Fuel Supply System Audi Q5 I

CLEAN WORKING CONDITIONS

Even a little contamination can lead to faults. When working on the fuel supply and the fuel injection system, observe the following guidelines for a clean working environment

1. Before loosening, connections and surrounding areas must be cleaned thoroughly with engine or brake cleaner, and then cleaned area must be dried completely.
2. Seal the open lines and connections immediately with clean plugs, for example, from the engine bung set VAS 6122.
3. Place removed parts on a clean surface and cover them. Use lint-free cloths.
4. Carefully cover or plug unpacked components if repairs cannot be performed immediately.
5. Only install clean components: Remove the replacement parts from their packaging just prior to installing them. Do not use parts that have been stored outside of their original packaging (for example in tool boxes etc.).
6. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
7. Protect the disconnected connectors from dirt and moisture and only connect when they are dry.

CONTACT CORROSION

Contact corrosion can occur if incorrect fasteners (bolts, nuts, washers, etc.) are used.

For this reason, only connecting elements with a special surface coating are installed.

In addition, rubber or plastic parts and adhesive are made of materials that do not conduct electricity.

If you are not sure about the suitability of parts, install new parts.

Note. Only original replacement parts are recommended, they are checked and compatible with aluminum. It is recommended to use Audi accessories. Damage resulting from contact corrosion is not covered by the warranty.

FUEL SYSTEM, BLEEDING

1. Due to the engine design and the transfer fuel pump -G6- installed in the fuel tank, do not bleed the fuel system.
2. The fuel system bleeds itself when the starter is operated.

FUEL TANK, DRAINING

A - Emptying a fuel tank more than 3 / 4 filled FUEL TANK, DRAINING .

B - Emptying a fuel tank less than 3 / 4 filled FUEL TANK, DRAINING .

Special tools and workshop equipment required

1. Assembly Tool T10118
2. Wrench T10202
3. Fuel Extracting Device VAS 5190
4. Adapter VAS 5190 /1 from the Adapter set for Fuel Extraction VAS 5190 /10

Procedure

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Move the passenger seat all the way forward if necessary.

Disconnect the battery -arrow-. Refer to Removal and Installation .

Scheme 1

A - Emptying a Fuel Tank More Than 3 / 4 Filled

Note. If the VAS 5190 has a suction hose with a mounted tip, then replace this with one that has a tip which screws on.

Remove the tip -1- from the fuel extraction unit suction hose VAS 5190.

Scheme 2

Connect the VAS 5190 /1 from the VAS 5190 /10 on the suction hose.

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

Vehicles through MY 12

Scheme 3

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

Scheme 4

Push the circlip -1- upward -arrow A- and compress the release -arrow B-.

Vehicles from MY 13

Open the connector safety catch with -T10118- and disconnect the connector -1- on the locking flange.

Disconnect the connector -2- on the locking flange.

Scheme 5

All Vehicles

Press the release button and disconnect the fuel line -2- from the locking flange.

Disconnect the fuel line -2- at the locking flange by pressing the release button.

Scheme 6

Press the release button and disconnect the metering pump fuel line -1- at the locking flange on vehicles with an auxiliary heater.

Connect the suction hose with the VAS 5190 /1 to the locking flange supply connection.

Scheme 7

Extract approximately 10 liters of fuel.

Press the release button and disconnect the VAS 5190 /1 on the locking flange.

Remove the VAS 5190 /1 on the suction hose and re-install the tip.

Remove locking ring using the T10202.

Scheme 8

Pull the locking flange a little bit out of the fuel tank and slide the VAS 5190 into the fuel tank through the gap between the locking flange and the opening.

Scheme 9

Extract any remaining fuel through the opening for the fuel delivery unit.

Install the locking flange for the fuel delivery unit FUEL DELIVERY UNIT .

B - Emptying a Fuel Tank Less Than 3 / 4 Filled

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

Vehicles through MY 12

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

Push the circlip -1- upward -arrow A- and compress the release -arrow B-.

Vehicles from MY 13

Open the connector safety catch with -T10118- and disconnect the connector on the locking flange.

Disconnect the connector on the locking flange.

All Vehicles

Disconnect the fuel line -2- at the locking flange by pressing the release button.

Press the release button and disconnect the metering pump fuel line -1- at the locking flange on vehicles with an auxiliary heater.

Remove locking ring using the T10202.

Pull the locking flange a little bit out of the fuel tank and slide the VAS 5190 into the fuel tank through the gap between the locking flange and the opening.

Extract the fuel through the opening for the fuel delivery unit.

Install the locking flange for the fuel delivery unit FUEL DELIVERY UNIT .

LEAK DETECTION SYSTEM

Function

The leak detection system recognizes leaks in the complete fuel system, including the fuel tank, EVAP canister and Evaporative Emission (EVAP) canister purge regulator valve 1 -N80-.

On the mechanical side, the leak detection system consists mainly of a vacuum-driven diaphragm pump, that is equipped with a reed contact on the actuation rod of the pump diaphragm. The pump is supplied with vacuum via the mechanical vacuum pump or the engine intake stroke.

1. When the leak detection is activated, the diaphragm pump pumps the fuel system up to 20 to 30 mbar. The pump diaphragm is then moved out so that the reed contact at the operating rod remains in the "open" position.
2. During leak diagnosis, the reed contact is monitored to check if it remains open within 15 seconds. This indicates the system is sealed.
3. If the pressure falls (indicating a leak), the diaphragm moves back and the reed contact closes.
4. If the reed contact closes within 15 seconds of leak detection time, a further test is performed: In this case the diaphragm pump pumps 4 times again. The Engine Control Module (ECM) measures the time for each of the 4 pumps until the reed contact is closed again. From that, the control module can recognize a "small leak" (smaller than 1 mm in diameter) or a "large leak".

The leak detection is activated automatically, shortly after each cold engine start (under 35 °C (95 °F)) and a continual drive faster than 10 km/h. In case a fault is detected, a Diagnostic Trouble Code (DTC) will be stored to memory. The Malfunction Indicator Lamp (MIL) in the instrument cluster lights up if the malfunction is recognized for 2 subsequent starts. Leak diagnosis can also be activated using the vehicle diagnosis, testing and information system VAS 5051B. Refer to LEAK DETECTION TEST, PERFORMING .

Note. After the cold start, the leak detection can repeated up to 10 times within the first 20 minutes. It can be determined if an automatic leak diagnosis was recently performed by using the VAS 5051B in measured value block 071. Refer to LEAK DETECTION TEST, PERFORMING .

SAFETY PRECAUTIONS

Note the following when working on the fuel system

Procedures before opening high pressure fuel injection system. Refer to [For engine(s) CAEB] General Information or to [For engine(s) CALB] General Information .

Carry out the following measures before starting work on the fuel supply

1. Disconnect the battery -arrow-. Refer to «Removal and Installation»(/audi/q5/i-2008-2012/remont/charging-system/#battery-starter-generator-cruise-control) .
2. Open the fuel filler flap briefly and then close it again.

Note the following when removing and installing components from a filled or partially filled fuel tank

1. The fuel tank may only be partially full. How much fuel can remain in the fuel tank may be read in the respective work description. Empty the fuel tank, refer to «FUEL TANK, DRAINING»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-tank-draining) .
2. Before starting work, switch on the exhaust extraction system and place an extraction hose close to the installation opening of fuel tank to extract escaping fuel fumes. If no exhaust extraction system is available, a radial fan (as long as the motor is not in the air flow) with a displacement greater than 15 m 3 /h can be used.
3. Prevent fuel from contacting skin! Wear fuel-resistant gloves!

