Transfer Fuel Pump - G6-, REMOVING AND INSTALLING, VEHICLES WITH 3.0L (V6)/4.2L (V8) ENGINES THROUGH 05/2010: 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 left single seat and the left 2/3 seat bench seat cushion 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 left 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 the nuts -1 to 4- and remove left locking flange cover.

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

Fig 3: Connecting Connector -Arrow- At Left Locking Flange

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

Fig 4: Identifying Removal Of Locking Ring With T10202

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

Fig 5: Locking Flange Connectors

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

-- Reach into the fuel tank opening and disconnt the fuel lines -3 and 4-. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 6: Fuel Lines Location

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NOTE:

Ignore items -1 and 2-.

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

Fig 7: 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 8: Identifying Locking Flange Cover - Tightening Specifications

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

-- Disconnect the connector -3- on the right locking flange.

Fig 9: Identifying Fuel Return Line -1-, Fuel Supply Line -2- To Right Locking Flange, And Connector -3-

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NOTE:

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

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 (212 °F) 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 .

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

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

Fig 10: Identifying Removal Of Locking Ring With T10202

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

Fig 11: Identifying Electrical Connectors -1 - And -2- On Underside Of Right Locking Flange

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-- Disconnect electrical connectors -1 and 2 - on underside of the right locking flange.

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

Fig 12: Fuel Lines Location

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-- Reach into the opening in the fuel tank and disconnect the delivery line -4- by pressing the releases.

-- Disconnect the suction jet line -3- to the suction jet pump. Disconnect the connector couplings, refer to CONNECTOR COUPLINGS, SEPARATING .

-- Pull the fuel lines out through the right 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 13: 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.