)
  4. Engine Control Module -J623- Removing and installing, refer to «ENGINE CONTROL MODULE»(ref-505776-S14561219682012100100000)
  5. Low Fuel Pressure Sensor -G410- 15 Nm
  6. Single Piston High Pressure Pump Removing and installing, refer to «HIGH PRESSURE PUMP»(ref-505776-S37366092442012100100000)
  7. Fuel Pressure Regulator Valve -N276
  8. Camshaft Adjustment Valve 1 -N205- Removing and installing, refer to «Removal and Installation»(ref-505813-S30772019442012100100000)
  9. 6-Pin Harness Connector For Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19- (black) (Scheme 480)
  10. Mass Air Flow Sensor -G70- Removing and installing, refer to «MASS AIR FLOW SENSOR»(ref-505776-S04377969992012100100000)
  11. Engine Coolant Temperature Sensor -G62- Component location (Scheme 466)
  12. Engine Speed Sensor -G28- Eectrical connectors on Knock Sensor (KS) 1 -G61- and Knock Sensor (KS) 2 -G66- Component location (Scheme 475)
  13. Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- The intake manifold runner position sensor -G336- must be adapted to the engine control module -J623- after removing or replacing the fuel rail vehicle diagnosis, testing and information system VAS 5052 "Guided Function". Removing and installing, refer to «INTAKE FLAP MOTOR AND INTAKE MANIFOLD RUNNER POSITION SENSOR»(ref-505776-S31518485982012100100000)
  14. Charge Air Pressure Sensor -G31- Component location (Scheme 477)
  15. Electrical Harness Connectors For the fuel injectors, camshaft position sensor -G40- and fuel pressure sensor -G247- Component location (Scheme 476)
  16. EVAP Canister Purge Regulator Valve -N80- Component location (Scheme 487)
  17. Turbocharger Recirculating Valve -N249- Component location (Scheme 487) Removing and installing, refer to «Removal and Installation»(ref-505805-S25714808202012100100000)
  18. Throttle Valve Control Module -J338- and Throttle Drive for EPC -G186- Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187- and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188- After replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- see vehicle diagnosis and service system VAS 5052 "Guided Function".
  19. Intake Air Temperature Sensor -G42
  20. After-Run Coolant Pump -V51- Component location (Scheme 479)
  21. Engine Coolant Temperature Sensor (on Radiator) -G83- Component location (Scheme 467)
  22. Fuel Pressure Sensor -G247- 22 Nm Component location (Scheme 468) Removing and installing, refer to «FUEL PRESSURE SENSOR»(ref-505776-S31108989872012100100000)
  23. Camshaft Position Sensor -G40- Component location (Scheme 469)
  24. A - Fuel Pump Control Module -J538- Component location (Scheme 472) If Fuel Pump (FP) Control Module -J538- is replaced, a fuel pump adaptation must be performed. Basic setting measured values block 103. Refer to «Diagnosis and Testing»(ref-505762-S23958735842012100100000) or via Vehicle Diagnosis and Service System VAS 5052 "Guided Functions"
  25. B - Brake Light Switch - F- and Brake Pedal Switch -F63- Component location (Scheme 474) Removing and installing, refer to «Removal and Installation»(ref-505735-S03755968862012100100000)
  26. C - Throttle Position Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- Component location (Scheme 465) On accelerator pedal (both sensors are stored in one housing) If the accelerator pedal module or engine control module is replaced in vehicles with automatic transmission, the kick-down function must be adapted. Removing and installing, refer to «Removal and Installation»(ref-505762-S03136779692012100100000)
  27. D - Clutch Position Sensor -G476- Component location (Scheme 473) Remove and install.
  28. E - E-Box Relay and Fuse Carrier Relay and fuse assignment
  29. F - Coolant Fan Control Control Module -J293- Component location (Scheme 478)
  30. G - Fuel Injector In fuel rail pipe Removing and installing, refer to «FUEL INJECTORS»(ref-505776-S03728529152012100100000) Cylinder 1 Fuel Injector -N30- Cylinder 2 Fuel Injector -N31- Cylinder 3 Fuel Injector -N32- Cylinder 4 Fuel Injector -N33- Fuel injectors referred to here are high pressure fuel injectors. They inject fuel directly into the cylinder under high pressure (max. approximately 110 bar).
  31. H - Oxygen Sensor After Catalytic Converter -G130- and Oxygen Sensor Heater 1 After Catalytic Converter -Z29- Component location (Scheme 483) Removing and installing, refer to «OXYGEN SENSOR AFTER CATALYTIC CONVERTER AND OXYGEN SENSOR 1 HEATER»(ref-505776-S02930451642012100100000)
  32. I - Knock Sensor I -G61- For cylinder 1 and 2 20 Nm Component location (Scheme 476)
  33. J - Knock Sensor 2 -G66- For cylinder 3 and 4 20 Nm Component location (Scheme 476)
  34. K - Oil Pressure Switch -F1- Component location (Scheme 476) Checking, removing and installing, refer to «Removal and Installation»(ref-505814-S32886081642012100100000)
  35. L - Exhaust Flap Valve 1 -N321- Component location (Scheme 489)