Note the following when removing and installing the fuel tank

1. Fuel tank must be empty for weight reasons. Empty the fuel tank, refer to «FUEL TANK, DRAINING»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-tank-draining) .

TEST CONDITIONS

1. Battery voltage at least 12.5 V.
2. Fuse for fuel pump OK, refer to appropriate SYSTEM WIRING DIAGRAM.
3. Fuel Pump (FP) control module -J538- OK; check "Guided Fault Finding" using the vehicle diagnostic tester.
4. Fuel Pump (FP) Relay -J17- OK, refer to appropriate SYSTEM WIRING DIAGRAM.
5. Fuel tank minimum 1 / 3 full.
6. Fuel filter OK.
7. Fuel lines OK (not plugged, not kinked).
8. Ignition switched off

Scheme 10

1. Accelerator Pedal Module With accelerator pedal position sensor -G79- and accelerator pedal position sensor 2 -G185- Removing and installing, refer to «ACCELERATOR PEDAL MODULE WITH Accelerator Pedal Position Sensor -G79- /Accelerator Pedal Position Sensor 2 -G185»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__accelerator-pedal-module-with-accelerator-pedal) On vehicles with S-Tronic transmission or automatic transmission, perform "kick-down adaptation" in "Guided Functions" after replacing using the vehicle diagnostic tester
2. Pedal Bracket
3. Bolt 8 Nm
4. Connector

Scheme 11

1. Vacuum Line To engine
2. Clamp Must be appropriate for the model type
3. Ventilation Line To the Leak Detection Pump (LDP) -V144- air filter
4. Bolt 4 Nm
5. Bolt 16 Nm
6. Rubber Grommet
7. Bushing
8. Bracket For the Evaporative Emission (EVAP) canister
9. EVAP Canister Installed location: In the bottom of the spare wheel well Removing and installing, refer to «EVAPORATIVE EMISSION (EVAP) CANISTER»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system)
10. Vent Line To fuel tank To disconnect, press release button on connection piece
11. Vent Line To EVAP canister purge regulator valve 1 -N80- To disconnect, press release button on connection piece
12. Gasket
13. Leak Detection Pump (LDP) -V144- Installed location: On the underbody under the rear underbody panel, on the left side Check in "Guided Fault-Finding" operating mode using the vehicle diagnostic tester Removing and installing, refer to «Leak Detection Pump (LDP) -V144»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__leak-detection-pump-ldp-v144)

Scheme 12

Tighten the nut -2- to 5 Nm.

Scheme 13

1. Vent Line From the Evaporative Emission (EVAP) canister to EVAP canister purge regulator valve 1 -N80- Clipped into the brackets under the vehicle underbody
2. EVAP Canister Purge Regulator Valve 1 -N80
3. Connection for the Breather Line on the Fuel Tank
4. Vent Line From the connection on the fuel tank to the EVAP canister Clipped into brackets under the vehicle underbody
5. Connecting Line From the Leak Detection Pump (LDP) -V144- to the air filter Clipped into brackets under the vehicle underbody
6. Air Filter Housing For the leak detection pump At the top inside the left rear wheel housing Removing and installing, refer to «Leak Detection Pump (LDP) -V144- AIR FILTER»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__leak-detection-pump-ldp-v144-air)
7. EVAP Canister Installed location: Under the luggage compartment floor Removing and installing, refer to «EVAPORATIVE EMISSION (EVAP) CANISTER»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system)
8. Leak Detection Pump (LDP) -V144- Installed location: On the EVAP canister under the bottom of the luggage compartment Check in "Guided Fault-Finding" operating mode using the vehicle diagnostic tester Removing and installing, refer to «Leak Detection Pump (LDP) -V144»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__leak-detection-pump-ldp-v144)
9. Vacuum Line From the engine to the leak detection pump Clipped into brackets under the vehicle underbody
10. To the Brake Booster
11. Vacuum Pump

Scheme 14

1. Vent Line From the Evaporative Emission (EVAP) canister to EVAP canister purge regulator valve 1 -N80- Clipped into the brackets under the vehicle underbody
2. Vacuum Line From the engine to the Leak Detection Pump (LDP) -V144- Clipped into the brackets under the vehicle underbody
3. Vent Line From the fuel tank locking flange to the EVAP canister Clipped into brackets under the vehicle underbody
4. Fuel Tank Locking Flange
5. Air Filter Housing For the leak detection pump At the top inside the left rear wheel housing Removing and installing, refer to «Leak Detection Pump (LDP) -V144- AIR FILTER»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__leak-detection-pump-ldp-v144-air)
6. Connecting Line From the leak detection pump to the air filter Clipped into brackets under the vehicle underbody
7. EVAP Canister Installed location: Under the luggage compartment floor Removing and installing, refer to «EVAPORATIVE EMISSION (EVAP) CANISTER»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system)
8. Leak Detection Pump (LDP) -V144- Installed location: On the EVAP canister under the bottom of the luggage compartment Check in "Guided Fault-Finding" operating mode using the vehicle diagnostic tester Removing and installing, refer to «Leak Detection Pump (LDP) -V144»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__leak-detection-pump-ldp-v144)
9. To the Brake Booster
10. EVAP Canister Purge Regulator Valve 1 -N80

Scheme 15

1. Fuel Delivery Unit With the fuel filter in the locking flange Fuel pump electrical, checking, refer to «Transfer Fuel Pump -G6-, CHECKING»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__transfer-fuel-pump-g6-checking-vehicles) Removing and installing, refer to «FUEL DELIVERY UNIT»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-delivery-unit-through-my-12) Fuel filter, removing and installing, refer to «FUEL FILTER»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-filter-vehicles-through-my-12) Fill the fuel tank with at least 5 liters of fuel. Checking residual pressure, refer to «[For engine(s) CAEB] Diagnosis and Testing»(ref-515412-S22489878652012120300000) or to «[For engine(s) CALB] Diagnosis and Testing»(/audi/q5/i-2008-2012/remont/fuel-system/#32l-fuel-injection-system-engine-codes-calb)
2. Fuel Line To engine Do not kink To remove from locking flange, press release button Attached to the fuel tank
3. Seal Replace Install dry
4. Locking Ring Tighten to 110 Nm. Use wrench T10202 for removing and installing
5. Fuel Line Vehicles with an auxiliary heater
6. Electrical Harness Connector For transfer fuel pump -G6- and fuel level sensor -G
7. Electrical Harness Connector Fuel Pump (FP) control module -J538
8. Bolt 2.5 Nm
9. Fuel Pump (FP) Control Module -J538- Removing and installing, refer to «Fuel Pump (FP) Control Module -J538»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-pump-fp-control-module-j538)
10. Fuel Level Sensor -G- Check the resistance values. Refer to «Fuel Level Sensor -G-, CHECKING»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-level-sensor-g-checking-vehicles) Removing and installing, refer to «Fuel Level Sensor -G»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-level-sensor-g)
11. Suction Jet Pump
12. Suction Jet Pipe To disconnect, press release button on connection piece

Scheme 16

1. Fuel Level Sensor -G Resistance values, checking, refer to «Fuel Level Sensor -G-, CHECKING»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-level-sensor-g-checking-vehicles) Removing and installing, refer to «FUEL LEVEL SENSOR -G»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-level-sensor-g)
2. Fuel Line To the engine Do not kink To remove from locking flange, press release button Clipped to the fuel tank
3. Connector Connector
4. Connector For fuel level sensor -G
5. Connector For the Fuel Pump (FP) control module -J538
6. Bolt 2.5 Nm
7. FP Control Module -J538 Removing and installing, refer to «FUEL PUMP (FP) CONTROL MODULE -J538»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-pump-fp-control-module-j538)
8. Locking Ring Tighten to 110 Nm Use wrench -T10202- to remove and install.
9. Seal Replace Install dry
10. Fuel Delivery Unit With the fuel filter in the locking flange Electric fuel pump, checking, refer to «TRANSFER FUEL PUMP -G6-, CHECKING»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__transfer-fuel-pump-g6-checking-vehicles) Removing and installing, refer to «FUEL DELIVERY UNIT»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-delivery-unit-through-my-12) Fuel filter, removing and installing, refer to «FUEL FILTER»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-filter-vehicles-through-my-12) Fill the fuel tank with at least 5 liters (5.2 quarts) of fuel after installing

Route the Ground (GND) connection -1- as illustrated

Make sure the following connectors are secure

Scheme 17

Route the Ground (GND) connection -1- as illustrated

Make sure the following connectors are secure

1. GND connection connector -arrows- on the fuel pressure regulator and locking flange.
2. Connector -2- for fuel level sensor on the locking flange.
3. Connector -3- for transfer FP on the locking flange.

