Audi Q7 2007 Operating instructions

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Repair Manual
Audi Q7 2007 ➤
Fuel Supply System
Engine ID BAR BHK BHL CJTB CJTC CNA
A
CJW
B
CJW
C
CJW
E
CTW
A
CTW
B
Edition 10.2018
Service
Service Department. Technical Information

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
20 - Fuel Supply
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2018 Audi AG, Ingolstadt D3E800224B0

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Working on Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 On Test Drives Using Test and Measuring Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Full or Partially Full Fuel Tanks, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Fuel Tank, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Fuel Supply and Injection System, Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Fuel Tank with Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Overview - Fuel Tank with Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Fuel Tank, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Fuel Tank with Attachments, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Fuel Pump, Fuel Delivery Unit and Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Overview - Fuel Delivery Unit and Fuel Gauge Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Fuel Pump, Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Fuel Pump Control Module J538 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Fuel Pump Control Module J538 , Through 10/2006, Removing and Installing . . . . . . . . . . 23
2.5 Fuel Pump Control Module J538 , From 11/2006, Removing and Installing . . . . . . . . . . . . 23
2.6 Fuel Pump, Checking Delivery Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.7 Fuel Pump, Checking Delivery Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.8 Fuel Pump, Checking Delivery Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.9 Fuel Delivery Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.10 Fuel Level Sensor G , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.11 Fuel Level Sensor G , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.12 Fuel Level Sensor 2 G169 , Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.13 Fuel Level Sensor 2 G169 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.14 Function of the Suction Jet Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.15 Suction Jet Pumps, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.1 Overview - Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.2 Fuel Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 EVAP Canister and Leak Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1 Overview - EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.2 EVAP Canister, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.3 EVAP Canister and Leak Detection System Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . 63
4.4 Leak Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.5 Leak Detection Test, Performing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.6 Leak Detection Pump V144 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5 Accelerator Pedal Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.1 Overview - Accelerator Pedal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.2 Accelerator Pedal Module with Throttle Position Sensors, Removing and Installing . . . . . . 68
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
Contents i

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Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
ii Contents

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00 – General, Technical Data
1 Safety Precautions
(Edition 10.2018)
⇒ “1.1 Working on Fuel System”, page 1
⇒ “1.2 On Test Drives Using Test and Measuring Devices”, page
2
⇒ “1.3 Full or Partially Full Fuel Tanks, Removing and Installing”,
page 2
⇒ “1.4 Fuel Tank, Removing and Installing”, page 2
1.1 Working on Fuel System
Note the Following when Working on the Fuel System:
WARNING
There is a risk of injury because the fuel is under very high
pressure.
♦ Reduce the fuel pressure down to residual pressure be‐
fore opening high pressure area of the fuel injection sys‐
tem.
♦ To reduce remaining residual pressure, place clean cloth
around the connector and carefully loosen connector.
Risk of escaping fuel.
♦ To prevent the fuel pump from running when the driver
door is opened, the fuel pump fuse must be removed for
safety reasons before opening the fuel system if the bat‐
tery is not disconnected or the fuel pump delivery unit
electrical connector is not disconnected.
– Procedures before opening high pressure fuel injection sys‐
tem. Refer to ⇒ Rep. Gr. 24 .
To Prevent Personal Injury and Damage to the Injection and Ig‐
nition System, Observe the Following:
♦ The ignition must be switched off before connecting or dis‐
connecting injection and ignition system wiring or tester ca‐
bles.
♦ Wash the engine only when the ignition is turned off.
♦ If the connectors were disconnected and the engine was star‐
ted, then the following faults were stored in the engine control
module DTC memories: Generate Readiness Code in Gui-
ded Functions -Vehicle Diagnostic Tester- .
Carry Out the Following Measures before Starting Work on the
Fuel Supply:
WARNING
Danger of explosion due to cell phones.
♦ Keep cell phones out of reach in the work space area.
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
1. Safety Precautions 1

