3.0l - Fuel Supply System - Engine Code(s): Cata Audi Q7 4L рестайлинг

REDUCING AGENT METERING SYSTEM, SAFETY PRECAUTIONS

Observe the following when working on the reducing agent metering system

Note the following when removing or installing any components of the reducing agent metering system

1. The reducing agent active/passive tanks must be empty when working on the reducing agent metering system. Be sure to read the work procedure whenever the reducing agent in the active or passive tank must be emptied. Drain the active or passive tank, if necessary. For information on the active tank, refer to «REDUCING AGENT ACTIVE TANK, DRAINING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-active-tank-draining) and for the passive tank, refer to «REDUCING AGENT PASSIVE TANK, DRAINING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-passive-tank-draining) .

Note the following when removing and installing the active or passive tank

1. The reducing agent active/passive tank must be empty. Drain the active or passive tank, if necessary. For information on the active tank, refer to «REDUCING AGENT ACTIVE TANK, DRAINING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-active-tank-draining) and for the passive tank, refer to «REDUCING AGENT PASSIVE TANK, DRAINING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-passive-tank-draining) .

FUEL SYSTEM

Note the following when working on the fuel system

To prevent personal injury and damage to the injection and pre-glow system, observe the following

1. The ignition must be switched off before connecting or disconnecting injection and pre-glow system wiring or tester cables.
2. Only clean engine with ignition switched off.
3. If electrical connectors were disconnected and the engine was started, then malfunctions have been stored in the engine control module. "Check DTC memory"

Disconnect battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

WORKING ON VEHICLES WITH START/STOP SYSTEM

When working on a vehicle with the Start/Stop System, note the following

CLEAN WORKING CONDITIONS

Even a little contamination can lead to faults. Observe the following guidelines for cleanliness when working on the fuel system, injection system and turbocharger

1. Thoroughly clean all connections and the surrounding area before disconnecting.
2. Place parts that have been removed on a clean surface and cover them. Use lint-free cloths.
3. Carefully cover over opened components or seal, if repairs are not performed immediately.
4. Only install clean components: Only unpack replacement parts immediately prior to installation. Do not use parts that have been stored unpacked (e.g. in tool boxes etc.).
5. When the system is open: Do not work with compressed air. Do not move vehicle unless absolutely necessary.
6. In addition, do not let diesel fuel flow onto coolant hoses. If necessary, the hoses must be cleaned again immediately. Replace corroded hoses.
7. Protect disconnected electrical connectors from dirt and moisture and only connect if dry.

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) Relay -J17- OK. Refer to appropriate SYSTEM WIRING DIAGRAM.
4. Fuel tank at least 1 / 4 filled.
5. Fuel filter OK (not dirty)
6. Fuel lines OK (not plugged, not kinked).
7. Ignition switched off.

REDUCING AGENT, AUTOMATIC REGENERATING

1. After switching off the ignition, any reducing agent is recirculated from the reducing agent injector -N474- metering line back into the active tank.
2. Before working in this area, wait 10 minutes after switching off the ignition so that the recirculation can complete.
3. Likewise, wait 10 minutes after switching off the ignition before disconnecting the battery so that the recirculation process can complete. Refer to «BATTERY, DISCONNECTING AND CONNECTING»(/audi/q7/4l-2009-2015/remont/charging-system/#battery-starter-generator-cruise-control__battery-disconnecting-and-connecting) .

ADAPTING ADAPTATION VALUE AFTER DRAINING REDUCING AGENT OR REPLACING COMPONENTS

The adaptation value in the engine control module must be adapted with the vehicle tester when the reducing agent is drained or one of the components listed below is replaced.

1. Active tank
2. Reducing agent pump
3. Reducing agent injector
4. Reducing agent line
5. Engine Control Module

Perform the adaptation using

FUEL TANK, DRAINING

Special tools and workshop equipment required

1. Wrench T10202
2. Fuel Extracting Device VAS 5190
3. Carpet knife, commercially available

Procedure

Observe safety precautions. Refer to FUEL SYSTEM .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Switch off ignition and remove ignition key.

Remove the cone piece -2- from the shaft piece -1- on the VAS 5190.

Scheme 82

Using insulating tape, apply a mark -arrow- on hose at length -a- = 1, 775 mm from end of suction hose.

Remove the cap from the fuel filler tube.

Install the shaft piece -1- for the VAS 5190 on the fuel tank filler tube.

Scheme 83

Push the suction hose as far into fuel tank until the mark applied earlier -arrow- is positioned on shaft piece.

Note. If using a siphoning device without shaft piece, proceed principally in the same manner. In this case, apply a mark -arrow- using insulating tape on hose at length -a- = 1, 710 mm from end of suction hose. The suction hose is inserted correctly when the marking applied earlier aligns with the lip of the fuel filler neck. If the hose can only be inserted with difficulty, coat it thinly with engine oil. Never use lubricants containing silicon.

Drain fuel tank through fuel filler tube as much as possible.

Carefully pull out the suction hose.

Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Cut the floor covering at the left along the perforation -arrows- using a standard box cutter -1-.

Scheme 84

Fold carpet cut-out to side -arrow-.

Scheme 85

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

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

Scheme 86

Remove locking ring with T10202.

Scheme 87

Pull the left locking flange -3- slightly out of the fuel tank.

Scheme 88

Disconnect the connector -2- underneath the left locking flange.

Extract the fuel in the left fuel tank chamber using VAS 5190 through the opening in the fuel tank chamber.

Assembly is in reverse order of removal, note the following

1. Tightening specifications, refer to «FUEL DELIVERY UNIT, SUCTION JET PUMP AND FUEL LEVEL SENSOR ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata)

Note. Replace seal.

Install the new sealing ring -1- for the left locking flange dry.

Connect electrical connector -2- underneath the left locking flange.

Bring the left locking flange into the installation position

Scheme 89

1. The tab -2- on left locking flange faces toward the arrow marking and must lie between tabs -1- and -3- on fuel tank.

Tighten the locking ring for the left locking flange with the T10202.

Connect the connector -arrow- at left locking flange.

Install the left locking flange cover. (Scheme 93)

Insert the carpet frame for the service tank access into the floor covering. Refer to Removal and Installation .

Install the left single seat and the left 2/3 seat bench seat cushion in the second row of seats. Refer to 2ND ROW, 2-SEATER .

AUXILIARY FUEL PUMP

Bleed the fuel system. Refer to Diagnosis and Testing

FUEL FILTER

Bleed the fuel system. Refer to Diagnosis and Testing

FUEL SYSTEM, BLEEDING

Bleed the fuel system. Refer to Diagnosis and Testing .

REDUCING AGENT ACTIVE TANK, DRAINING

Special tools and workshop equipment required

1. Reservoir

Procedure

Observe safety precautions. Refer to SAFETY PRECAUTIONS .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

On a vehicle with air suspension, activate vehicle lift mode. Refer to Description and Operation .

Remove the right rear wheel.

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

Note. Place a clean cloth under the separating location to catch any reducing agent that may leak out. Seal off all open lines and connections with clean plugs.

Disconnect the return line -1- on the reducing agent delivery unit by pressing the release button.

Scheme 90

Attach an extension hose -2- to the reducing agent delivery unit connection -arrow- and drain the reducing agent into the container.