Scheme 464

Scheme 464
Scheme 464

2 - Accelerator pedal module, electrical connector

Removing and installing. Refer to Removal and Installation

Scheme 465

Scheme 465
Scheme 465

Scheme 466

Scheme 466
Scheme 466

Scheme 467

Scheme 467
Scheme 467
  1. Removing and installing, refer to «FUEL PRESSURE SENSOR»(ref-505776-S31108989872012100100000)

Scheme 468

Scheme 468
Scheme 468

Scheme 469

Scheme 469
Scheme 469

Scheme 470

Scheme 470
Scheme 470

Scheme 471

Scheme 471
Scheme 471
  1. If Fuel Pump Control Module -J538- is replaced, a fuel pump adaptation must be performed. Basic setting, measuring value block 103. Refer to «Diagnosis and Testing»(ref-505762-S23958735842012100100000) .

Scheme 472

Scheme 472
Scheme 472

Remove and install. .

Scheme 473

Scheme 473
Scheme 473

Removing and installing. Refer to Removal and Installation .

Scheme 474

Scheme 474
Scheme 474

1 - 3-pin harness connector (green) for Knock Sensor (KS) 1 -G61

2 - 3-pin harness connector (brown) for Knock Sensor (KS) 2 -G66

3 - Oil pressure switch -F1

4 - Engine speed (RPM) sensor -G28

5 - 3-pin connector (gray) for Engine Speed (RPM) Sensor -G28

Scheme 475

Scheme 475
Scheme 475

1 - Knock Sensor (KS) I -G61

2 - Knock Sensor (KS) II -G66

3 - Oil pressure switch -F1

4 - 3-pin harness connector (brown) for Knock Sensor (KS) 2 -G66

5 - 3-pin connector (gray) for Engine Speed (RPM) Sensor -G28

6 - Electrical connector for Camshaft Position (CMP) Sensor -G40- and Fuel Pressure Sensor -G247

7 - 8-pin harness connector for fuel injectors

Scheme 476

Scheme 476
Scheme 476

Scheme 477

Scheme 477
Scheme 477

1 - Coolant Fan Control Module -J293-, connector

Note. The Coolant Fan Control Module -J293- is integrated in the Coolant Fan -V7-.

Scheme 478

Scheme 478
Scheme 478

Scheme 479

Scheme 479
Scheme 479

Heated Oxygen Sensor (HO2S) -G39- and Oxygen Sensor (O2S) Heater -Z19

Scheme 480

Scheme 480
Scheme 480

Scheme 481

Scheme 481
Scheme 481

Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) -Z29- on right of vehicle floor

Scheme 482

Scheme 482
Scheme 482

Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWC) -G130- and Oxygen Sensor (O2S) Heater 1 (behind Three Way Catalytic Converter (TWC)) -Z29

Scheme 483

Scheme 483
Scheme 483

1 - Turbocharger, removing and installing, refer to Removal and Installation

2 - Tighten wastegate bypass regulator valve -N75- to 3 Nm.

