Audi Q7 2007 Operating instructions

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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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
with respect to the correctness of information in this document. Copyright by AUDI AG.
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

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

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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.
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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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.
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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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.
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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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.
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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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.
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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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.
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