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Caution
Danger of causing damage to electronic components.
♦ Complete the steps for disconnecting the battery.
♦ Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 .
♦ Open the fuel filler cap briefly and then close it again.
1.2 On Test Drives Using Test and Measur‐
ing Devices
If Testing Equipment Must Be Used During A Road Test, Observe
the Following:
WARNING
Distraction and testing equipment that is not secured properly
can cause accidents.
The passenger airbag could pose a risk if it deploys in a colli‐
sion.
• Operating testing equipment while driving causes it to shift
position.
• There is an increased risk of injury due to unsecured test‐
ing equipment.
♦ Always secure testing equipment on the rear seat with a
strap and have a second person on the rear seat operate
them.
1.3 Full or Partially Full Fuel Tanks, Remov‐
ing and Installing
Note the Following when Removing and Installing Fuel Tank
Components Which are Completely or Partially Filled:
♦ 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. Refer to ⇒ “1.2 Fuel Tank, Draining”, page 7 .
♦ 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 no exhaust extrac‐
tion system is available, a radial fan (as long as motor is not
in air flow) with a displacement greater than 15 m3/h can be
used.
♦ Do not let fuel come in contact with bare skin. Wear fuel-re‐
sistant gloves.
1.4 Fuel Tank, Removing and Installing
♦ Fuel tank must be empty. Refer to
⇒ “1.2 Fuel Tank, Draining”, page 7 .
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
2 Rep. Gr.00 - General, Technical Data

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2 General Repair Information
⇒ “2.1 Fuel Supply and Injection System, Clean Working Condi‐
tions”, page 3
⇒ “2.2 Test Conditions”, page 3
⇒ “2.3 Contact Corrosion”, page 3
2.1 Fuel Supply and Injection System,
Clean Working Conditions
Even a little contamination can lead to faults. When working on
the fuel supply and fuel injection system, observe the following
guidelines for a clean working environment:
♦ Before loosening, connections and surrounding areas must be
cleaned thoroughly with engine or brake cleaner, and then
cleaned area must be dried completely.
♦ Seal the open lines and connections immediately with clean
plugs, for example, from the Engine Bung Set - VAS6122- .
♦ Place removed parts on a clean surface and cover them. Use
a lint-free cloth.
♦ Carefully cover or plug unpacked components if repairs can‐
not be performed immediately.
♦ Install only clean parts: remove the replacement parts from
their packaging just before Installation them. Do not use parts
that have been stored unpacked (e.g. in tool boxes etc.).
♦ When the system is open: do not work with compressed air.
Do not move vehicle unless absolutely necessary.
♦ Protect the disconnected connectors from dirt and moisture
and only connect when they are dry.
2.2 Test Conditions
• Battery voltage at least 12.5 V.
• Fuse for fuel pump OK. Refer to the Wiring Diagrams.
• The Fuel Pump Relay - J17- is OK . Refer to the Wiring Dia‐
grams.
• Fuel Pump Control Module - J538- OK; check in Guided
Fault Finding -Vehicle Diagnostic Tester- .
•Fuel tank minimum 1/4 full.
• Fuel filter is OK.
• Fuel lines OK (not plugged, not kinked).
• The ignition is off.
2.3 Contact Corrosion
Contact corrosion can occur if incorrect fasteners are used (bolts,
nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
installed.
Rubber or plastic parts and adhesives are also made of non-con‐
ductive materials.
If there are doubts about whether parts can be used or not, then
use new parts. Refer to the Parts Catalog.
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
2. General Repair Information 3

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Note:
♦ Only original replacement parts are recommended. They are
checked and compatible with aluminum.
♦ The use of Audi accessories is recommended.
♦ Contact corrosion damage is not covered under warranty.
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
4 Rep. Gr.00 - General, Technical Data

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20 – Fuel Supply
1 Fuel Tank with Attachments
⇒ “1.1 Overview - Fuel Tank with Attachments”, page 5
⇒ “1.2 Fuel Tank, Draining”, page 7
⇒ “1.3 Fuel Tank with Attachments, Removing and Installing”,
page 11
1.1 Overview - Fuel Tank with Attachments
1 - Left Heat Shield
2 - Vent Line
❑ From the EVAP canister
to the EVAP Canister
Purge Regulator Valve
1 - N80- .
❑ Do not kink.
❑ To disconnect, press re‐
lease button on connec‐
tion piece.
❑ Clipped in on fuel tank.
3 - Vacuum Line
❑ Engine/ Leak Detection
Pump - V144-
❑ Clipped in on fuel tank.
4 - Fuel Line
❑ To the engine.
❑ To disconnect, press re‐
lease button on connec‐
tion piece.
❑ Clipped in on fuel tank.
5 - Right Heat Shield
6 - Bolt
❑ Tightening specification
and sequence. Refer to
⇒ Fig. ““Fuel Tank,
Tightening Specifica‐
tions and Sequence”“ ,
page 7 .
7 - Mounting Strap
❑ Observe varying
lengths.
❑ Pay attention to the installed position.
8 - Nut
❑ 9 Nm
9 - Shield
❑ For the fuel filler tube.
10 - Bolt
❑ 9 Nm
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
1. Fuel Tank with Attachments 5