3 - Tighten turbocharger recirculating valve -N249- to 7 Nm (observe installation location, next illustration)

Scheme 484

Scheme 484
Scheme 484

Scheme 485

Scheme 485
Scheme 485

1 - Turbocharger, removing and installing, refer to Removal and Installation

2 - Tighten wastegate bypass regulator valve -N75- to 3 Nm.

Scheme 486

Scheme 486
Scheme 486

1 - Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80

2 - Turbocharger Recirculating Valve -N249

Scheme 487

Scheme 487
Scheme 487

Markings -arrows- must align.

Scheme 488

Scheme 488
Scheme 488

1 - Exhaust flap valve 1 -N321- connector

Check vacuum diaphragm for the exhaust flap. Refer to Diagnosis and Testing .

Scheme 489

Scheme 489: AIR FILTER ASSEMBLY OVERVIEW
Scheme 489: AIR FILTER ASSEMBLY OVERVIEW
  1. Gasket Secured in bottom part of air filter housing
  2. Front Air Guide Clean off dirt, leaves and salt residue
  3. Bolt 2 Nm
  4. Air Duct Lower Section Clean off dirt, leaves and salt residue
  5. Air Duct Cover
  6. Bolt 5 Nm
  7. Bolt 3 Nm
  8. Air Guide Hose
  9. Mass Air Flow Sensor -G70- Removing and installing, refer to «MASS AIR FLOW SENSOR»(ref-505776-S04377969992012100100000)
  10. Seal Replace if damaged
  11. Air Filter Housing Upper Section Clean air filter housing-upper section of salt residue, dirt and leaves
  12. Air Filter Element Removing and installing, refer to «AIR FILTER»(ref-505776-S38221468262012100100000) Always use a genuine air filter element Observe change intervals
  13. Air Filter Housing Lower Section Clean air filter housing-lower section of salt residue, dirt and leaves Removing and installing, refer to «AIR FILTER HOUSING»(ref-505776-S01461600312012100100000) Clean off dirt, leaves and salt residue
  14. Bolt 10 Nm
  15. Rubber Grommet
  16. Bolt 10 Nm
  17. Air Filter Housing Bracket
  18. Retaining Pin 10 Nm
  19. Rubber Grommet

Scheme 490

Scheme 490: INTAKE MANIFOLD ASSEMBLY OVERVIEW
Scheme 490: INTAKE MANIFOLD ASSEMBLY OVERVIEW
  1. Intake Air Temperature Sensor -G42- Bolt 5 Nm
  2. Intake Air Temperature Sensor -G42
  3. Intake Manifold Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(ref-505776-S28411835002012100100000)
  4. EVAP Canister Purge Regulator Valve -N80
  5. Single-Piston High-Pressure Pump Bolt 3 pieces 10 Nm
  6. Fuel Pressure Regulator Valve -N276
  7. Mechanical Single-Piston High-Pressure Pump With Fuel Pressure Regulator Valve -N276- and Low Fuel Pressure Sensor -G410- An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approximately 6 bar. When installing the high-pressure pump, make sure that no dirt enters the fuel system. The fuel system must be pressureless, releasing fuel pressure. Refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(ref-505776-S24086708162012100100000) . Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(ref-505776-S37366092442012100100000)
  8. Fuel Return Line to Fuel Tank Connection Do not install fuel line with tension (be aware of cleanliness)
  9. Fuel Supply Line to Fuel Rail Replace connecting piece Tighten connections to 30 Nm Do not install fuel line with tension (be aware of cleanliness). Torque specification: 27 Nm.
  10. Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- After replacing the fuel rail, the intake manifold runner position sensor -G336- must be adapted to the engine control module vehicle diagnosis and service system VAS 5052 "Guided Function". Removing and installing, refer to «INTAKE FLAP MOTOR AND INTAKE MANIFOLD RUNNER POSITION SENSOR»(ref-505776-S31518485982012100100000)
  11. Intake Flap Motor -V157- with Intake Manifold Runner Position Sensor -G336- Bolt 7 Nm
  12. Intake Manifold Support
  13. Intake Manifold Support Bolt 23 Nm
  14. Throttle Valve Control Module -J338-, Throttle Drive for Electronic Power Control -G186-, Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187- and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188- After replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- see vehicle diagnosis and service systemVAS 5052 "Guided Function".
  15. Throttle Valve Control Module -J338- Bolt 4 pieces 7 Nm
  16. Intake Manifold Support Nut 10 Nm
  17. Seal Replace
  18. Fuel Rail Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(ref-505776-S28411835002012100100000)
  19. Fuel Pressure Sensor -G247- 20 Nm

