Fuel Tank, Draining, Fuel Delivery Unit Faulty

WARNING: This page is about a different car, the 2024 Audi SQ7, 2024 Audi Q7, 2023 Audi SQ7, and 2023 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Fuel Extractor:VAS 5190A

Fig 1: Fuel Extraction Device VAS5190A
Courtesy of AUDI
Fuel Extraction - Adapter 2:VAS 5190/2

Fig 2: Identifying Fuel Extraction Adapter
Courtesy of AUDI

Procedure

Fig 3: Fuel Extracting Device

Courtesy of AUDI

-- 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 Fuel Extraction - Adapter Set:VAS 5190 /10 onto the suction hose -1- from the Fuel Extractor :VAS 5190A .

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

-- Switch off the ignition.

-- Open the fuel filler door.

Fig 4: The Fuel Filler Cap

Courtesy of AUDI

-- 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:

Courtesy of AUDI

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.

-- 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:

Courtesy of AUDI

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.

-- 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 Fuel Extraction - Adapter 2:VAS 5190/2 to the supply line in the engine/motor compartment.

Courtesy of AUDI

CAUTION:

Danger due to escaping fuel.

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

-- Extract approximately 15 liters of fuel through the supply line using the Fuel Extractor:VAS 5190A .

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 5: Unclipping Retaining Tabs On Cover From Seat Rail And Removing Cover

Courtesy of AUDI

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.

Courtesy of AUDI

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

Courtesy of AUDI

-- 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 -arrow-.

Courtesy of AUDI

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

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

Courtesy of AUDI

-- 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 .

Courtesy of AUDI

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

Fig 6: Identifying Fuel Sending Unit Wrench

Courtesy of AUDI

CAUTION:

Danger due to escaping fuel.

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

-- Remove the locking ring using the Wrench - Fuel Sending Unit:T10202 .

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

Courtesy of AUDI

-- With the sealing flange lifted, slide the suction hose from the Fuel Extractor :VAS 5190A through the opening into the fuel tank.

Fig 7: Identifying Fuel Extraction Unit

Courtesy of AUDI

-- Extract fuel from both fuel tank chambers with the Fuel Extractor:VAS 5190A .

Assembling

Assemble in the reverse order of removal.

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 .