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11 - Rubber Gasket
12 - Cover
❑ Attached to the fuel filler door insert with an permanent fastener.
13 - Bolt
❑ 5 Nm
14 - Ground Connection
❑ For discharging electrostatic charge.
❑ Installed position / check requirements. Refer to
⇒ Fig. ““Installation Position of Ground (GND) Connection”“ , page 7 .
❑ Ensure connector fits securely at metal ring of fuel filler tube.
15 - Bolt
❑ 9 Nm
16 - Overflow Hose
17 - Vent Line Bracket
❑ Secured to longitudinal member.
18 - Carrier Plate
19 - Bolt
❑ Tightening specification and sequence. Refer to
⇒ Fig. ““Fuel Tank, Tightening Specifications and Sequence”“ , page 7 .
20 - Fuel Tank
❑ Removing and installing. Refer to
⇒ “1.3 Fuel Tank with Attachments, Removing and Installing”, page 11 .
21 - Connectors
❑ For electric fuel pump and fuel level sensor.
❑ Remain on fuel tank when it is removed.
22 - Fuel Pump Control Module - J538-
❑ Illustrated: installed location through 10.06.
❑ Location from 11.2006. Refer to
⇒ Fig. ““ Fuel Pump Control Module -J538- for Vehicles from 11.2006 - Tightening Specifications”“ , page
7 .
❑ Removing and installing: vehicles through 10.06. Refer to
⇒ “2.4 Fuel Pump Control Module J538 , Through 10/2006, Removing and Installing”, page 23 , ve‐
hicles from 11.06. Refer to
⇒ “2.5 Fuel Pump Control Module J538 , From 11/2006, Removing and Installing”, page 23 .
23 - Bolt
❑ 3.5 Nm
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
6 Rep. Gr.20 - Fuel Supply

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with respect to the correctness of information in this document. Copyright by AUDI AG.
Fuel Tank, Tightening Specifications and Sequence
– Tighten the bolts in 3 steps as follows:
Stage Bolts Tightening Specification
1. -9, 10, 11, and 12-33 Nm
2. -1, 4, 5, and 8- 33 Nm
3. -2, 3, 6, and 7- 33 Nm
Fuel Pump Control Module - J538- for Vehicles from 11.2006 -
Tightening Specifications
• Installed location: on the right side of the underbody, under the
rear seat bench and under the floor covering
– Tighten nuts -arrows- to 3.5 Nm.
Installation Position of Ground (GND) Connection
– Route Ground (GND) connection -2- as shown in illustration.
– Engage ground wire on EVAP canister -arrow-.
– Ensure connector of Ground (GND) connection fits securely
at metal ring -1- of fuel filler tube.
WARNING
Risk of explosion due to electrostatic charge.
♦ After Installation, check electrical connection on fuel filler
neck metal ring to an empty spot on the body using an
Ohm meter.
• Specified value: approximately 0 Ω.
1.2 Fuel Tank, Draining
Special tools and workshop equipment required
♦ Wrench - Fuel Sending Unit - T10202-
♦ Fuel Extraction Unit - VAS5190-
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
1. Fuel Tank with Attachments 7

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Procedure
Follow all safety precautions. Refer to
⇒ “1 Safety Precautions”, page 1 .
Follow the guidelines for clean working conditions. Refer to
⇒ “2.1 Fuel Supply and Injection System, Clean Working Condi‐
tions”, page 3 .
– Open the fuel filler door.
Caution
Danger of causing damage to other electronic components
when disconnecting the battery.
♦ Complete the steps for disconnecting the battery.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 .
WARNING
Risk of explosion due to electrostatic charge.
♦ Secure the Fuel Extraction Unit - VAS5190- ground wire
to a bare area of the chassis.
– Remove the cone piece -2- from the shaft piece -1- on the Fuel
Extraction Unit - VAS5190- .
– Using insulating tape, apply a mark -arrow- on hose at length
-a- = 1775 mm from end of suction hose.
– Remove the fuel cap from the fuel filler tube.
– Install the adapter -1- for the Fuel Extraction Unit - VAS5190-
on the fuel tank filler tube.
– Push the suction hose as far into fuel tank until the mark ap‐
plied earlier -arrow- is positioned on shaft piece.
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
8 Rep. Gr.20 - Fuel Supply