Open the fuel tank flap.

Remove the locking cap -2- from the reducing agent filler tube.

Scheme 91

Note. Ignore -1-.

Drain as much of the reducing agent in the active tank through the hose extension as possible.

REDUCING AGENT PASSIVE TANK, DRAINING

Special tools and workshop equipment required

1. Reservoir

Procedure

Observe safety precautions. Refer to SAFETY PRECAUTIONS .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remove the reducing agent passive tank. Refer to REDUCING AGENT PASSIVE TANK .

Seal off the connection -2- on the passive tank with a clean plug.

Attach an extension hose -4- to the connection -3- and place it in a container.

Tip the passive tank to drain as much reducing agent as possible.

Carefully remove the hose -5- from the connection -arrow- and the reducing agent transfer pump -V436- -1-.

Push the hose down and hold it in the container.

Drain the rest of the reducing agent in the passive tank through the hose.

FULL OR PARTIALLY FILLED FUEL TANKS, REMOVING AND INSTALLING

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 fuel tank if necessary. Refer to «FUEL TANK, DRAINING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-tank-draining) .
2. Before starting work, switch on exhaust extraction system and place an extraction hose close to the installation opening of fuel tank to extract escaping fuel fumes. If shop exhaust system is not available, a fan (motor located outside of the air flow) with an air flow rate of at least 15m 3 /h can be used.
3. Prevent fuel from contacting skin! Wear fuel-resistant gloves!

Scheme 92

1. Fuel Return Line From the fuel system cooler To disconnect, press release button on connection piece Clipped in on fuel tank
2. Fuel Supply Line To fuel filter To disconnect, press release button on connection piece Clipped in on fuel tank
3. Bolt Tightening order «FUEL TANK WITH ATTACHMENTS»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-tank-with-attachments) 33 Nm
4. Securing Strap Right rear Note installation position
5. Bolt Tightening order «FUEL TANK WITH ATTACHMENTS»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-tank-with-attachments) 33 Nm
6. Securing Strap Right rear Note installation position
7. Nut 9 Nm
8. Protective Plate For fuel filler tube
9. Overflow Hose
10. Rubber Gasket
11. Cap Secured to the fuel filler door with a retainer
12. Bolt 5 Nm
13. Ground (GND) Connection For discharging electrostatic charge Make sure the connector fits securely on the fuel filler tube metal ring After installing, check the fuel filler neck electrical connection to a bare area of the chassis using an Ohm meter - Specified value: approximately 0ohms
14. Bolt 9 Nm
15. Line Bracket
16. Carrier Plate
17. Bolt Tightening order «FUEL TANK WITH ATTACHMENTS»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-tank-with-attachments) 33 Nm
18. Fuel Tank With heat shield Removing and installing, refer to «FUEL TANK WITH ATTACHMENTS»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-tank-with-attachments)
19. Securing Strap Left Note installation position
20. Bolt Tightening order «FUEL TANK WITH ATTACHMENTS»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-tank-with-attachments) 33 Nm
21. Transfer Line From the reducing agent transfer pump -V436- to the active tank Clipped in on fuel tank
22. Metering Line From the reducing agent pump -V437- to the reducing agent injector -N474- Clipped in on fuel tank
23. Vent Line From the passive tank to the active tank Clipped in on fuel tank
24. Filling Line From the passive tank to the active tank Clipped in on fuel tank

Tighten the nuts -1 through 4- to 9 Nm

Scheme 93

Route Ground (GND) connection -1- as shown in illustration.

Ensure connector of Ground (GND) connection fits securely at metal ring of fuel filler tube.

Note. Ignore -item 2-.

Scheme 94

1. Fuel Level Sensor -G- Clipped in at retaining ring -item 16- Resistance values, checking, refer to «FUEL LEVEL SENSOR, CHECKING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-level-sensor-checking) Removing and installing, refer to «FUEL LEVEL SENSOR»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-level-sensor)
2. Fuel Delivery Unit With Transfer Fuel Pump (FP) -G6- Checking Transfer Fuel Pump (FP) -G6- electrically, refer to «TRANSFER FUEL PUMP IN FUEL TANK, CHECKING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__transfer-fuel-pump-in-fuel-tank) Insert in the retaining ring -item 16- and turn 15° clockwise to engage (bayonet connection) Removing and installing, refer to «FUEL DELIVERY UNIT AND TRANSFER FUEL PUMP»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-delivery-unit-and-transfer-fuel) After installing, fuel vehicle with at least 5 liters of fuel
3. Right Locking Flange Installed location «FUEL DELIVERY UNIT AND TRANSFER FUEL PUMP»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-delivery-unit-and-transfer-fuel)
4. Seal Replace Install dry
5. Locking Ring Use wrench T10202 for removal and installation Tighten to 110 Nm.
6. Electrical Harness Connector For transfer fuel pump -G6- and fuel level sensor -G
7. Fuel Return Line From the fuel system cooler To disconnect, press release button on connection piece Do not kink Clipped in on fuel tank
8. Fuel Supply Line To fuel filter To disconnect, press release button on connection piece Do not kink Clipped in on fuel tank
9. Electrical Harness Connector For fuel level sensor 2 -G169
10. Locking Ring Use wrench T10202 for removal and installation Tighten to 110 Nm.
11. Seal Replace Install dry
12. Left Locking Flange Installed location «FUEL LEVEL SENSOR 2»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-level-sensor-2)
13. Suction Jet Pump Clipped in at retaining ring -item 14- Removing and installing, refer to «SUCTION JET PUMP»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__suction-jet-pump) After installing, fuel vehicle with at least 5 liters of fuel
14. Retaining Ring Welded to fuel tank
15. Fuel Level Sensor 2 -G169- Clipped in at retaining ring -item 14- Resistance values, checking, refer to «FUEL LEVEL SENSOR 2, CHECKING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-level-sensor-2-checking) Removing and installing, refer to «FUEL LEVEL SENSOR 2»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-level-sensor-2)
16. Retaining Ring Welded to fuel tank

SUCTION JET PUMP ASSEMBLY OVERVIEW

1. Fuel tank is divided into a left and a right chamber. Use a suction jet pump -3- to move fuel from left fuel tank chamber to the right one for the fuel delivery unit baffle housing -1-.
2. Function of the suction jet pump is based on a simple physical principle: A nozzle in the suction jet pump -3- compresses and accelerates the suction jet from the right fuel pump supply pipe -1-. This acceleration draws the surrounding fuel in and forces it to the fuel delivery unit baffle housing

Scheme 95

1. Fuel Delivery Unit With Transfer Fuel Pump (FP) -G6
2. Suction Jet Pipe To disconnect, press release button on connection piece
3. Suction Jet Pump
4. Fuel Supply Line Clipped on the right fuel delivery unit

Scheme 96

1. Electrical Harness Connector
2. Nut 9 Nm
3. Bracket For auxiliary fuel pump -V393
4. Rubber Bracket Installed with the nubs into the bracket -3
5. Secure the fuel line from the connector flange of the fuel tank using hose clamps appropriate for the model type To engine
6. Auxiliary Fuel Pump -V393- Fuel Delivery, Checking, refer to «AUXILIARY FUEL PUMP, CHECKING DELIVERY QUANTITY»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__auxiliary-fuel-pump-checking-delivery) Removing and installing, refer to «AUXILIARY FUEL PUMP»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata)
7. Rubber Bracket Installed with the nubs into the bracket -3
8. Secure the fuel line from the connector flange of the fuel tank using hose clamps appropriate for the model type From fuel filter