Pull on the connector to make sure it is locked secure.

Scheme 18

1. Fuel Delivery Unit
2. Fuel Line to Auxiliary Heater Metering Pump
3. Guide Tube With spring
4. Locking Flange With integrated fuel pressure regulator and fuel filter The fuel pressure regulator and fuel filter cannot be replaced individually.
5. Guide Tube
6. Fuel Line To the engine Do not kink To disconnect, press release button on connection piece Install until it clicks into place Press again and pull to make sure the connection is engaged correctly.
7. Connector For the fuel level sensor -G- and transfer Fuel Pump (FP) -G6 Pull on the connector to make sure it is locked secure.

Scheme 19

1. Fuel Delivery Unit
2. Connector For fuel level sensor -G Pull on the connector to make sure it is locked secure.
3. Guide Tube With spring
4. Fuel Line to Auxiliary Heater Metering Pump Not applicable for the NA market
5. Locking Flange With integrated fuel pressure regulator and fuel filter The fuel pressure regulator and fuel filter cannot be replaced individually.
6. Guide Tube
7. Fuel Line To the engine Do not kink To disconnect, press release button on connection piece Install until it clicks into place Press again and pull to make sure the connection is engaged correctly.
8. Assembly Tool Engaged on the locking flange
9. Connector For the transfer Fuel Pump (FP) -G6 Pull on the connector to make sure it is locked secure.

Scheme 20

1. Vent Line To Evaporative Emission (EVAP) canister purge regulator valve 1 - N80 To disconnect, press release button on connection piece Clipped into brackets under the vehicle underbody
2. O-ring
3. Valve
4. Vent Line From the fuel tank To disconnect, press release button on connection piece
5. Vent Line Vents to the outside at the left rear under the wheel housing liner
6. EVAP Canister Component location: on the underbody under the left rear floor panel Removing and installing, refer to «EVAP CANISTER»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__evap-canister)
7. Bolt 16 Nm

Scheme 21

1. Nut 20 Nm
2. Fuel Line To engine Do not kink Attached to the fuel tank To disconnect, press release button on connection piece
3. Fuel Tank Removing and installing, refer to «FUEL TANK WITH ATTACHMENTS»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-tank-with-attachments)
4. Bolt 20 Nm For securing the fuel filler tube and the ground connection -9
5. Overflow Hose
6. Rubber Gasket
7. Cover Turn until it engages audibly Attached to fuel filler door insert with fastening device
8. Ground Connection For discharging electrostatic charge Installed position (Scheme 23)Make sure the connector is securely seated and wiring is secured by the fuel filler tube bolt -5- After installing, check the electrical connection of the metal ring on the fuel filler neck to a bare area of the chassis an using Ohm meter - Specified value: approximately 0 ohms.
9. Bolt 20 Nm
10. Vent Line To the EVAP canister Do not kink To disconnect, press release button on connection piece Attached to the fuel tank
11. Securing Strap Rear
12. Bolt 20 Nm
13. Heat Shield for Fuel Tank
14. Bolt 2 Nm
15. Exhaust System Mounts
16. Bolt Tightening specification. Refer to «[For engine(s) CAEB] Description and Operation»(ref-515352-S41645056342012120300000) or to «[For engine(s) CALB] Description and Operation»(/audi/q5/i-2008-2012/remont/exhaust/#32l-exhaust-system-emission-controls-engine-codes-calb)
17. Rubber Grommet
18. Securing Strap Front
19. Spacer Sleeve
20. Bolt 20 Nm

Tighten the bolts -arrows- for the cover -1- to 1.5 Nm.

Scheme 22

Tighten the bracket nuts -1, 3 and 4- to 20 Nm.

Scheme 23

Make sure the filler tube threaded connections -1 and 2- are free of corrosion so the ground connection to the body is not affected.

Route the ground connection -3- as shown in illustration

Engage the ground connection contact -7- into the opening in fuel tank and then install the spacer bushing -6-.

Make sure the ground connector -4- fits securely on the fuel filler tube metal ring -5-.

FASTENER TIGHTENING SPECIFICATIONS

Locking Flange Cover - Tightening Specifications

Tighten the bolts -arrows- for the cover -1- to 1.5 Nm.

Bracket - Tightening Specification

Tighten the bracket nuts -1, 3 and 4- -2- to 20 Nm.

TRANSFER FUEL PUMP -G6-, CHECKING, VEHICLES THROUGH MY 12

Special tools and workshop equipment required

1. Remote Control V.A.G 1348/3A
2. Multimeter V.A.G 1526D
3. Connector Test Set V.A.G 1594C

Procedure

Observe test conditions. Refer to TEST CONDITIONS .

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

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

Push the circlip -1- upward -arrow A- and compress the release -arrow B-.

Press on the marked location -arrow A- and remove the cover -2-.

Scheme 24

Release the latch -arrow B- and open the cover -1-.

Connect the V.A.G 1348/3A using the adapter V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

Scheme 25

Tape the V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect connector terminal -5- with an adapter cable from the V.A.G 1594C to chassis ground.

Route the V.A.G 1348/3A toward the front in the engine compartment.

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Press the button of the remote control.

1. Running noise of pump must be audible.

Note. The fuel pump runs quietly. Avoid surrounding noises while testing the fuel pump.

If no operating noise can be heard

Connect multimeter between terminal -1 and 5- of harness connector for voltage measurement.

Scheme 26

Press the switch on the remote control.

1. Specified value: Approximately battery voltage.

If the specification is not obtained

Repair the open circuit in the wiring according to wiring diagram.

If specified value is obtained, although no running-noise can be heard at pump

Scheme 27

Remove the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

Check the electrical wires between the locking flange and fuel pump to make sure they are connected and routed correctly.

If no fault is detected in the electrical wires, replace the fuel delivery unit.

Install the fuel delivery unit while following the information on connecting the battery FUEL DELIVERY UNIT .

TRANSFER FUEL PUMP -G6-, CHECKING, VEHICLES FROM MY 13

Check the electric fuel pump in Guided Fault Finding see vehicle diagnosis tester.

FUEL LEVEL SENSOR -G-, CHECKING, VEHICLES THROUGH MY 12

Special tools and workshop equipment required

1. Multimeter V.A.G 1526D
2. Connector Test Set V.A.G 1594C

Procedure

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

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

Push the circlip -1- upward -arrow A- and compress the release -arrow B-.

Connect the multimeter to measure the resistance between contacts -2 and 3-.