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Note
♦ If using a siphoning device without shaft piece, proceed prin‐
cipally in the same manner.
♦ In this case, make a mark -arrow- on the hose -a- = 1,400 mm
from end of suction hose using insulating tape. 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.
– Empty fuel tank as much as possible via fuel filler tube.
– Carefully pull out the suction hose.
– Remove the left seat cushion in the second row. Refer to ⇒
Body Interior; Rep. Gr. 72 .
WARNING
Risk of injury.
♦ Wear safety gloves.
– Cut the floor covering along the perforation -arrows- on the left
side with a carpet knife -1-.
– Fold the floor covering to the side -arrow-.
– Remove nuts -1 to 4- and remove left locking flange cover.
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
1. Fuel Tank with Attachments 9

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– Disconnect electrical harness connector -1- at left locking
flange.
– Disconnect the vent line -2- by pressing release button.
– Remove locking ring with Wrench - Fuel Sending Unit -
T10202- .
– Pull left locking flange with fuel filter housing and gasket out
of fuel tank slightly.
– Disconnect electrical connector on inner side of locking flange
-arrow-.
– Lay aside left locking flange with connected fuel lines.
– Extract the fuel in the left fuel tank chamber through the open‐
ing using the Fuel Extraction Unit - VAS5190- .
Assemble in reverse order of disassembling. Note the following:
• Tightening specification. Refer to
⇒ “2.1 Overview - Fuel Delivery Unit and Fuel Gauge Sensor”,
page 17 .
Note
Replace seal.
– Connect electrical connector -arrow- on underside of left lock‐
ing flange.
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
10 Rep. Gr.20 - Fuel Supply

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– Install the new locking flange seal dry.
– Bring the left locking flange into the installation position.
• The tab -2- on left locking flange faces toward the arrow mark‐
ing and must lie between tabs -1 and 3- on fuel tank.
– Install locking flange cover.
– Insert the frame into the floor covering. Refer to the Parts Cat‐
alog and ⇒ Body Interior; Rep. Gr. 70 .
– Install the left seat cushion in the second row. Refer to ⇒ Body
Interior; Rep. Gr. 72 .
– Be sure to follow the procedure for connecting the battery and
afterwards. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 .
1.3 Fuel Tank with Attachments, Removing
and Installing
Special tools and workshop equipment required
♦ Engine/Gearbox Jack - VAG1383A-
♦ Subframe Support - T10031-
Removing
Follow all safety precautions. Refer to
⇒ “1 Safety Precautions”, page 1 .
Follow the guidelines for clean working conditions. Refer to
⇒ “2.1 Fuel Supply and Injection System, Clean Working Condi‐
tions”, page 3 .
– On a vehicle with air suspension, activate vehicle lift mode.
Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 43 .
– Open the fuel filler door.
Caution
Danger of causing damage to other electronic components
when disconnecting the battery.
♦ Complete the steps for disconnecting the battery.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 .
WARNING
Risk of injury due to fuel tank weight.
♦ Fuel tank must be empty to remove.
– Empty fuel tank. Procedure. Refer to
⇒ “1.2 Fuel Tank, Draining”, page 7 .
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
1. Fuel Tank with Attachments 11

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
WARNING
Risk of vehicle tipping on hoist with rear axle removed.
♦ Before Removal the subframe bolts, secure the vehicle
(for example load the luggage compartment with approx‐
imately 50 kg (110 lb)).
– Remove the rear axle. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 42 .
– Hang driveshaft -1- on body with a suitable chain or with weld‐
ing wire as shown in illustration -arrows-.
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-.
• Dimension -a- = 220 mm.
– Clean the area around the fuel filler tube.
– Remove fuel filler cap -arrow- from fuel filler tube.
– Close off the opening of the fuel filler tube with a clean piece
of foam to prevent dirt from falling in.
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
12 Rep. Gr.20 - Fuel Supply