Scheme 97

1. Coolant Hose
2. Coolant Hose
3. Fuel Return Hose To fuel tank
4. Fuel Return Hose From fuel filter
5. Radiator For the fuel system Removing and installing, refer to «FUEL SYSTEM COOLER»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-system-cooler)
6. Nut 8 Nm
7. Bolt 8 Nm
8. Bracket
9. Spring-Type Clip

Scheme 98

1. Bolt 8 Nm
2. Fuel Filter Housing Removing and installing, refer to «FUEL FILTER»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata)
3. Spring-Type Clip
4. Fuel Supply Hose From fuel tank Connection identified by "VF" on the filter housing cover
5. Bolt 8 Nm
6. Fuel Return Hose From engine Connection identified by "RF" on the filter housing cover
7. Bleeder Screw 5 Nm
8. Seal Replace
9. Fuel Supply Hose To the auxiliary fuel pump Connection identified by "VM" on the filter housing cover
10. Fuel Return Hose To fuel cooler Connection identified by "RT" on the filter housing cover
11. Filter Housing Cover Flow direction is identified Do not interchange connections
12. Gasket Available as a replacement part only with -13
13. Filter Element
14. Gasket Available as a replacement part only with -13
15. Bolt 8 Nm
16. Nut 8 Nm

REDUCING AGENT ACTIVE TANK AND ATTACHMENTS ASSEMBLY OVERVIEW

Note. Component location: Under wheel housing liner in right rear wheel housing.

Scheme 99

1. Union Nut Use wrench T50014 for removal and installation Tightening «REDUCING AGENT DELIVERY UNIT»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-delivery-unit)
2. Reducing Agent Delivery Unit With reducing agent tank sensor -G684- With reducing agent temperature sensor -G685- With Reducing Agent Tank Heater -Z102- With filter Removing and installing, refer to «REDUCING AGENT DELIVERY UNIT»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-delivery-unit)
3. Seal Replace Install dry
4. Bolt 9 Nm
5. Active Tank For reducing agent Removing and installing, refer to «REDUCING AGENT ACTIVE TANK»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-active-tank)
6. Transfer Line From the reducing agent transfer pump -V436- to the active tank Clipped in on fuel tank
7. Cap
8. Filling Line From the active tank to the passive tank Clipped in on fuel tank
9. Reducing Agent Pump -V437- With reducing agent pump heater -Z103- With reducing agent metering system pressure sensor -G686- Removing and installing, refer to «REDUCING AGENT PUMP»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-pump) WARNING: Danger due to reducing agent leaking out. To prevent large amounts of reducing agent when opening the metering line, wait for the recirculation process to complete. Refer to «REDUCING AGENT, AUTOMATIC REGENERATING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-automatic-regenerating) .
10. Metering Line From the reducing agent pump -V437- to the reducing agent injector -N474- Clipped in on fuel tank WARNING: Danger due to reducing agent leaking out. To prevent large amounts of reducing agent when opening the metering line, wait for the recirculation process to complete. Refer to «REDUCING AGENT, AUTOMATIC REGENERATING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-automatic-regenerating) .
11. Bolt 1.8 Nm
12. Return Line Clip onto the active tank
13. Supply Line Clip onto the active tank

REDUCING AGENT PASSIVE TANK AND ATTACHMENTS ASSEMBLY OVERVIEW

Note. Component location: Lower left on the underbody.

Scheme 100

1. Lock Washer 1.5 Nm
2. Underbody Protection
3. Bolt 60 Nm
4. Passive Tank For reducing agent Removing and installing, refer to «REDUCING AGENT PASSIVE TANK»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-passive-tank)
5. Bolt 35 Nm
6. Filling Line From the active tank Clipped in on fuel tank
7. Vent Line To the active tank Clipped in on fuel tank
8. Metering Line From the reducing agent pump -V437- to the reducing agent injector -N474- With reducing agent tank heater -Z104- Clipped in on fuel tank WARNING: Danger due to reducing agent leaking out. To prevent large amounts of reducing agent when opening the metering line, wait for the recirculation process to complete. Refer to «REDUCING AGENT, AUTOMATIC REGENERATING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-automatic-regenerating) .
9. Transfer Line To the active tank Clipped in on fuel tank
10. Bolt 1.8 Nm
11. Reducing Agent Transfer Pump -V436- Removing and installing, refer to «REDUCING AGENT TRANSFER PUMP»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-transfer-pump)
12. Hose From the passive tank to the reducing agent transfer pump -V436
13. Mounting Straps
14. Bolt 35 Nm

REDUCING AGENT METERING SYSTEM CONTROL MODULE ASSEMBLY OVERVIEW

Note. Component location: The reducing agent metering system control module -J880- is located on the right side under the rear bench seat, directly below the floor covering.

Scheme 101

1. Bracket
2. Nut 2 Nm
3. Reducing Agent Metering System Control Module -J880- Removing and installing, refer to «REDUCING AGENT METERING SYSTEM CONTROL MODULE»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-metering-system-control-module)
4. Nut 2 Nm

Scheme 102

1. Bolt 10 Nm
2. Accelerator Pedal Module With Throttle Position (TP) Sensor -G79- and Accelerator Pedal Position Sensor 2 -G185- Removing and installing, refer to «ACCELERATOR PEDAL MODULE WITH ACCELERATOR PEDAL POSITION SENSOR»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__accelerator-pedal-module-with-accelerator-pedal) Perform after the first kick-down adaptation in .
3. Electrical Harness Connector
4. Bolt 10 Nm
5. Lower Driver's Side Instrument Panel Cover Mount

FASTENER TIGHTENING SPECIFICATIONS

Locking Flange Cover - Tightening Specifications

Tighten the nuts -1 through 4- to 9 Nm

TRANSFER FUEL PUMP IN FUEL TANK, CHECKING

Special tools and workshop equipment required

1. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-3
2. Hand-Held Multimeter V.A.G 1526D
3. Connector Test Set V.A.G 1594C

Procedure

Observe test conditions. Refer to TEST CONDITIONS .

Open the left plenum chamber cover -1- above the E-box.

Scheme 103

Turn the quick-release fasteners -1, 3 and 4- counter-clockwise 90° -arrows-.

Scheme 104

Remove the relay/fuse holder cover -2-.

Remove the fuel pump fuse in the relay/fuse holder in the E-box on the left side of the plenum chamber. Refer to appropriate SYSTEM WIRING DIAGRAM.

Scheme 105

Cover 2nd connector -arrow 2- terminal of V.A.G 1348/3-3. with insulating tape to prevent short circuit

Scheme 106

Connect the V.A.G 1348/3A and V.A.G 1348/3-3 to the left terminal -arrow 1- on the fuse pump fuse socket. Refer to appropriate SYSTEM WIRING DIAGRAM.

Release the clip and open the positive terminal pick-off cover -A-.

Connect alligator clip to positive terminal pick-off.

Press the switch on the remote control.

1. It must be possible to hear pump noise near the right fuel tank.

Note. Fuel Pump (FP) runs quietly. Avoid surrounding noises while testing the fuel pump.