Scheme 28

Fuel level sensor installed

1. Sensor at lower stop: approximately 285 ohms.
2. Sensor at upper stop: approximately 60 ohms.

Note. If measured value is 0 ohms there is a short circuit. If measured value is there is and open circuit in the wiring. To check resistance values "tank full" or "tank empty", the fuel delivery unit must be removed and the sensor floater must be placed in upper or lower end position. Refer to FUEL DELIVERY UNIT With the fuel level sensor removed, the following values are obtained because of the greater deflection of the floater arm

Fuel level sensor removed

1. Sensor at lower stop: approximately 285 ohms.
2. Sensor at upper stop: approximately 53 ohms.

Connect the multimeter to measure the resistance between contacts -3 and 4-.

Fuel level sensor installed or removed

1. Any sensor position: Approximately 340 ohms.

Assemble in reverse order of disassembling. Note the following

Install the right locking flange cover. see scheme 30

Install the right 1/3 rear seat. Refer to Removal and Installation .

FUEL LEVEL SENSOR -G-, CHECKING, VEHICLES FROM MY 13

Special tools and workshop equipment required

1. Hand-Held Multimeter -V.A.G 1526EAudi
2. Connector Test Set -V.A.G 1594C

Procedure

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

Disconnect the connector -2- on the locking flange.

Note. Ignore -1-.

Scheme 29

Push the circlip -1- upward -arrow A- and squeeze the release -arrow B-.

The Fuel Level Sensor is Installed

Note. The fuel tank must be filled completely in order to an exact reading of the resistance on the "fuel tank full" when it is installed. Drive at least 500 meters after filling the fuel tank full to get rid of any bubbles in the fuel tank. Then fill the fuel tank again.

Connect the multimeter to measure the resistance between contacts -1 and 2-.

Scheme 30

1. Fuel tank empty: approximately 285 ohms.
2. Fuel tank full: approximately 60 ohms.

Connect the multimeter to measure the resistance between contacts -1 and 3-.

1. Fuel tank empty: approximately 60 ohms.
2. Fuel tank full: approximately 285 ohms.

Connect the multimeter to measure the resistance between contacts -2 and 3-.

1. Arbitrary sensor position: approximately 340 ohms

The Fuel Level Sensor is Removed

Note. To check resistance values "tank full" or "tank empty", the fuel level sensor must be removed and the floater of the sensor must be placed in the upper or lower end position. With fuel level sensor removed, the following values are obtained because of the greater deflection of the floater arm

Connect the multimeter to measure the resistance between contacts -1 and 2-.

1. Fuel tank empty: approximately 285 ohms.
2. Fuel tank full: approximately 53 ohms.

Connect the multimeter to measure the resistance between contacts -1 and 3-.

1. Fuel tank empty: approximately 53 ohms.
2. Fuel tank full: approximately 285 ohms.

Connect the multimeter to measure the resistance between contacts -3 and 4-.

1. Arbitrary sensor position: approximately 340 ohms.

The fuel level sensor -G- is faulty when the following is detected

1. Large deviations in measured values
2. Measured value 0 ohms (short circuit).
3. Measured value °°ohms (open circuit).
4. No fault in the electric wires.

Install the fuel delivery unit/ fuel level sensor. Refer to FUEL DELIVERY UNIT

Install the right locking flange cover. Refer to

Install the right 1/3 rear seat. Refer to Removal and Installation .

FUEL PUMP CONTROL MODULE -J538-, CHECKING

1. The voltage for the fuel pump is supplied via the FP control module.
2. FP control module testing occurs in "Guided Fault Finding" using the vehicle diagnostic tester.

FUEL PRESSURE AND HOLDING PRESSURE, CHECKING, VEHICLES THROUGH MY 12

Special tools and workshop equipment required

1. Remote Control Connection -V.A.G 1348/3A
2. Connector Test Set -V.A.G 1594C
3. Pressure Tester -VAS 6550- with Hose -VAS 6550/1- and Hose -VAS 6550/2
4. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1

Disconnect the connector -1- on the locking flange.

Push the circlip -1- upward -arrow A- and squeeze the release -arrow B-.

Press on the marked location -arrow A- and remove the cover -2-.

Release the latch -arrow B- and open the cover -1-.

Connect the -V.A.G 1348/3A- using the -V.A.G 1348/3-3- and cable from the -V.A.G 1594C- to the terminal -1-.

Tape -V.A.G 1348/3-3- with insulating tape -arrow- to prevent a short circuit.

Connect connector terminal -5- with an adapter cable from - V.A.G 1594C- to chassis ground.

Route -V.A.G 1348/3A- toward front in engine compartment.

Connect the alligator clamp to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- inside the plenum chamber.

Press the release ring -1- and disconnect the fuel line -2-.

Scheme 31

Connect the -VAS 6550- and the -VAS 6550/2- to the fuel supply line.

Scheme 32

Connect the -VAS 6550/1- and hold it inside a fuel resistant container.

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Scheme 33

Press the button of the remote control.

If the fuel flows without bubbles, close the drain -B-, so that the fuel pressure increases.

1. The level is perpendicular to the direction of flow.

Read the fuel pressure on the -VAS 6550

1. Specified value: 4.0 to 8.0 bar (58 to 116 psi).

If the specification is not attained

Check the fuel delivery quantity for the fuel pump. Refer to FUEL PUMP DELIVERY RATE, CHECKING, VEHICLES THROUGH MY 12 or FUEL PUMP DELIVERY RATE, CHECKING, VEHICLES FROM MY 13

Checking Holding Pressure

Watch the pressure fall on the -VAS 6550- while checking the holding pressure and checking for leaks

1. After 10 minutes there must be a residual pressure of at least 3 bar (43.5 psi).

If the holding pressure drops below 3 bar (43.5 psi)

1. Check the connection between the -VAS 6550- and the fuel supply line for leaks.
2. Check the -VAS 6550- for leaks.
3. Check fuel lines and their connections for leaks.

If no faults are detected

1. Replace the locking flange with the fuel filter and fuel pressure regulator. Refer to «FUEL FILTER»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-filter-vehicles-through-my-12)

Repeat the residual pressure check.

If there are still leaks

1. The fuel pump check valve in the fuel pump leaks: replace the fuel delivery unit. Refer to «FUEL DELIVERY UNIT»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-delivery-unit-through-my-12)

Assembly is performed in the reverse order of disassembly, noting the following

1. The ignition must be turned off.

Note. Open the shut-off valve -B- and drain valve -C- and let the fuel drain into the measuring container before to removing the pressure gauge for the fuel pressure.

Remove the -VAS 6550- and -VAS 6550/1- and -VAS 6550/2-.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL PRESSURE AND HOLDING PRESSURE, CHECKING, VEHICLES FROM MY 13

Special tools and workshop equipment required

1. Pressure Tester -VAS 6550- with Hose -VAS 6550/1- and Hose -VAS 6550/2
2. Vehicle Tester
3. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS

Press the release ring -1- and disconnect the fuel line -2-.

Connect the -VAS 6550- and the -VAS 6550/2- to the fuel supply line.

Connect the -VAS 6550/1- and hold it inside a fuel resistant container.

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Connect the tester.

Turn on the ignition and select the following menu items on the vehicle diagnosis tester

1. OBD
2. Basic Setting
3. Empty Fuel Tank

Push Start : the fuel pump starts.

If the fuel flows without bubbles, close the drain -B-, so that the fuel pressure increases.

1. The level is perpendicular to the direction of flow.

Read the fuel pressure on the -VAS 6550

1. Specified value: 4.0 to 8.0 bar (58 to 116 psi).

Press the Stop button.

