Fuel Pump - G23-, REMOVING AND INSTALLING, 6.0L (V12) ENGINE: Removing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2015 Audi Q7, 2014 Audi Q7, 2013 Audi Q7, 2011 Audi Q7, and 2010 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

Follow all safety precautions, refer to WORKING ON FUEL SYSTEM .

Follow the guidelines for clean working conditions, refer to CLEAN WORKING CONDITIONS .

The fuel tank must be completely empty to remove the fuel delivery unit. Procedure to empty the fuel tank FUEL TANK, DRAINING .

-- Remove the right rear single seat in the second row of seats, refer to Seat Frames .

Fig 1: Cut The Floor Covering Along The Perforation

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WARNING:

Risk of injury.

Wear safety gloves

-- Cut the floor covering along the perforation -arrows- on the right side with a carpet knife -1-.

-- Fold carpet cut-out to side -arrow-.

Fig 2: Identifying Locking Flange Cover - Tightening Specifications

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-- Remove nuts -1 to 4- and remove right locking flange cover.

NOTE:

Place a clean cloth under the separating location to catch any fuel that may leak out.

Fig 3: Fuel Lines Location

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WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Disconnect fuel lines -1 and 2-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Disconnect the connector -4- on the right locking flange.

-- Vehicles with parking heater: Disconnect the fuel line -3- to the parking heater. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Remove locking ring using the Wrench - Fuel Sending UnitT10202.

Fig 4: Identifying Removal Of Locking Ring With T10202

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-- Pull right locking flange with seal out of fuel tank a bit.

Fig 5: Identifying Electrical Connectors -1 - And -2- On Underside Of Right Locking Flange

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-- Disconnect the connectors -1- and -2- underneath the right locking flange.

-- Disconnect fuel lines -2 and 3-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 6: Removing Auxilary Heather Supply Line

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-- Reach into the opening in the fuel tank, press the releases -arrow- and disconnect the auxiliary heater supply line -1- from the fuel delivery unit.

-- Remove the right locking flange and seal.

-- Disconnect the fuel line -2- to the left fuel delivery unit. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 7: Fuel Delivery Lines Location

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NOTE:

Ignore -items 1 and 3-.

-- Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats, refer to Seat Frames .

Fig 8: Cut The Floor Covering Along The Perforation

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury.

Wear safety gloves

-- Cut the floor covering along the perforation -arrows- on the left side with a carpet knife -1-.

-- Fold carpet cut-out to side -arrow-.

Fig 9: Identifying Locking Flange Cover - Tightening Specifications

Courtesy of AUDI OF AMERICA, LLC

-- Remove the nuts -1 to 4- and remove left locking flange cover.

NOTE:

Place a clean cloth under the separating location to catch any fuel that may leak out.

Fig 10: Fuel Delivery Fuel Lines Location

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Disconnect fuel lines -2 and 3-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Disconnect the connector -1- on the left locking flange.

-- Remove locking ring using the Wrench - Fuel Sending UnitT10202.

Fig 11: Identifying Removal Of Locking Ring With T10202

Courtesy of AUDI OF AMERICA, LLC

-- Pull left locking flange with seal out of fuel tank a bit.

Fig 12: Locking Flange Connectors Location

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-- Disconnect the connectors -1- and -2- on the bottom of the left locking flange.

-- Disconnect the fuel lines -3 and 4-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Reach into the opening in the fuel tank and disconnect the delivery line -1- by pressing the releases.

Fig 13: Fuel Delivery Unit Components Location

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the suction jet line -2- to the suction jet pump. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Pull the fuel lines out through the left opening in the fuel tank.

-- Reach into the opening in the fuel tank and turn the fuel delivery unit -1- counterclockwise 15° -arrow- to release (bayonet connection).

Fig 14: Identifying Fuel Delivery Unit -1-, Notch -3-, And Retaining Ring Tab -4-

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NOTE:

The fuel delivery unit is illustrated without the fuel tank.

The notch -3- on the fuel delivery unit then aligns with the retaining ring tab -4-.

-- Remove the fuel delivery unit.

NOTE:

Be sure there is still some fuel inside the fuel delivery unit.