If no noise is heard, remove the fuel delivery unit. Refer to FUEL DELIVERY UNIT AND TRANSFER FUEL PUMP .

Check if the electrical wiring between the flange and fuel pump is connected and has continuity.

Scheme 107

If no malfunction is detected in the wires, the fuel pump is faulty. Replace the fuel delivery unit.

Install the fuel delivery unit FUEL DELIVERY UNIT AND TRANSFER FUEL PUMP .

TRANSFER FUEL PUMP IN FUEL TANK, CHECKING DELIVERY RATE

Special tools and workshop equipment required

1. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-3
2. Measuring container, fuel-resistant

Procedure

Observe test conditions. Refer to TEST CONDITIONS .

Open the left plenum chamber cover -1- above the E-box.

Turn the quick-release fasteners -1, 3 and 4- counter-clockwise 90° -arrows-.

Remove the relay/fuse holder cover -2-.

Remove the fuel pump fuse in the relay/fuse holder in the E-box on the left side of the plenum chamber. Refer to appropriate SYSTEM WIRING DIAGRAM.

Cover 2nd connector -arrow 2- terminal of V.A.G 1348/3-3 with insulating tape to prevent short circuit.

Connect the V.A.G 1348/3A and V.A.G 1348/3-3 to the left terminal -arrow 1- on the fuse pump fuse socket. Refer to appropriate SYSTEM WIRING DIAGRAM.

Release the clip and open the positive terminal pick-off cover -A-.

Connect alligator clip to positive terminal pick-off.

Remove the cap from the fuel filler tube.

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

Remove the fuel supply hose -1- from the fuel tank at the fuel filter.

Scheme 108

Note. Disregard the other items.

Hold the remove fuel supply hose -arrow- in a measuring container.

Scheme 109

Note. Attach an extension hose to the fuel supply hose if necessary.

Press the switch on the remote control for 15 seconds.

Scheme 110

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

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

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

1. The fuel tank does not have enough fuel in it.
2. Fuel lines pinched.
3. Fuel pump faulty.

Note. This test does not check if the fuel filter is clogged; check the filter separately if necessary.

FUEL LEVEL SENSOR, CHECKING

Special tools and workshop equipment required

1. Hand-Held Multimeter V.A.G 1526D
2. Connector Test Set V.A.G 1594 C
3. Carpet knife, commercially available

Procedure

Remove the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Cut the floor covering at the right along the perforation -arrows- using a standard box cutter -1-.

Fold carpet cut-out to side -arrow-.

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

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

Scheme 111

Note. Ignore -1 and 2-.

Connect multimeter between terminal -2- and -3- for resistance measurement.

Scheme 112

Fuel Level Sensor -G- installed

1. Sensor at lower stop: 863 to 960 ohms.
2. Sensor at upper stop: 67 to 86 ohms.

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

Fuel Level Sensor -G- removed

1. Sensor at lower stop: about 990 ohms
2. Sensor at upper stop: about 51 ohms

Assembly is in reverse order of removal, note the following

Connect the connector -3- at right locking flange.

Note. Ignore -1 and 2-.

Install the right locking flange cover. (Scheme 93)

Insert the carpet frame for the service tank access into the floor covering. Refer to Removal and Installation .

Install the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

FUEL LEVEL SENSOR 2, CHECKING

Special tools and workshop equipment required

1. Hand-Held Multimeter V.A.G 1526D
2. Connector Test Set V.A.G 1594 C
3. Carpet knife, commercially available

Procedure

Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Cut the floor covering along the perforation -arrows- using a standard box cutter -1-.

Fold carpet cut-out to side -arrow-.

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

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

Connect multimeter between terminal -2- and -3- for resistance measurement.

Scheme 113

Fuel level sensor 2 -G169- installed

1. Sensor at lower stop: 760 to 842 ohms.
2. Sensor at upper stop: 67 to 86 ohms.

Note. If measured value is 0 ohms there is a short circuit. If measured value is infinity ohms there is and open circuit in the wiring. To check resistance values "tank full" or "tank empty", the fuel level sensor 2 -G169- must be removed. Refer to FUEL LEVEL SENSOR 2 and the sensor floater must be placed in upper or lower end position. With fuel level sensor 2 -G169- removed, the following values are obtained because of the greater deflection of the floater arm

Fuel level sensor 2 -G169- removed

1. Sensor at lower stop: about 990 ohms
2. Sensor at upper stop: about 51 ohms

Assembly is in reverse order of removal, note the following

Connect the connector -arrow- at left locking flange.

Install the left locking flange cover. (Scheme 93)

Insert the carpet frame for the service tank access into the floor covering. Refer to Removal and Installation .

Install the left single seat and the left 2/3 seat bench seat cushion in the second row of seats. Refer to 2ND ROW, 2-SEATER .

AUXILIARY FUEL PUMP, CHECKING DELIVERY

Special tools and workshop equipment required

1. Vehicle Diagnostic, Testing and Information System, for example Vehicle Diagnostic, Testing and Information System VAS 5051B
2. Hose with inner diameter 8 mm, fuel resistant
3. Measuring container, fuel-resistant

Procedure

1. The transfer fuel pump -G6- delivery rate is OK. Refer to «TRANSFER FUEL PUMP IN FUEL TANK, CHECKING DELIVERY RATE»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__transfer-fuel-pump-in-fuel-tank) .

Observe test conditions. Refer to TEST CONDITIONS .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Carefully pull the engine cover off the 4 bolts one after the other -arrows-.

Scheme 114

Disconnect the fuel supply hose -1-.

Scheme 115

Note. Ignore -2-.

Connect the fuel resistant hose to the fuel supply line -arrow- and hold it inside a fuel resistant container.

Scheme 116

Vehicle Diagnostic, Testing and Information System, for example Vehicle Diagnostic, Testing and Information System VAS 5051B, switch on the ignition.

Press the button Parameter .

Press the Start button, wait 15 seconds and then press the Stop button.

Check the amount of fuel in the measuring container.

1. Specified value: About 1 liter at minimum 12.5V 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 in reverse order of removal, note the following

Note. Secure all hose connections with hose clamps appropriate for the mode.

FUEL SYSTEM, CHECKING FOR LEAKS

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

The following can occur if there are leaks in the fuel system

1. Foam or air bubbles can form in the supply line.
2. Lack of performance, misfire.
3. Starting difficulties.

Check the fuel tank system and the fuel lines for leaks.

Check whether seals under locking flanges are OK and lock rings are properly tightened on fuel tank.

Check all fuel lines, components and hose connections in the fuel tank system

1. Fuel lines to engine.
2. Fuel lines to the fuel tank.
3. Fuel Filter
4. Fuel Tank

REDUCING AGENT METERING SYSTEM CONTROL MODULE, CHECKING

1. The voltage for the reducing agent metering system control module -J880- is supplied by the reducing agent transfer pump -V436-.
2. Reducing agent metering system control module -J880- testing occurs in .

FUEL TANK WITH ATTACHMENTS

Special tools and workshop equipment required

1. Engine/Transmission Jack V.A.G 1383 A
2. Support T10031
3. Carpet knife, commercially available

Removing

Observe safety precautions. Refer to FUEL SYSTEM .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Fuel Tank, Emptying. Refer to FUEL TANK, DRAINING .