If the specification is not attained

Check the fuel delivery quantity for the fuel pump. Refer to FUEL PUMP DELIVERY RATE, CHECKING, VEHICLES THROUGH MY 12 or FUEL PUMP DELIVERY RATE, CHECKING, VEHICLES FROM MY 13

Checking Holding Pressure

Watch the pressure fall on the -VAS 6550- while checking the holding pressure and checking for leaks

1. After 10 minutes there must be a residual pressure of at least 3 bar (43.5 psi).

If the holding pressure drops below 3 bar (43.5 psi)

1. Check the connection between the -VAS 6550- and the fuel supply line for leaks.
2. Check the -VAS 6550- for leaks.
3. Check fuel lines and their connections for leaks.

If no faults are detected

1. Replace the locking flange with the fuel filter and fuel pressure regulator. Refer to «FUEL FILTER»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-filter-vehicles-through-my-12)

Repeat the residual pressure check.

If there are still leaks

1. The fuel pump check valve in the fuel pump leaks: replace the fuel delivery unit. Refer to «FUEL DELIVERY UNIT»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system__fuel-delivery-unit-through-my-12)

Assembly is performed in the reverse order of disassembly, noting the following

1. The ignition must be off.

Note. Open the shut-off valve -B- and drain valve -C- and let the fuel drain into the measuring container before to remove the pressure gauge for the fuel pressure.

Remove the -VAS 6550- and hose lines -VAS 6550/1- and - VAS 6550/2-.

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL PUMP DELIVERY RATE, CHECKING, VEHICLES THROUGH MY 12

Special tools and workshop equipment required

1. Remote Control Connection -V.A.G 1348/3A
2. Connector Test Set -V.A.G 1594C
3. Pressure Tester -VAS 6550- with Hose -VAS 6550/1- and Hose -VAS 6550/2

Procedure

Follow all test requirements. Refer to TEST CONDITIONS

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

Disconnect the connector -1- on the locking flange.

Push the circlip -1- upward -arrow A- and squeeze the release -arrow B-.

Press on the marked location -arrow A- and remove the cover -2-.

Release the latch -arrow B- and open the cover -1-.

Connect the -V.A.G 1348/3A- using the -V.A.G 1348/3-3- and cable from the -V.A.G 1594C- to the terminal -1-.

Tape -V.A.G 1348/3-3- with insulating tape -arrow- to prevent a short circuit.

Connect connector terminal -5- with an adapter cable from - V.A.G 1594C- to chassis ground.

Route -V.A.G 1348/3A- toward front in engine compartment.

Connect the alligator clamp to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- inside the plenum chamber.

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Scheme 34

Press the release ring -1- and disconnect the fuel line -2-.

Connect the -VAS 6550- and the -VAS 6550/2- to the fuel supply line.

Connect the -VAS 6550/1- and hold it inside a fuel resistant container.

Open the shut-off valves -A and B

1. The levers point in the direction of flow.

Note. In order to measure the fuel delivery rate, there must be an initial pressure inside the fuel line against which the fuel pump must work during the measuring. This initial pressure can be adjusted by remote control as follows

Press the switch in the remote control to create an initial pressure within the fuel system: the fuel pump starts and close the shut-off valve -B- on the pressure gauge slowly.

Specified value: 4 bar (58 psi) pressure.

From this point on do not move position of shut-off valve.

Empty measuring container.

Press the remote control switch for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm3/15 s).

Scheme 35

Note. Voltage at fuel pump with engine stopped and fuel pump running is approximate. 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. The fuel lines are pinched.
2. The fuel filter is clogged.
3. The transfer Fuel Pump (FP) -G6- is faulty.

Assembly is performed in the reverse order of disassembly, noting the following

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL PUMP DELIVERY RATE, CHECKING, VEHICLES FROM MY 13

Special tools and workshop equipment required

1. Pressure Tester -VAS 6550- with Hose -VAS 6550/1- and Hose -VAS 6550/2
2. Vehicle tester
3. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Press the release ring -1- and disconnect the fuel line -2

Connect the -VAS 6550- and the -VAS 6550/2- to the fuel supply line.

Connect the -VAS 6550/1- and hold it inside a fuel resistant container.

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Connect the tester.

Turn on the ignition and select the following menu items on the vehicle diagnosis tester

1. OBD
2. Engine Electronics
3. Basic Setting
4. Empty Fuel Tank

Note. In order to measure the fuel delivery rate, there must be an initial pressure inside the fuel line against which the fuel pump must work during the measuring. Adjust the initial pressure with the - VAS 6550- as follows

Press Start and create an initial pressure in the fuel system: the fuel pump starts to run and slowly close the shut-off valve -B- on the pressure tester.

1. Specified value: 4 bar (58 psi) pressure.

From this point on do not move position of shut-off valve.

Press the Stop button.

Empty measuring container.

To measure, press the Start button again and let the fuel pump run for 15 seconds.

After 15 seconds, press the Stop button.

1. Specified value: minimum delivery rate 800 cm 3/15 s.

Assembly is performed in the reverse order of disassembly, noting the following

Attach the fuel line so that it clicks into place.

Press the fuel line on again and pull to make sure the connection is engaged correctly.

FUEL PUMP DELIVERY RATE, CHECKING

Special tools and workshop equipment required

1. Remote Control Connection -V.A.G 1348/3A
2. Connector Test Set -V.A.G 1594C
3. Pressure Tester -VAS 6550- with Hose -VAS 6550/1- and Hose -VAS 6550/2
4. Measuring container, fuel-resistant

Procedure

Follow all test requirements. Refer to TEST CONDITIONS

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

Disconnect the connector -1- on the locking flange.

Push the circlip -1- upward -arrow A- and squeeze the release -arrow B-.

Press on the marked location -arrow A- and remove the cover -2-.

Release the latch -arrow B- and open the cover -1-.

Connect the -V.A.G 1348/3A- using the -V.A.G 1348/3-3- and cable from the connector test set -V.A.G 1594C- to the terminal -1-.

Tape -V.A.G 1348/3-3- with insulating tape -arrow- to prevent a short circuit.

Connect connector terminal -5- with an adapter cable from - V.A.G 1594C- to chassis ground.

Route -V.A.G 1348/3A- toward front in engine compartment.

Connect the alligator clamp to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- inside the plenum chamber.

Open the fuel filler door.

Remove the fuel filler cap -arrow-.

Loosen the clamp and remove the fuel line -1-.

Connect the -VAS 6550/1- and hose -1- to the fuel supply line and secure them with clamps -2-.

Connect -VAS 6550/1- to the -VAS 6550-.

Connect the -VAS 6550/2- and hold it inside a fuel resistant container.

Open the shut-off valves -A and B-.

1. The levers point in the direction of flow.

Note. In order to measure the fuel delivery rate, there must be an initial pressure inside the fuel line against which the fuel pump must work during the measuring. This initial pressure can be adjusted by remote control as follows

Press the switch in the remote control to create an initial pressure within the fuel system: the fuel pump starts and close the shut-off valve -B- on the pressure gauge slowly.

1. Specified value: 4 bar (58 psi) pressure.

From this point on do not move position of shut-off valve.

Empty measuring container.

Press the remote control switch for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm3/15 s).

Scheme 36

Note. Voltage at fuel pump with engine stopped and pump running is approximate 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. The fuel lines are pinched.
2. The fuel filter is clogged.
3. The fuel pump is faulty.

Assembly is performed in the reverse order of disassembly, noting the following

Secure the fuel line with a clamp and then pull on it to make sure it is secure.

LEAK DETECTION TEST, PERFORMING

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Dia. 3094

Diagnostic leak test occurs in "Guided Fault Finding" using the vehicle diagnostic tester.