Scheme 491

Scheme 491: FUEL RAIL ASSEMBLY OVERVIEW
Scheme 491: FUEL RAIL ASSEMBLY OVERVIEW
  1. Radial Adjustment Replace if damaged
  2. Fuel Injector With combustion chamber seal (Teflon seal), always replace Replace O-rings Note correct installation position Removing and installing, refer to «FUEL INJECTORS»(ref-505776-S03728529152012100100000)
  3. Support Ring
  4. Fuel Rail Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(ref-505776-S28411835002012100100000)
  5. Fuel Pressure Sensor -G247- 22 Nm Tighten connections to 30 Nm
  6. Low Fuel Pressure Sensor -G410
  7. Fuel Pressure Regulator Valve -N276
  8. Mechanical Single-Piston High-Pressure Pump With Fuel Pressure Regulator Valve -N276- and Low Fuel Pressure Sensor -G410- An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approximately 6 bar. When installing high-pressure pump, make sure that no dirt enters the fuel system. The fuel system must be pressureless to install the high-pressure pump, releasing fuel pressure. Refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(ref-505776-S24086708162012100100000) . Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(ref-505776-S37366092442012100100000)
  9. EVAP Canister Purge Regulator Valve -N80
  10. Throttle Valve Control Module -J338-, Throttle Drive for Electronic Power Control -G186-, Throttle Drive Angle Sensor 1 (for Electronic Power Control (EPC)) -G187- and Throttle Drive Angle Sensor 2 (for Electronic Power Control (EPC)) -G188- After replacing the throttle valve control module -J338-, it must be adapted to the engine control module -J623- see vehicle diagnosis and service systemVAS 5052 "Guided Function".
  11. Intake Air Temperature Sensor 2 -G299- 5 Nm
  12. Intake Manifold Bolts 9 Nm
  13. Intake Manifold Removing and installing, refer to «INTAKE MANIFOLD WITH FUEL RAIL»(ref-505776-S28411835002012100100000)

HIGH PRESSURE PUMP ASSEMBLY OVERVIEW

WARNINGFuel system is under high pressure! Before opening the system, perform the procedure for releasing fuel pressure. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

Scheme 492

Scheme 492
Scheme 492
  1. Air Deflector Plates Removable Check for damages and correct positioning
  2. Sleeve remains inserted in cylinder head after removing the high-pressure pump, removable
  3. O-Ring Replace
  4. Mechanical Single-Piston High-Pressure Pump An electrical fuel pump, located in the fuel tank, supplies fuel to the mechanical high-pressure pump at a pressure of approximately 6 bar. When installing the high-pressure pump, make sure that no dirt enters the fuel system. The fuel system must be pressureless, releasing fuel pressure, refer to «BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM»(ref-505776-S24086708162012100100000) Do not install fuel lines with tension Removing and installing, refer to «HIGH PRESSURE PUMP»(ref-505776-S37366092442012100100000)
  5. Fuel Pressure Regulator Valve -N276
  6. Low Fuel Pressure Sensor -G410- 15 Nm
  7. High-Pressure Pump Bolts 10 Nm
  8. Fuel Return Line to Fuel Tank Connection When replacing threaded supports, always leave old sealing ring in pump. It is pinched during initial assembly by the supplier and cannot be removed. The threaded support has a "biting edge" for sealing for this purpose.
  9. Fuel Supply Line to Fuel Rail Connection Replace connecting piece Tighten connections to 30 Nm Do not install fuel line with tension (ensure cleanliness), tightening specifications: 27 Nm
  10. Hole In Cylinder Head For High-Pressure Pump
  11. Fuel Injector Replace O-rings Note correct installation position Removing and installing, refer to «FUEL INJECTORS»(ref-505776-S03728529152012100100000)

More articles — 2.0L - Fuel Injection System - Engine Code(s): Bpy & Cdma (Roadster)