On a vehicle with air suspension, activate vehicle lift mode. Refer to Description and Operation .

Switch off ignition and remove ignition key.

Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Remove the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Cut the floor covering at the left and right along the perforation -arrows- using a standard box cutter -1-.

Fold carpet cut-out to side -arrow-.

Remove the left and right nuts on the locking flange cover -1 to 4- and then remove the cover.

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

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

Disconnect the fuel return line -1- and the fuel supply line -2- from the right locking flange by pressing the release buttons.

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

Open the fuel tank flap.

Clean the area around the fuel filler tube.

Remove the locking cap -1- from the fuel filler tube.

Remove the locking cap -2- from the reducing agent filler tube.

Note. Seal the openings on the filler neck with clean plugs to prevent dirt from entering the chambers.

Remove the tank door unit and the rubber buffer. Refer to Removal and Installation .

Scheme 117

Remove the fuel filler tube bolts -arrows-.

Remove rear axle. Refer to Removal and Installation .

Hang driveshaft -1- on body with a suitable chain or with welding wire as shown in illustration -arrows-.

Scheme 118

Note. Driveshaft CV joints must only be moved without force and only as far as stop which is approximately a 10° angle.

Lower driveshaft by dimension -a-.

1. Dimension -a- = 220 mm.

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

Remover the reducing agent active tank. Refer to REDUCING AGENT ACTIVE TANK .

Disconnect the Ground (GND) wire -1- from the fuel filler tube.

Remove the fuel filler tube bolts -arrows-.

Remove the nuts -arrows- and then remove the fuel filler tube protective plate -3-.

Scheme 119

Drive pins -1- through with a punch.

Remove the bracket -2- with the lines from the longitudinal member.

Remove the left and right bolts on the floor panel trim near the fuel tank. Refer to Removal and Installation .

Remove the reducing agent passive tank. Refer to REDUCING AGENT PASSIVE TANK .

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

Remove the metering line -2- by pressing the release button.

Disconnect electrical connector -1-.

Unclip the fuel supply line -1- and the fuel return line -2- on the fuel tank -arrows-.

Scheme 120

Unclip parking brake cable bracket -3- at fuel tank.

Place V.A.G 1383 A with T10031 (without threaded rods) under fuel tank for support, as shown in illustration.

Scheme 121

1. The T10031 mounting plates must be positioned near the round impressions in the bottom of the fuel tank.

Support fuel tank with V.A.G 1383 A and T10031.

A 2nd technician must also support fuel tank by hand.

Identify location of fuel tank securing bands.

Scheme 122

Remove bolts -1 to 10- and remove securing bands and carrier plate.

Note. To improve clarity, the fuel tank is shown without the Engine/Transmission Jack.

Next lower back of fuel tank to driveshaft.

A second technician must also support the fuel tank by hand at the rear edge.

Carefully guide filler tube out of wheel housing so avoid paint damage.

Lower fuel tank with Engine/Transmission Jack V.A.G 1383 A while a 2nd technician guides it.

Installing

1. Tightening specifications, refer to «FUEL TANK WITH ATTACHMENTS ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata) .

Make sure the lines are clipped to the fuel tank.

Position fuel tank on the vehicle underbody using the tensioning bands and carrier plate with the V.A.G 1383 A and T10031.

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

Tighten the bolts in the sequence described to secure the fuel tank to the vehicle underbody.

Carrier plate -7, 8, 9, 10-.

Rear left and right tensioning band -1, 4, 5, 6-.

Front right tension strap -2, 3-.

Tighten the fuel filler tube bolt -2-.

Check if the Ground (GND) wiring -1- and the contact show signs of oxidation. If necessary, remove.

Tighten the fuel filler tube -arrows-.

The rest of the installation is in reverse order of removal, note the following

Install the rubber buffer and the fuel door unit. Refer to Removal and Installation .

Install rear axle. Refer to Removal and Installation .

Tighten the left and right floor panel trim in the center. Refer to Removal and Installation .

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

On a vehicle with air suspension, deactivate vehicle lift mode. Refer to Description and Operation .

Install the locking flange covers. Refer to

Install the left single seat and the left 2/3 seat bench seat cushion in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Install the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

FUEL DELIVERY UNIT AND TRANSFER FUEL PUMP

Special tools and workshop equipment required

1. Wrench T10202
2. Carpet knife, commercially available

Removing

Observe safety precautions. Refer to FUEL SYSTEM .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

1. The fuel tank must be completely empty to remove the fuel delivery unit. Procedure to empty the fuel tank. Refer to «FUEL TANK, DRAINING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-tank-draining) .

Remove the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Cut the floor covering at the right along the perforation -arrows- using a standard box cutter -1-.

Fold carpet cut-out to side -arrow-.

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.

Disconnect the fuel return line -1- and the fuel supply line -2- from the right locking flange by pressing the release buttons.

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

Remove locking ring with T10202.

Pull the right locking flange off the fuel tank slightly.

Disconnect the connectors -1- and -2- underneath the right locking flange.

Scheme 123

Disconnect the fuel lines -1- and -3- underneath right locking flange by pressing the release button.

Scheme 124

Reach into the opening in the fuel tank and disconnect the auxiliary heater supply line -5- from the fuel delivery unit by pressing the releases.

Remove the right locking flange -2- and sealing ring -4-.

Reach into the opening in the fuel tank and disconnect the delivery line -7- by pressing the releases.

Disconnect the suction jet pipe -6- to suction jet pump by pressing release button.

Reach into the opening in the fuel tank and turn the fuel delivery unit -1- counterclockwise 15° -arrow- to release (bayonet connection).

Scheme 125

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

1. The notch -3- on the fuel delivery unit then aligns with the retaining ring tab -4-.

Remove the fuel line out of the opening in the fuel tank and remove the fuel delivery unit upward.

Note. Be sure there is still some fuel inside the fuel delivery unit.

Installing

1. Tightening specifications, refer to «FUEL DELIVERY UNIT, SUCTION JET PUMP AND FUEL LEVEL SENSOR ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata) .

Installation is in reverse order of removal, note the following

Note. Replace seals.

Install the fuel delivery unit into the fuel tank.

1. The notch -3- on the fuel delivery unit then aligns with the retaining ring tab -4-.
2. It must be possible to push the fuel delivery unit downward.

Turn the fuel delivery unit -1- clockwise 15° to secure (bayonet connection).

Push the suction jet pipe -6- onto the suction jet pump until it engages audibly.

Attach the supply line -7- until it audibly latches to the fuel delivery unit.

Attach the supply line -5- to the auxiliary heater until it audibly latches to the fuel delivery unit.

Attach the fuel lines -1- and -3- to the right locking flange -2- until they audibly engage.

Install the new sealing ring -4- for the right locking flange dry.

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

Bring the right locking flange into the installation position

Scheme 126

1. Tab -2- on right locking flange faces toward arrow marking and must lie between tabs -1- and -3- on fuel tank.

Tighten the locking ring for the right locking flange with the T10202.

Connect the fuel return line -1- and the fuel supply line -2- to the right locking flange.

Connect the connector -3- at right locking flange.

Install the right locking flange cover. (Scheme 93)

Insert the carpet frame for the service tank access into the floor covering. Refer to Removal and Installation .