Checking Fuel Supply and Tank Ventilation Systems for Leaks

Note. The following describes individual areas in the fuel supply and ventilation systems where leaks are possible. After repairing a possible leak, perform a leak test to ensure that leak was successfully repaired.

Turn off ignition.

Make sure the fuel tank cap -arrow- was closed completely during the test.

Check whether the seal of the fuel filler cap was damaged or crimped. Replace if necessary.

Remove the rear bench seat. Refer to Removal and Installation .

Remove the bolts -arrows- and locking flange cover -1-.

Note. Observe installation notes for locking flanges FUEL DELIVERY UNIT .

Check sealing rings seals under locking flanges are OK and lock rings are properly tightened on fuel tank. Also check the fuel line connections.

Visually check all wires and hose connections of fuel supply system and replace leaking lines, for example

1. Line from EVAP canister to Evaporative Emission (EVAP) canister purge regulator valve -N80
2. Lines from EVAP canister to Leak Detection Pump (LDP) -V144-.
3. Line from fuel tank to EVAP canister (below heat shield for EVAP canister).
4. Lines for tank ventilation (beneath right rear wheel housing liner).
5. Fuel lines to engine.

Note. Leaks at lines and components of tank system can sometimes be located using a nonflammable, environmentally compliant leak detection spray. For this, initiate leak diagnostic several times in sequence to build up pressure in the system. At leaking areas, bubbles will form.

Perform a visual inspection on the fuel system components and tank ventilation system

1. Fuel tank
2. EVAP canister
3. Leak detection pump
4. EVAP canister purge regulator valve 1

Note. Due to the form or function of the components, leaking areas may not always be localized by spraying on leak detection spray. It may be necessary to clamp off the relevant component using 3094 and initiate tank leak detection diagnostic. If the leak is no longer indicated, the component that was clamped off is faulty. If clamped off directly at the leak detection pump and a leak is still indicated, the leak detection pump itself is leaking.

TRANSFER FUEL PUMP (FP) -G6-, CHECKING DELIVERY

Special tools and workshop equipment required

1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/17-1A
4. Fuel Line Feed Adapter V.A.G 1318/23
5. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-3
6. Connector Test Set V.A.G 1594C
7. Hose, fuel resistant
8. Measuring container, fuel-resistant

Procedure

Observe test conditions. Refer to TEST CONDITIONS .

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

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

Push the circlip -1- upward -arrow A- and compress the release -arrow B-.

Press on the marked location -arrow A- and remove the cover -2-.

Release the latch -arrow B- and open the cover -1-.

Connect the V.A.G 1348/3A using the V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

Tape the V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect connector terminal -5- with an adapter cable from the V.A.G 1594C to chassis ground.

Route the V.A.G 1348/3A toward the front in the engine compartment.

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Remove the cover from the fuel filler tube.

Disconnect the fuel line -2- by pulling release ring -1-.

Attach the V.A.G 1318/23 and V.A.G 1318/17-1A to V.A.G 1318.

Scheme 37

Push the V.A.G 1318/17-1A onto the disconnected fuel line.

Attach the V.A.G 1318/11 to the V.A.G 1318.

Push an assisting hose -arrow- onto it and hold it into a measuring container.

Open shut-off valve on pressure gauge.

1. The lever points in the direction of flow.

Generate pressure in the fuel system by pressing the switch on the remote control and slowly closing the shut-off valve on the pressure gauge.

1. Specified value: 4 bar positive pressure.

From this point on do not move position of the shut-off valve.

Empty the measuring container.

Press the remote control switch for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15s).

Note. Voltage at fuel pump with engine stopped and fuel pump running is approximate. 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. Fuel lines pinched.
2. Fuel filter clogged.
3. Transfer FP faulty.

Assembly is performed in reverse order.

Special tools and workshop equipment required

1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
2. Pressure Gauge Adapter V.A.G 1318/10-12 and Adapter V.A.G 1318/15
3. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
4. Measuring container, fuel-resistant

Procedure

Observe test conditions. Refer to TEST CONDITIONS .

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

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

Push the circlip -1- upward -arrow A- and compress the release -arrow B-.

Press on the marked location -arrow A- and remove the cover -2-.

Release the latch -arrow B- and open the cover -1-.

Connect the V.A.G 1348/3A using the V.A.G 1348/3-3 and cable from the V.A.G 1594C to the terminal -1-.

Tape the V.A.G 1348/3-3 with insulating tape -arrow- to prevent a short circuit.

Connect connector terminal -5- with an adapter cable from V.A.G 1594C to chassis ground.

Route the V.A.G 1348/3A toward the front in engine compartment.

Connect the alligator clip to the battery jump start terminal -U6- -A- in the terminal 30 wire junction 2 -TV22- in the plenum chamber.

Remove the cover from the fuel filler tube.

Remove the bolts -arrows-.

Scheme 38

Remove the air duct -1- and the air filter housing intermediate flange -2-.

Remove the fuel supply line from the high pressure pump -arrow-.

Scheme 39

Connect the V.A.G 1318 with the V.A.G 1318/11 and V.A.G 1318/15 in the fuel line.

Scheme 40

Push an assisting hose -arrow- onto it and hold it into a measuring container.

Open the pressure gauge shut-off valve.

1. The lever points in the direction of flow.

Generate pressure in the fuel system by pressing the switch on the remote control and slowly closing the shut-off valve on the pressure gauge.

1. Specified value: 4 bar positive pressure.

From this point on do not move position of shut-off valve.

Empty measuring container.

Press the remote control switch for 15 seconds.

Compare quantity of fuel delivered with minimum delivery rate in diagram (cm 3 /15 s).

Note. Voltage at the fuel pump with the engine stopped and pump running is approximate. 2 volts less than battery voltage.

If minimum delivery quantity is not obtained, the following malfunctions may be present

1. Fuel lines pinched.
2. Fuel filter clogged.
3. Fuel pump faulty.

Assembly is performed in reverse order.

ACCELERATOR PEDAL MODULE WITH ACCELERATOR PEDAL POSITION SENSOR -G79- /ACCELERATOR PEDAL POSITION SENSOR 2 -G185

Removing

Scheme 41

Remove the driver side lower instrument panel cover. Refer to Removal and Installation .

Disconnect the electrical connector -2- by pressing the release -1- up -arrow-.

Remove the bolt -3- and remove the accelerator pedal module downward.

Installing

Scheme 42

1. Tightening specification, refer to «ACCELERATOR PEDAL MODULE OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system) .

Install in reverse order, paying attention to the following

Engage the accelerator pedal module -4- on the bottom of the pedal bracket -1-, insert the centering pin -2- and tighten the bolt -3-.

Install the driver side lower instrument panel cover. Refer to Removal and Installation .

On vehicles with S-Tronic transmission or automatic transmission, perform "kick-down adaptation" in "Guided Functions" after replacing using the vehicle diagnostic tester.

EVAP CANISTER

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remove the left rear underbody cover. Refer to Removal and Installation .

Press the release button and remove the ventilation lines.

1. 1- from the air filter inside the wheel housing
2. 3- to the fuel tank
3. 5- to the Evaporative Emission (EVAP) canister purge regulator valve 1 -N80

Remove the bolts -2, 4 and 6- and the EVAP canister.

Scheme 43

Installing

Connect the air and vent lines until they engage audibly.

Install the rear left floor panel. Refer to Removal and Installation

Note. Checking for leaks, refer to LEAK DETECTION TEST, PERFORMING .

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remove the left rear underbody cover. Refer to Removal and Installation .

Disconnect the connector -7-.

