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

WARNING: This page is about a different variant/trim than selected.

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

Courtesy of AUDI OF AMERICA, LLC

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

Courtesy of AUDI OF AMERICA, LLC

-- 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.