Install the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

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

FUEL LEVEL SENSOR

Special tools and workshop equipment required

1. Wrench T10202
2. Carpet knife, commercially available

Removing

Observe safety precautions. Refer to FUEL SYSTEM .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

1. The fuel tank must be completely empty to remove the fuel level sensor -G-. To empty the fuel tank. Refer to «FUEL TANK, DRAINING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-tank-draining) .

Remove the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Cut the floor covering at the right along the perforation -arrows- using a standard box cutter -1-.

Fold carpet cut-out to side -arrow-.

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.

Disconnect the fuel return line -1- and the fuel supply line -2- from the right locking flange by pressing the release buttons.

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

Remove locking ring with T10202.

Pull the right locking flange off the fuel tank slightly.

Disconnect the connectors -1- and -2- underneath the right locking flange.

Disconnect the fuel lines -1- and -3- underneath right locking flange by pressing the release button.

Reach into the opening in the fuel tank and disconnect the auxiliary heater supply line -5- from the fuel delivery unit by pressing the releases.

Remove the right locking flange -2- and sealing ring -4-.

Note. Ignore -6 and 7-.

Grasp in fuel tank opening and remove fuel level sensor G through guide -arrow 2- while pressing locking tab -arrow 1-.

Scheme 127

Note. Fuel Level Sensor G is shown without fuel tank to provide a better illustration.

Installing

1. Tightening specifications, refer to «FUEL DELIVERY UNIT, SUCTION JET PUMP AND FUEL LEVEL SENSOR ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata) .

Installation is in reverse order of removal, note the following

Note. Replace seals.

Insert fuel level sensor -G- into guide until it engages audibly.

Attach the supply line -5- to the auxiliary heater until it audibly latches to the fuel delivery unit.

Attach the fuel lines -1- and -3- to the right locking flange -2- until they audibly engage.

Install the new sealing ring -4- for the right locking flange dry.

Note. Ignore items -6 and 7-.

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

Bring the right locking flange into the installation position

1. Tab -2- on right locking flange faces toward arrow marking and must lie between tabs -1- and -3- on fuel tank.

Tighten the locking ring for the right locking flange with the T10202.

Connect the fuel return line -1- and the fuel supply line -2- to the right locking flange.

Connect the connector -3- at right locking flange.

Install the right locking flange cover. (Scheme 93)

Insert the carpet frame for the service tank access into the floor covering. Refer to Removal and Installation .

Install the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

FUEL LEVEL SENSOR 2

Special tools and workshop equipment required

1. Carpet knife, commercially available

Removing

Observe safety precautions. Refer to FUEL SYSTEM .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

1. The fuel tank must be completely empty to remove the fuel level sensor 2 -G169-. To empty the fuel tank. Refer to «FUEL TANK, DRAINING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__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 2ND ROW, 2-SEATER .

Cut the floor covering at the left along the perforation -arrows- using a standard box cutter -1-.

Fold carpet cut-out to side -arrow-.

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

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

Remove locking ring with T10202.

Pull the left locking flange -3- slightly out of the fuel tank.

Disconnect the connector -2- underneath the left locking flange.

Remove the sealing ring -1- from the fuel tank.

Reach into the fuel tank opening and remove fuel level sensor 2 -G169- out of the guide -4- -arrow 2-. -3- by pressing the release tab -arrow 1-.

Scheme 128

Installing

1. Tightening specifications, refer to «FUEL DELIVERY UNIT, SUCTION JET PUMP AND FUEL LEVEL SENSOR ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata) .

Installation is in reverse order of removal, note the following

Note. Replace seal.

Insert fuel level sensor 2 -G169- in guide until it engages audibly.

Connect electrical connector -2- underneath the left locking flange -3-.

Install the new sealing ring -1- for the left locking flange dry.

Bring the left locking flange into the installation position

1. The tab -2- on left locking flange faces toward the arrow marking and must lie between tabs -1- and -3- on fuel tank.

Tighten the locking ring for the left locking flange with the T10202.

Connect the connector -arrow- at left locking flange.

Install the left locking flange cover. (Scheme 93)

Insert the carpet frame for the service tank access into the floor covering. Refer to Removal and Installation .

Install the left single seat and the left 2/3 seat bench seat cushion in the second row of seats. Refer to 2ND ROW, 2-SEATER .

SUCTION JET PUMP

Special tools and workshop equipment required

1. Wrench T10202
2. Carpet knife, commercially available

Removing

Observe safety precautions. Refer to FUEL SYSTEM .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

1. To remove suction jet pump, fuel tank should be completely empty. Procedure to empty the fuel tank. Refer to «FUEL TANK, DRAINING»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__fuel-tank-draining) .

Remove the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Cut the floor covering at the right along the perforation -arrows- using a standard box cutter -1-.

Fold carpet cut-out to side -arrow-.

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.

Disconnect the fuel return line -1- and the fuel supply line -2- from the right locking flange by pressing the release buttons.

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

Remove locking ring with T10202.

Pull the right locking flange off the fuel tank slightly.

Disconnect the connectors -1- and -2- underneath the right locking flange.

Disconnect the fuel lines -1- and -3- underneath right locking flange by pressing the release button.

Reach into the opening in the fuel tank and disconnect the auxiliary heater supply line -5- from the fuel delivery unit by pressing the releases.

Remove the right locking flange -2- and sealing ring -4-.

Reach into the opening in the fuel tank and disconnect the delivery line -7- by pressing the releases.

Disconnect the suction jet pipe -6- to suction jet pump by pressing release button.

Remove the left single seat and the left 2/3 seat bench seat cushion in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Cut the floor covering at the left along the perforation -arrows- using a standard box cutter -1-.

Fold carpet cut-out to side -arrow-.

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

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

Remove locking ring with T10202.

Pull the left locking flange -3- slightly out of the fuel tank.

Disconnect the connector -2- underneath the left locking flange.

Remove the sealing ring -1- from the fuel tank.

Reach into the fuel tank opening and remove fuel level sensor 2 -G169- out of the guide -4- -arrow 2-. -3- by pressing the release tab -arrow 1-.

Remove suction jet pump from guide -3- -arrow 2- by pressing locking tabs at the same time -arrow 1-.

Scheme 129

Note. The suction jet pump is illustrated without the fuel tank.

Carefully remove suction jet pump -4- through the fuel tank opening.

Installing

1. Tightening specifications, refer to «FUEL DELIVERY UNIT, SUCTION JET PUMP AND FUEL LEVEL SENSOR ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata) .

Installation is in reverse order of removal, note the following

Note. Replace seals. Verify that the suction jet pump is securely engaged.

Push the suction jet pump fuel lines through the left opening on the fuel tank into the right fuel tank chamber.

Insert the suction jet pump into guide and press it down until it audibly engages.

Insert fuel level sensor 2 -G169- in guide until it engages audibly.

Connect electrical connector -2- underneath the left locking flange -3-.

Install the new sealing ring -1- for the left locking flange dry.

Bring the left locking flange into the installation position

1. The tab -2- on left locking flange faces toward the arrow marking and must lie between tabs -1- and -3- on fuel tank.

Tighten the locking ring for the left locking flange with the T10202.

Connect the connector -arrow- at left locking flange.