Scheme 44

Press the release button and remove the ventilation lines

1 - Ventilation hose to fuel tank

6 - vacuum line to the engine

9 -Vent line to the EVAP canister purge regulator valve 1 -N80

Remove the clamps and disconnect the vent line -4- to the Leak Detection Pump (LDP) -V144- air filter.

Remove the bolts -2, 5 and 8- and remove the EVAP canister -3-.

Installing

1. Tightening specification, refer to «EVAP CANISTER AND LEAK DETECTION SYSTEM OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system) .

Install in reverse order, paying attention to the following

Note. Secure all hose connections with hose clamps of the same type as those equipped by the factory.

Connect the air and vent lines until they engage audibly.

FUEL DELIVERY UNIT THROUGH MY 12

Special tools and workshop equipment required

1. Wrench T10202

REMOVING

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Move the passenger seat all the way forward if necessary.

Disconnect the battery -arrow-. Refer to Removal and Installation .

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

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

Push the circlip -1- upward -arrow A- and compress the release -arrow B-.

Disconnect the fuel line -2- at the locking flange by pressing the release button.

Press the release button and disconnect the metering pump fuel line -1- at the locking flange on vehicles with an auxiliary heater.

Remove locking ring using the T10202.

Pull the locking flange -2- just a little out of the fuel tank and remove the sealing ring -1-.

Scheme 45

Move the locking flange toward the right side of the vehicle, reach into the fuel tank through the gap between the locking flange and the opening and carefully guide the fuel line -3- out of the fuel tank.

Remove the fuel delivery unit locking flange -4- from the opening in the fuel tank and lay it on the side with the lines still connected.

Reach through the opening in the fuel tank and unlock the suction jet pump -arrows-.

Scheme 46

Pull suction jet pump -2- carefully upward with suction jet pipe -1- still connected.

Disconnect suction jet pipe from suction jet pump by pressing release button.

Remove the suction jet pump.

Reach through the opening in the fuel tank and carefully remove the fuel delivery unit -3-.

Note. When removing fuel delivery unit, be sure not to bend floater arm on the fuel level sensor -G-.

INSTALLING

1. Tightening specification, refer to «FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system) .

Install in reverse order, paying attention to the following

Note. Replace the seal. When inserting fuel delivery unit, be sure not to bend floater arm on the fuel level sensor. Make sure the fuel hoses are secure.

Make sure the ground wire -1- on the fuel pressure regulator and the locking flange is attached securely -arrows-.

Scheme 47

Install the fuel delivery unit -1- in the fuel tank with the locking flange which was moved to the side; when doing this pay attention to the installation position of the fuel level sensor.

Scheme 48

1. The fuel level sensor floater -3- must point toward the right side of the vehicle through the opening in the baffle.

Insert the suction jet pump -2- into the fuel tank and connect the suction jet pipe.

1. The suction jet pump must be guided between the 2 ridges in the baffle in the drive direction.

Attach the suction jet pump to the fuel delivery unit. To do this, reach into the fuel tank through the opening.

1. Suction jet pump must engage audibly.

Make sure the suction jet pipe and the suction jet pump are securely locked in place.

Note. To improve clarity, a cross-sectional view of the fuel tank is shown.

Move the locking flange toward the right side of the vehicle, insert the locking flange -2- and fuel line into the fuel tank, and carefully install the fuel line -3-.

Install the new locking flange seal -1- over the locking flange stretched and dry.

Make sure the fuel hoses and wires are routed correctly as illustrated

Scheme 49

1. The fuel supply line -1- must be routed in front of the guide pipe -3-.
2. The suction jet pipe -2- must be routed behind the guide pipe -3-.
3. The auxiliary heater fuel supply line -5- must be routed behind the guide pipe -4-.

Insert the guide tubes -3 and 4- of the locking flange into the guide holes -arrows- of the fuel delivery unit.

Note. The fuel delivery unit is illustrated without the fuel tank.

Bring the locking flange into the installation position.

Scheme 50

1. The tab -2- on the locking flange faces toward the rear of the vehicle and must be between the tabs -1 and 3- on the fuel tank.

Tighten the locking ring with T10202.

Connect the fuel lines -1 and 2-.

Connect the connector.

Install the right locking flange cover. see scheme 30

Install the right 1/3 rear seat. Refer to Removal and Installation .

Connect the battery and observe safety precautions after connecting battery. Refer to Removal and Installation .

After installing fuel delivery unit, fill vehicle with at least 5 liters of fuel.

FUEL DELIVERY UNIT, VEHICLES FROM MY 13

Special tools and workshop equipment required

1. Wrench -T10202
2. Assembly Tool -T10118

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS

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

Move the passenger seat all the way forward if necessary.

Disconnect the battery -arrow-. Refer to Removal and Installation .

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

Open the connector safety catch with -T10118- and disconnect the connector -1- on the locking flange.

Disconnect the connector -2- on the locking flange.

Push the circlip -1- upward -arrow A- and squeeze the release -arrow B-.

Press the release button and disconnect the fuel line -2- from the locking flange.

Push the circlip -1- upward -arrow A- and squeeze the release -arrow B-.

Press the release button and disconnect the fuel line -2- from the locking flange.

Remove locking ring with -T10202-.

Pull the locking flange -2- just a little out of the fuel tank and remove the sealing ring -1-.

Pull the locking flange with the fuel line and the electric wires as far as possible out of the opening in the fuel tank.

Turn and the tilt the fuel delivery unit with the fuel level sensor and remove through the opening in the fuel tank.

Note. Be careful not to bend the floater arm on the fuel level sensor when removing fuel delivery unit.

Installing

Install in reverse order of removal. Note the following

1. Tightening specification, refer to «FUEL DELIVERY UNIT/FUEL LEVEL SENSOR OVERVIEW, VEHICLES THROUGH MY 12»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system) or to «FUEL DELIVERY UNIT/FUEL LEVEL SENSOR OVERVIEW, VEHICLES FROM MY 13»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system)

Install the right locking flange cover. Refer to

Install the right 1/3 rear seat. Refer to Removal and Installation .

Connect the battery and complete the steps required after connecting the battery. Refer to Removal and Installation .

FUEL FILTER, VEHICLES THROUGH MY 12

Note. The fuel pressure regulator and fuel filter are part of the locking flange. They can only be replaced together with the locking flange for the fuel delivery unit.

Removing

Scheme 51

Remove the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

Disconnect the connector -3-.

Disengage the fuel return line -2-.

Press the release button and remove the fuel supply line -5-.

Remove the locking flange -4- from the fuel delivery unit -1-.

Installing

Install in reverse order, paying attention to the following

Make sure the spring is on the guide tube.

Pay attention to the installation position of the fuel lines FUEL DELIVERY UNIT .

FUEL FILTER, VEHICLES FROM MY 13

Note. The fuel pressure regulator and fuel filter are part of the locking flange. They can only be replaced together with the locking flange for the fuel delivery unit.

Removing

Remove the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

Disconnect the connectors -2-.

Press the release button and remove the fuel line -5-.

Disengage the assembly aid -4- on the locking flange.

Remove the locking flange -3- from the fuel delivery unit -6-.

Installing

Install in reverse order of removal. Note the following

Make sure the spring is on the guide tube.

FUEL LEVEL SENSOR -G

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remove the fuel delivery unit. Refer to FUEL DELIVERY UNIT .

Release the retaining tabs -arrows- with a screwdriver and pull the fuel level sensor upward and out.

Scheme 52

Disconnect the connectors -1 through 3-.

Scheme 53

Installing

Install in reverse order, paying attention to the following

Connect the electrical connections -1 through 3- and make sure they are securely engaged.