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove the fuel filler door insert. Refer to ⇒ Body Exterior;
Rep. Gr. 55 .
– Pry out rubber gasket -1- and remove it outward.
– Unfasten the bolts -arrows- for fuel filler tube.
– Remove the right rear wheel housing liner. Refer to ⇒ Body
Exterior; Rep. Gr. 66 .
– Press the release button and disconnect the vent lines
-1 and 2-.
– Remove the vacuum line -3- from the Leak Detection Pump -
V144- .
– Disconnect ground (GND) wire -4- from fuel filler tube.
– Remove the bolts -5 and 6- from the fuel filler tube.
– Remove fuel filler tube protective plate -arrows-.
– Drive pins -1- through with a punch.
– Remove bracket -2- with vent lines from longitudinal member.
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
1. Fuel Tank with Attachments 13

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove the sill panel cover bolts marked with an -arrow- on
the left side of the underbody.
– Remove the sill panel cover bolts marked with an -arrow- on
the right side of the underbody.
– Unclip lines -1 to 3- at fuel tank and bracket -arrows-.
– Unclip parking brake cable bracket -4- at fuel tank.
– Disconnect fuel pump and fuel level sensor electrical connec‐
tors -1 and 2- at left longmember.
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
14 Rep. Gr.20 - Fuel Supply

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Place the Engine/Gearbox Jack - VAG1383A- with Subframe
Support - T10031- (without threaded rods) under the fuel tank
for support, as illustrated.
• The Subframe Support - T10031- mounting plates must be
positioned near the round impressions in the bottom of the fuel
tank.
– Support the fuel tank with the Engine/Gearbox Jack -
VAG1383A- and Subframe Support - T10031- .
– A second technician must also support fuel tank by hand.
– Identify location of fuel tank securing bands.
WARNING
Risk of injury due to fuel tank weight.
♦ The fuel tank must be empty when Removing it.
– Remove bolts -1 to 12- 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 is needed to hold the rear edge of the fuel
tank.
– Carefully guide filler tube out of wheel housing so avoid paint
damage.
– Thread through gap between body and fuel tank.
WARNING
Risk of injury from fuel.
♦ To reduce residual pressure remaining in fuel system, lay
a clean cloth around the connector and carefully loosen
connector.
– Disconnect fuel line -3- by pressing release buttons.
– Disconnect ventilation line -1- and vacuum line -2- by pressing
the release buttons.
– Lower the fuel tank with the Engine/Gearbox Jack -
VAG1383A- while a second technician guides it.
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
1. Fuel Tank with Attachments 15

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Installing
• Tightening specifications. Refer to
⇒ “1.1 Overview - Fuel Tank with Attachments”, page 5 and
⇒ Fig. ““Fuel Tank, Tightening Specifications and Sequence”“ ,
page 7 .
– Check whether vent line and wiring harness to fuel pumps and
fuel level sensors are clipped in at fuel tank.
– Position the fuel tank with mounting straps and plate to vehicle
floor using the Engine/Gearbox Jack - VAG1383A- and Sub‐
frame Support - 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 this sequence: plate, left and right rear
tensioning straps and left and right front tensioning straps.
Refer to
⇒ Fig. ““Fuel Tank, Tightening Specifications and Sequence”“ ,
page 7 .
– Tighten the bolts -5 and 6- for the fuel filler tube.
– Check if the ground (GND) wiring -4- and the contact show
signs of oxidation. If necessary, remove.
WARNING
Risk of explosion due to electrostatic charge.
♦ After installation, check electrical connection on fuel filler
neck metal ring to an empty spot on the body using an
Ohm meter.
• Specified value: approximately 0 Ω.
– Connect vacuum line -3- to fuel system diagnostic pump.
– Install the vent lines -1 and 2- so that they engage audibly.
– Tighten fuel filler tube in place -arrows-.
Install in reverse order of removal. Note the following:
– Install the fuel filler door insert. Refer to ⇒ Body Exterior; Rep.
Gr. 55 .
– Install the rear axle. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 42 .
– Install the right rear wheel housing liner. Refer to ⇒ Body Ex‐
terior; Rep. Gr. 66 .
– Be sure to follow the procedure for connecting the battery and
afterwards. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 .
– On a vehicle with air suspension, deactivate vehicle lift mode.
Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 43 .
Audi Q7 2007 ➤
Fuel Supply System - Edition 10.2018
16 Rep. Gr.20 - Fuel Supply