Push the suction jet pipe -6- onto the suction jet pump until it engages audibly.

Attach the supply line -7- until it audibly latches to the fuel delivery unit.

Attach the supply line -5- to the auxiliary heater until it audibly latches to the fuel delivery unit.

Attach the fuel lines -1- and -3- to the right locking flange -2- until they audibly engage.

Install the new sealing ring -4- for the right locking flange dry.

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

Bring the right locking flange into the installation position

1. Tab -2- on right locking flange faces toward arrow marking and must lie between tabs -1- and -3- on fuel tank.

Tighten the locking ring for the right locking flange with the T10202.

Connect the fuel return line -1- and the fuel supply line -2- to the right locking flange.

Connect the connector -3- at right locking flange.

Install the locking flange covers. (Scheme 93)

Insert the carpet frame for the service tank access into the floor covering. Refer to Removal and Installation .

Install the single seat cushion or the 2/3 seat bench in the 2nd row of seats. Refer to 2ND ROW, 2-SEATER .

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

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Dia. 3094

Removing

Disconnect the connector -4- and the auxiliary fuel pump -V393- -2-.

Scheme 130

Note. Place a cloth underneath to catch any leaking fuel.

Clamp off the fuel hoses -1- and -3- with 3094.

Remove the fuel hoses from the auxiliary fuel pump -V393-.

Spray the rubber nobs -2- and -4- on the rubber bracket for the auxiliary fuel pump -V393- -3- with a silicone-free lubricating spray.

Scheme 131

Remove the rubber nobs from the auxiliary fuel pump -V393- bracket -1-.

Installing

Installation is in reverse order of removal, note the following

Bleed the fuel system. Refer to Diagnosis and Testing .

FUEL SYSTEM COOLER

Note. The fuel system cooler is located at the left front of the engine compartment behind the fuel filter.

Special tools and workshop equipment required

1. Hose Clamp Pliers V.A.G 1921
2. Hose Clamps Up to 25 mm Dia 3094
3. Reservoir

Removing

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Open the cap on the coolant reservoir.

Remove the fuel filter from the bracket, the fuel hoses remain connected to the fuel filter. Refer to FUEL FILTER .

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

Remove the fuel return hose -3- from the fuel system cooler and the fuel filter with the hoses still connected and lay them to the side.

Scheme 132

Clamp off the coolant hoses -1 and 2- using 3094 and remove them from the fuel system cooler.

Remove the fuel return hose -6- from the fuel cooler.

Remove the bolt -5- and the fuel system cooler -4- from the bracket.

Installing

1. Tightening specifications. Refer to «FUEL SYSTEM COOLER ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata) .

Installation is in reverse order of removal, note the following

Note. Secure all hose connections with spring-type clamps appropriate for the model.

Install the fuel filter. Refer to FUEL FILTER .

Fill with coolant and check the level. Refer to General Information .

Special tools and workshop equipment required

1. Hose Clamp Pliers V.A.G 1921

Removing

Observe safety precautions. Refer to FUEL SYSTEM .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

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

Remove the fuel hoses -1, 2, 3 and 4- from the fuel filter.

Remove the bolts -5- and -7- as well as the nut -6-.

Remove the fuel filter.

Installing

1. Tightening specifications. Refer to «FUEL FILTER ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata) .

Installation is in reverse order of removal, note the following

Note. Secure all hose connections with spring-type clamps appropriate for the model.

Connect the fuel hoses as follows

VF - Supply hose to the fuel filter

VM - Supply hose to the engine

RF -Return hose to the fuel filter

RT -Return line to the fuel cooler

Bleed the fuel system. Refer to Diagnosis and Testing .

REDUCING AGENT PUMP

Removing

Observe safety precautions. Refer to SAFETY PRECAUTIONS .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Switch off ignition and remove ignition key.

Reducing Agent Active Tank, Draining. Refer to REDUCING AGENT ACTIVE TANK, DRAINING .

Disconnect electrical connector -4-.

Scheme 133

Remove the bolt -2- and disengage the reducing agent pump -V437- -3- on the active tank.

Note. Place a clean cloth under the separating location to catch any reducing agent that may leak out. Seal off all open lines and connections with clean plugs.

Press the release button and disconnect the supply line -1- and return line -5-.

Remove the metering line -6- by pressing the release button.

Installing

1. Tightening specifications, refer to «REDUCING AGENT ACTIVE TANK AND ATTACHMENTS ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-active-tank-and-attachments) .

Installation is in reverse order of removal, note the following

Make sure the lines are clipped to the active tank.

REDUCING AGENT ACTIVE TANK

Removing

Observe safety precautions. Refer to SAFETY PRECAUTIONS .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Switch off ignition and remove ignition key.

Reducing Agent Active Tank, Draining. Refer to REDUCING AGENT ACTIVE TANK, DRAINING .

Open the fuel tank flap.

Clean the area around the reducing agent filler tube.

Remove the locking cap -2- from the reducing agent filler tube.

Note. Seal the opening on the reducing agent filler tube with a plug to prevent dirt from entering the active tank.

Disconnect the connectors -2, 4, 5 and 6- and free up the wiring harness.

Scheme 134

Note. Place a clean cloth under the separating location to catch any reducing agent that may leak out. Seal off all open lines and connections with clean plugs.

Remove the metering line -7- by pressing the release button.

Disconnect the filling line -8- by pressing the release button.

Remove the bolts -1, 3 and 9-. A second technician must support the active tank.

Lower the active tank -1- slightly.

Scheme 135

Carefully guide filler tube out of rubber buffer inside the wheel housing so avoid paint damage.

Remove the transfer line -2- by pressing the release button.

Installing

1. Tightening specifications, refer to «REDUCING AGENT ACTIVE TANK AND ATTACHMENTS ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-active-tank-and-attachments) .

Installation is in reverse order of removal, note the following

Make sure the lines are clipped to the active tank.

REDUCING AGENT DELIVERY UNIT

Special tools and workshop equipment required

1. Special Wrench T50014

Removing

Observe safety precautions. Refer to SAFETY PRECAUTIONS .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remover the reducing agent active tank. Refer to REDUCING AGENT ACTIVE TANK .

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

Press the release button and disconnect the supply line -3- and return line -1-.

Scheme 136

Remove the connectors -5- on the bracket and free them up.

Remove the union nut -2- using the T50014 and carefully remove the reducing agent delivery unit -4- upward.

Installing

1. Tightening specifications, refer to «REDUCING AGENT ACTIVE TANK AND ATTACHMENTS ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-active-tank-and-attachments) .

Note. Replace seal. Thoroughly clean the sealing ring surfaces.

Install the reducing agent delivery unit -2- in the active tank. Slide the heating element through the gap between the reducing agent delivery unit and installation opening into the active tank.

Scheme 137

Stretch the new sealing ring -1- over the reducing agent delivery unit and place it on the installation opening.

Bring the reducing agent delivery unit into the installation position

1. The tab -arrow A- on the reducing agent delivery unit must fit into the groove -arrow B- on the rim of the opening for the active tank.

Install the union nut -2- so that the marking -3- lines up a the beginning of the first thread -4-. The arrow marking -1- on the active tank is found here.

Scheme 138

First tighten the union unit by hand, then tighten it using the T50014 for a total of 5 / 4 turns (450°).

