Fuel Tank, Draining, Fuel Delivery Unit Faulty

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

Special tools and workshop equipment required

Fuel Extractor: VAS5190A
Fuel Extraction - Adapter 2: VAS5190/2

Procedure

-- Observe the safety instructions. Refer to SAFETY PRECAUTIONS .

-- Follow the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .

-- Attach a suitable adapter from the : VAS5190/10 onto the suction hose -1- from the : VAS5190A .

Fig 1: Fuel Extracting Device

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-- Move the front seats all the way forward into the highest position.

-- Switch off the ignition.

-- Open the fuel filler door.

Fig 2: The Fuel Filler Cap

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-- Remove the fuel filler neck cap -arrow-.

-- Disconnect the ground cable from the battery terminal. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

There is a risk of the fuel tank exploding due to electrostatic discharge.

Severe injuries and burns are possible.

- Attach the fuel siphoning device ground cable to a bare area on the body.

Q7 before Product Improvement:

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CAUTION:

There is a risk of injury due to the fuel being under pressure.

The fuel system is under pressure. Injuries are possible from fuel spraying out.

Before opening the fuel system:

-- Wear protective eyewear.

-- Wear safety gloves.

-- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Wear protective eyewear.

-- Wear safety gloves.

-- Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Free up the fuel hose from the brackets -1 and 3- and disconnect the connector coupling -2-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Q8 and Q7 from Product Improvement:

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WARNING:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Free up the fuel hose -1- at the bracket -2- and disconnect the connection coupling -3-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Continuation for All Vehicles:

-- Attach the suction hose with : VAS5190/2 to the supply line in the engine compartment.

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CAUTION:

Danger due to escaping fuel.

- Drain the fuel tank when working on the fuel system.

-- Extract approximately 15 liters (4 gallons) of fuel through the supply line using the : VAS5190A .

Audi Q7:

-- Remove the right front and rear sill panels. Refer to SILL PANEL, REMOVING AND INSTALLING .

-- Remove the bench seat / right and center single seats. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Remove the right luggage compartment floor support. Refer to OVERVIEW - LUGGAGE COMPARTMENT FLOOR .

-- Remove the rear cover -1- for both seat rails on the front passenger seat. To do so, carefully release the tabs -3, 4 and 5- on the seat rail -2- using a screwdriver.

Fig 3: Unclipping Retaining Tabs On Cover From Seat Rail And Removing Cover

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NOTE:

The front passenger seat does not need to be removed.

-- Remove the carpet under the seat rail.

-- Remove the covers and connector station for the bench seat / single seats in the carpet.

-- Fold the carpet near the sealing flange cover to the side.

Audi Q8:

-- Remove the seat frame mount. Refer to OVERVIEW - BENCH SEAT/SINGLE SEATS .

Continuation for All Vehicles:

-- Remove the bolts -1, 2 and 3- and remove the sealing flange cover.

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-- Release the catches -arrows- using a screwdriver and remove the Fuel Pump Control Module -J538- -1- from the bracket.

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-- Release and disconnect the connector -2- for the Fuel Pump Control Module -J538-.

-- Release the catch -2- with a screwdriver and turn the bracket -1- for the Fuel Pump Control Module -J538- counter-clockwise in direction of -arrow-.

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-- Disengage the bracket at the locking ring and remove.

-- Release and disconnect the connectors -1 and 2- from the sealing flange.

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-- Vehicles with parking heater: disconnect the fuel line -1- to the parking heater metering pump at the sealing flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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-- Disconnect the fuel line -2- from the sealing flange. Disconnect the connector couplings. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

Fig 4: Identifying Fuel Sending Unit Wrench

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CAUTION:

Danger due to escaping fuel.

- Drain the fuel tank when working on the fuel system.

-- Remove the locking ring using the : T10202 .

-- Pull the sealing flange -1- slightly out of the fuel tank opening and remove the seal -2-.

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-- With the sealing flange lifted, slide the suction hose from the : VAS5190A through the opening into the fuel tank.

Fig 5: Identifying Fuel Extraction Unit

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-- Extract fuel from both fuel tank chambers with the : VAS5190A .

Assembling

Assemble in the reverse order of removal. Note the following:

Audi Q7:

-- Install the support for the luggage compartment floor. Refer to OVERVIEW - LUGGAGE COMPARTMENT FLOOR .

-- Install the bench seat / single seats. Refer to BENCH SEAT/SINGLE SEAT, REMOVING AND INSTALLING .

-- Install the sill panels. Refer to OVERVIEW - SILL PANEL .

Audi Q8:

-- Install the seat frame mount. Refer to OVERVIEW - BENCH SEAT/SINGLE SEATS .