Insert the fuel level sensor in the guides on the fuel delivery unit and push down until it engages.

Install the fuel delivery unit while following the information on connecting the battery FUEL DELIVERY UNIT .

FUEL PUMP (FP) CONTROL MODULE -J538

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Move the passenger seat all the way forward if necessary.

Disconnect the battery -arrow-. Refer to Removal and Installation .

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

Lift the insulation mat and remove the bolts -1-.

Scheme 54

Pull the FP control module -3- in between the fuel tank and the vehicle underbody.

Disconnect the connector -2- and remove the FP control module.

Installing

1. Tightening specification, refer to «FUEL DELIVERY UNIT AND FUEL LEVEL SENSOR OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system) .

Install in reverse order, paying attention to the following

Install the right locking flange cover. see scheme 30

Install the right 1/3 rear seat. Refer to Removal and Installation .

Connect the battery and observe safety precautions after connecting battery. Refer to Removal and Installation .

FUEL TANK WITH ATTACHMENTS

Special tools and workshop equipment required

1. Engine/Transmission Jack V.A.G 1383 A
2. Assembly Tool T10118

Removing

Follow all Safety Precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Move the passenger seat all the way forward if necessary.

Disconnect the battery -arrow-. Refer to Removal and Installation .

Remove the right 1/3 rear seat. Refer to Removal and Installation .

Remove the bolts -arrows- and remove the locking flange cover -1-.

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

Pull the lock -1- upward -arrow A- and press -arrow B-, disconnect the connector -2-.

Open the tank door.

Clean the area around the fuel filler tube.

Remove the locking cap -arrow- from the fuel filler tube.

Note. To prevent dirt from entering the fuel tank, seal the opening with a clean foam piece.

Remove the right rear wheel.

Remove right rear wheel housing liner. Refer to Removal and Installation .

Remove fuel filler tube bolts -1 and 2-.

Note. Ignore -3 to 7-.

Remove rear section of the exhaust system. Refer to [For engine(s) CAEB] Description and Operation or to [For engine(s) CALB] Description and Operation .

Remove rear axle. Refer to Removal and Installation .

Scheme 55

Remove the right floor panel in the center. Refer to Description and Operation .

Remove the nuts -1, 3 and 4- and remove the bracket -2-.

Disconnect the fuel line -1- on the right front of the fuel tank by pressing the release button.

Scheme 56

Press the release button and disconnect the EVAP canister vent line -arrow-.

Scheme 57

Place the V.A.G 1383 A under the fuel tank for support.

Scheme 58

Support fuel tank using the V.A.G 1383 A.

Remove the bolts -1- and remove the exhaust system bracket -2-.

Scheme 59

Remove the bolts -3 to 6-.

Lower the fuel tank with the V.A.G 1383 A while guiding it by hand.

Installing

1. For the correct tightening specifications, refer to «FUEL TANK WITH ATTACHMENTS OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system) .

Install in reverse order, paying attention to the following

Make sure the fuel and vent lines are clipped to the fuel tank properly.

Check if the Ground (GND) wiring on both connections show signs of oxidation. If necessary, remove.

Make sure the filler tube threaded connections -1 and 2- are free of corrosion so the ground connection to the body is not affected.

Route the GND connection -3- as illustrated.

Engage the GND connection contact -7- into the opening in fuel tank and then install the spacer bushing -6-.

Make sure the GND connector -4- fits securely on the fuel filler tube metal ring -5-.

Position the fuel tank with mounting straps on the underbody using the V.A.G 1383 A.

Make sure the fuel tank is positioned so that the filler tube can be guided into the opening of the body correctly.

Install the exhaust system bracket -2- and tighten the bolts -1 through 6-.

Tighten the fuel filler tube bolts -1 and 2-.

Install the bracket. (Scheme 22)

Install the rear axle. Refer to Removal and Installation .

Install the floor panel. Refer to Removal and Installation .

Install the rear section of the exhaust system. Refer to [For engine(s) CAEB] Description and Operation or to [For engine(s) CALB] Description and Operation .

Install the rear right wheel housing liner. Refer to Removal and Installation .

Mount the right rear wheel. Refer to Removal and Installation .

Install the right locking flange cover. see scheme 30

Install the right 1/3 rear seat. Refer to Removal and Installation .

Connect the battery and observe safety precautions after connecting battery. Refer to Removal and Installation .

LEAK DETECTION PUMP (LDP) -V144

Removing

Scheme 60

Remove the Evaporative Emission (EVAP) canister. Refer to EVAPORATIVE EMISSION (EVAP) CANISTER .

Unclip the vacuum line bracket -3-.

Remove the bolts -1-.

Remove the LDP -2- from the EVAP canister.

Installing

1. Tightening specification, refer to «EVAP CANISTER AND LEAK DETECTION SYSTEM OVERVIEW»(/audi/q5/i-2008-2012/remont/fuel-system/#fuel-supply-system) .

Install in reverse order, paying attention to the following

Note. Replace the gasket.

Install the EVAP canister. Refer to EVAPORATIVE EMISSION (EVAP) CANISTER .

LEAK DETECTION PUMP (LDP) -V144- AIR FILTER

Removing

Follow all safety precautions. Refer to SAFETY PRECAUTIONS .

Follow the guidelines for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remove the left rear wheel.

Remove the left rear wheel housing liner. Refer to Removal and Installation .

Press the release button and remove the vent line -arrow-.

Scheme 61

Remove the nut -2- and remove the LDP air filter -1-.

Installing

Install in reverse order, paying attention to the following

Tighten the nut for the LDP air filter. (Scheme 12)

Install the rear left wheel housing liner. Refer to Removal and Installation .

Mount the left rear wheel. Refer to Removal and Installation .

Scheme 62

Special tools and workshop equipment required

1. Fuel Inj. Pressure Gauge-CIS V.A.G 1318
2. Adapter V.A.G 1318/11
3. Adapter V.A.G 1318/17-1A
4. Fuel Line Feed Adapter V.A.G 1318/23
5. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-3
6. Connector Test Set V.A.G 1594C

Special tools and workshop equipment required

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. Wrench T10202
2. Pressure Gauge Adapter V.A.G 1318/10-12
3. Pressure Gauge Adapter V.A.G 1318/10-12 and Adapter V.A.G 1318/15
4. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-2
5. Engine/Transmission Jack V.A.G 1383 A
6. Multimeter V.A.G 1526D
7. Fuel Extracting Device VAS 5190
8. Adapter VAS 5190 /1 from the Adapter set for Fuel Extraction VAS 5190 /10

See also:
• Removal and Installation
• Removal and Installation
• [For engine(s) CALB] General Information
• [For engine(s) CALB] Description and Operation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• FUEL TANK, DRAINING
• SAFETY PRECAUTIONS
• CLEAN WORKING CONDITIONS
• FUEL DELIVERY UNIT
• LEAK DETECTION TEST, PERFORMING
• ACCELERATOR PEDAL MODULE WITH Accelerator Pedal Position Sensor -G79- /Accelerator Pedal Position Sensor 2 -G185
• EVAPORATIVE EMISSION (EVAP) CANISTER
• Leak Detection Pump (LDP) -V144
• Leak Detection Pump (LDP) -V144- AIR FILTER
• Transfer Fuel Pump -G6-, CHECKING
• FUEL FILTER
• Fuel Pump (FP) Control Module -J538
• Fuel Level Sensor -G-, CHECKING
• Fuel Level Sensor -G
• EVAP CANISTER
• FUEL TANK WITH ATTACHMENTS
• TEST CONDITIONS
• FUEL PUMP DELIVERY RATE, CHECKING, VEHICLES THROUGH MY 12