Removing and installing fuel pump G23, vehicles with 6.0 ltr. (V12) engine — AUDI

🧭 Before you start

Fits: Audi Q7 (4L, 2005–2015)

• Opens: fuel
• Renewed: seal

Don't miss

• Lay a clean cloth under the separating points to catch escaping fuel.
• Disregard (items 1, 3).
• The fuel delivery unit is shown without fuel tank for illustration purposes.
• Keep in mind that the fuel delivery unit still contains fuel.
• Install new seal for flange (right-side); seal must be dry.

🔧 Engine codes this applies to

📋 Procedure

1. Remove individual seat (right-side) in 2nd row of seats 72.
2. ⚠ Injury risk!Wear protective gloves. — Use a commercially available carpet knife (1) to cut open floor covering (right-side) along perforation (arrows).
3. Fold back carpet flap to one side (arrow).
4. Unscrew nuts (1 … 4) and detach cover for flange (right-side). [Note: Lay a clean cloth under the separating points to catch escaping fuel.]
5. ⚠ The fuel can become extremely hot. This can cause injuries.In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with common rail engine, even after the engine is switched off. Allow the fuel to cool down before disconnecting the lines - danger of scalding.Wear protective gloves.Wear safety goggles.Risk of injury - fuel system operates under high pressure.To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection. — Disconnect fuel lines (1 and 2). Disconnecting plug-in connectors

6. Unplug electrical connector (4) on flange (right-side).
7. Vehicles with auxiliary heater: Disconnect fuel line (3) to auxiliary heater. Disconnecting plug-in connectors
8. Unscrew locking ring using wrench T10202.
9. Pull flange (right-side) with seal slightly out of fuel tank.
10. Unplug electrical connectors (1) and (2) on underside of flange (right-side).
11. Disconnect fuel lines (2 and 3). Disconnecting plug-in connectors
12. Reach into opening in fuel tank and detach supply line (1) for auxiliary heater from fuel delivery unit by pressing release tabs (arrow).
13. Detach flange (right-side) with seal.
14. Disconnect fuel line (2) leading to fuel delivery unit (left-side). Disconnecting plug-in connectors [Note: Disregard (items 1, 3).]
15. Remove individual seat (left-side) or 2/3 section of seat bench (left-side) in 2nd row of seats 72.
16. ⚠ Injury risk!Wear protective gloves. — Use a commercially available carpet knife (1) to cut open floor covering (left-side) along perforation (arrows).
17. Fold back carpet flap to one side (arrow).
18. Unscrew nuts (1 … 4) and detach cover for flange (left-side). [Note: Lay a clean cloth under the separating points to catch escaping fuel.]
19. ⚠ The fuel can become extremely hot. This can cause injuries.In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with common rail engine, even after the engine is switched off. Allow the fuel to cool down before disconnecting the lines - danger of scalding.Wear protective gloves.Wear safety goggles.Risk of injury - fuel system operates under high pressure.To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection. — Disconnect fuel lines (2 and 3). Disconnecting plug-in connectors
20. Unplug electrical connector (1) on flange (left-side).
21. Unscrew locking ring using wrench T10202.
22. Pull flange (left-side) with seal slightly out of fuel tank.
23. Unplug electrical connectors (1) and (2) on underside of flange (left-side).
24. Disconnect fuel lines (3 and 4). Disconnecting plug-in connectors
25. Working through fuel tank opening, press release tab and disconnect supply line (1).
26. Disconnect supply line for suction-jet pump (2). Disconnecting plug-in connectors
27. Pull fuel lines out of opening on left side of fuel tank.
28. Reach into opening in fuel tank and release fuel delivery unit (1) by turning 15° in anti-clockwise direction (arrow) (quick-release fastener). [Note: The fuel delivery unit is shown without fuel tank for illustration purposes.]
29. Lift out fuel delivery unit. [Note: Keep in mind that the fuel delivery unit still contains fuel.] [Note: Renew seal.]
30. Insert fuel delivery unit into fuel tank.
31. Lock fuel delivery unit (3) into position by turning 15° clockwise (arrow) (quick-release fastener).
32. Push fuel line through opening on left of fuel tank towards right fuel tank chamber.
33. Reach into opening on right of fuel tank and attach fuel line (2) to fuel delivery unit (left-side) so that it engages audibly. [Note: Disregard (items 1, 3).]
34. Attach supply line (1) leading to auxiliary heater to fuel delivery unit (arrow) so that it engages audibly.
35. Attach fuel lines (2) and (3) on underside of flange (right-side) so that they engage audibly.
36. Plug in electrical connector (1) for fuel pump on underside of flange (right-side).
37. Wind electrical wire (2) for fuel gauge senderG twice around electrical wire (1) for fuel pump and then connect these wires to flange (right-side).
38. Install new seal for flange (right-side); seal must be dry.
39. Move flange (right-side) into installation position:
40. Install cover for flange (right-side) .
41. Insert retaining frame (Electronic parts catalogue) in floor covering 70.
42. Install individual seat (right-side) in 2nd row of seats 72.
43. Reach into opening on left of fuel tank and attach supply line (1) to fuel delivery unit so that it engages audibly.
44. Fit supply line (2) leading to suction-jet pump so that it engages audibly.
45. Fit fuel lines (3) and (4) onto flange (left-side) so that they engage audibly.
46. Connect electrical connectors (1) and (2) to underside of flange (left-side).
47. Install new seal for flange (left-side); seal must be dry.
48. Move flange (left-side) to installation position:
49. Install cover for flange (left-side) .
50. Insert retaining frame (Electronic parts catalogue) in floor covering 70.
51. Install individual seat (left-side) or 2/3 section of seat bench (left-side) in 2nd row of seats 72.
52. Vehicles with auxiliary heater: Bleed fuel supply line leading to metering pump .
53. Put at least 5 litres of fuel into tank after installing fuel delivery unit.

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