Scheme 139

1. The marking -3- on the union nut -2- must align with the marking -1- (the arrow lines up with the lines on the side).

The rest of the installation is in reverse order of removal, note the following

Install the reducing agent active tank. Refer to REDUCING AGENT ACTIVE TANK .

REDUCING AGENT PASSIVE TANK

Special tools and workshop equipment required

1. Engine/Transmission Jack V.A.G 1383 A

Removing

Observe safety precautions. Refer to SAFETY PRECAUTIONS .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Reducing Agent Active Tank, Draining. Refer to REDUCING AGENT ACTIVE TANK, DRAINING .

On a vehicle with air suspension, activate vehicle lift mode. Refer to Description and Operation .

Remove the left underbody trim bolts in the center near the passive tank. Refer to Removal and Installation .

Scheme 140

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

Remove the bolts -1, 2 and 4-.

Scheme 141

Note. The passive tank is shown with the engine/transmission jack.

Lower the passive tank -3- with the V.A.G 1383 A approximately 100 mm while guiding the passive tank by hand.

Note. Place a clean cloth under the separating location to catch any reducing agent that may leak out. Seal off all open lines and connections with clean plugs.

Unclip the transfer line -2- on the bracket -arrow- and disconnect the reducing agent transfer pump -V436- by pressing the release button.

Disconnect the connector -1- and free up the electrical wire.

Note. Place a clean cloth under the separating location to catch any reducing agent that may leak out. Seal off all open lines and connections with clean plugs.

Disconnect the supply line -1- and the ventilation line -2- by pressing the release button.

Scheme 142

Lower the passive tank with the engine/transmission jack V.A.G 1383 A while guiding the tank by hand.

Installing

1. Tightening specifications, refer to «REDUCING AGENT PASSIVE TANK AND ATTACHMENTS ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-passive-tank-and-attachments) .

Installation is in reverse order of removal, note the following

Install the left underbody trim in the center. Refer to Removal and Installation .

Make sure the lines are clipped to the passive tank.

REDUCING AGENT TRANSFER PUMP

Special tools and workshop equipment required

1. Hose Clamps Up to 25 mm Dia. 3094

Removing

Observe safety precautions. Refer to SAFETY PRECAUTIONS .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Remove the reducing agent passive tank. Refer to REDUCING AGENT PASSIVE TANK .

Note. Place a clean cloth under the separating location to catch any reducing agent that may leak out. Seal off all open lines and connections with clean plugs.

Remove the transfer line -1- by pressing the release button.

Clamp off the hose -5- with the 3094.

Carefully remove the hose from the connection on the reducing agent transfer pump -V436-.

Disconnect electrical connector -3-.

Remove the bolt -4- and remove the reducing agent transfer pump -V436- and rubber bracket -2-.

Installing

1. Tightening specifications, refer to «REDUCING AGENT ACTIVE TANK AND ATTACHMENTS ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-active-tank-and-attachments) .

Installation is performed in reverse order.

REDUCING AGENT METERING SYSTEM CONTROL MODULE

Note. The reducing agent metering system control module -J880- is located on the right side under the rear bench seat, directly below the floor covering.

Removing

Observe safety precautions. Refer to FUEL SYSTEM .

Observe rules for cleanliness. Refer to CLEAN WORKING CONDITIONS .

Move the passenger seat all the way forward if necessary.

Disconnect battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Remove the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Remove the right rear sill trim strip. Refer to Removal and Installation .

Press the floor covering to the side and disconnect the connector -1-.

Scheme 143

Remove the nuts -2 and 4- and remove the reducing agent metering system control module -J880- -3-.

Installing

1. Tightening specifications, refer to «REDUCING AGENT METERING SYSTEM CONTROL MODULE ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata__reducing-agent-metering-system-control-module) .

Installation is in reverse order of removal, note the following

Install sill trim strip. Refer to Removal and Installation .

Install the right single seat in the second row of seats. Refer to 2ND ROW, 2-SEATER .

Connect the battery and observe safety precautions after connecting battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

ACCELERATOR PEDAL MODULE WITH ACCELERATOR PEDAL POSITION SENSOR

Removing

Remove driver's side lower instrument panel cover. Refer to Description and Operation .

Remove driver's side lower instrument panel cover mount -2- -arrow-.

Scheme 144

Disconnect electrical connector -3-.

Remove bolts -1- and -4- and remove accelerator pedal module.

Installing

1. Tightening specifications, refer to «ACCELERATOR PEDAL MODULE ASSEMBLY OVERVIEW»(/audi/q7/4l-2009-2015/remont/fuel-system/#30l-fuel-supply-system-engine-codes-cata) .

Installation is in reverse order of removal, note the following

Install driver's side lower instrument panel cover. Refer to Description and Operation .

Perform after the first kick-down adaptation in "Guided Functions"

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

1. Wrench T10202
2. Fuel Extracting Device VAS 5190
3. Remote Control V.A.G 1348/3A with Adapter Cable V.A.G 1348/3-3
4. Hand-Held Multimeter V.A.G 1526D
5. Connector Test Set V.A.G 1594C
6. Vehicle Diagnostic, Testing and Information System VAS 5051B
7. Engine/Transmission Jack V.A.G 1383 A
8. Support T10031
9. Hose Clamps Up to 25 mm Dia. 3094
10. Hose Clamp Pliers V.A.G 1921
11. Special Wrench T50014

See also:
• BATTERY, DISCONNECTING AND CONNECTING
• 2ND ROW, 2-SEATER
• Removal and Installation
• Diagnosis and Testing
• Description and Operation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• General Information
• Description and Operation
• REDUCING AGENT ACTIVE TANK, DRAINING
• REDUCING AGENT PASSIVE TANK, DRAINING
• FUEL SYSTEM
• CLEAN WORKING CONDITIONS
• FUEL DELIVERY UNIT, SUCTION JET PUMP AND FUEL LEVEL SENSOR ASSEMBLY OVERVIEW
• REDUCING AGENT PASSIVE TANK
• FUEL TANK, DRAINING
• FUEL TANK WITH ATTACHMENTS
• FUEL LEVEL SENSOR, CHECKING
• FUEL LEVEL SENSOR
• TRANSFER FUEL PUMP IN FUEL TANK, CHECKING
• FUEL DELIVERY UNIT AND TRANSFER FUEL PUMP
• FUEL LEVEL SENSOR 2
• SUCTION JET PUMP
• FUEL LEVEL SENSOR 2, CHECKING
• AUXILIARY FUEL PUMP, CHECKING DELIVERY QUANTITY
• FUEL SYSTEM COOLER
• REDUCING AGENT DELIVERY UNIT
• REDUCING AGENT ACTIVE TANK
• REDUCING AGENT PUMP
• REDUCING AGENT, AUTOMATIC REGENERATING
• REDUCING AGENT TRANSFER PUMP
• REDUCING AGENT METERING SYSTEM CONTROL MODULE
• ACCELERATOR PEDAL MODULE WITH ACCELERATOR PEDAL POSITION SENSOR
• TEST CONDITIONS
• REDUCING AGENT ACTIVE TANK AND ATTACHMENTS ASSEMBLY OVERVIEW
• REDUCING AGENT PASSIVE TANK AND ATTACHMENTS ASSEMBLY OVERVIEW