Removing and installing suction-jet pump, vehicles with 3.0 ltr. (V6) or 4.2 ltr. (V8) engine) from 06.2010 onwards — AUDI

🧭 Before you start

Fits: Audi Q7 (4L, 2005–2015)

• Opens: fuel
• Renewed: seals

Don't miss

• Lay a clean cloth under the separating points to catch escaping fuel.
• The suction-jet pump is shown without fuel tank for illustration purposes.
• Renew seals.Check that suction-jet pump has engaged properly.
• Electrical wire must be clipped onto retaining tabs (arrows), as shown in illustration.
• Install new seal (1) for flange (left-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).
5. Unplug electrical connector (4) on flange (right-side).

6. If fitted, unplug electrical connector (3) on flange. [Note: Lay a clean cloth under the separating points to catch escaping fuel.]
7. ⚠ 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
8. Vehicles with auxiliary heater: Disconnect fuel line to auxiliary heater. Disconnecting plug-in connectors
9. Unscrew locking ring using wrench T10202.
10. Pull flange (4) slightly out of fuel tank and detach seal (1).
11. Unplug electrical connectors (2 and 3) on underside of flange.
12. Pull fuel line (5) out of fuel tank and disconnect fuel line. Disconnecting plug-in connectors
13. Reach into opening in fuel tank and detach supply line (2) for auxiliary heater from fuel delivery unit by pressing release tabs.
14. Reach into opening in fuel tank and disconnect return line (1) from fuel delivery unit. Disconnecting plug-in connectors
15. Take off flange.
16. Reach into opening in fuel tank and detach supply line (1) from fuel delivery unit by pressing release tabs (arrow).
17. Reach into opening in fuel tank and disconnect supply line for suction-jet pump (2). Disconnecting plug-in connectors
18. Remove individual seat (left-side) or 2/3 section of seat bench (left-side) in 2nd row of seats 72.
19. ⚠ Injury risk!Wear protective gloves. — Use a commercially available carpet knife (1) to cut open floor covering (left-side) along perforation (arrows).
20. Fold back carpet flap to one side (arrow).
21. Unscrew nuts (1 … 4) and detach cover for flange (left-side).
22. Unplug electrical connector (arrow) on flange (left-side).
23. Unscrew locking ring using wrench T10202.
24. Pull flange (left-side) (3) slightly out of fuel tank.
25. Unplug electrical connector (2) on underside of flange (left-side).
26. Detach seal (1) from fuel tank.
27. Reach into opening in fuel tank, press retaining tab (arrow 1) and at the same time pull fuel gauge sender 2G169(item 3) out of guide (4)(arrow 2).
28. Press retaining tab (arrow 1) and at the same time pull suction-jet pump out of guide (3)(arrow 2). [Note: The suction-jet pump is shown without fuel tank for illustration purposes.]
29. Carefully take out suction-jet pump (4) through opening in fuel tank. [Note: Renew seals.Check that suction-jet pump has engaged properly.]
30. Push fuel supply lines for suction-jet pump through opening on left of fuel tank towards right fuel tank chamber.
31. Insert suction-jet pump in guide and press down until it clicks into place.
32. Before installation, check routing of wires for fuel gauge sender 2G169.
33. Electrical wire must be clipped onto retaining tabs (arrows), as shown in illustration.
34. Press fuel gauge sender 2G169 into guide so that it engages audibly.
35. Plug in electrical connector (2) on underside of flange (left-side) (3).
36. Install new seal (1) for flange (left-side); seal must be dry.
37. Move flange (left-side) to installation position:
38. Remove locking ring for flange (left-side) using wrench T10202.
39. Plug in electrical connector (arrow) at flange (left-side).
40. Connect supply line (2) for suction-jet pump so that it engages audibly.
41. Connect supply line (1) to fuel delivery unit so that it engages audibly.
42. Connect return line (1) to fuel delivery unit so that it engages audibly.
43. Attach supply line (2) leading to auxiliary heater to fuel delivery unit so that it engages audibly.
44. Push on fuel line (5) so that it engages audibly and slide fuel line into fuel tank.
45. Push on electrical connectors (2 and 3) on underside of flange so they engage audibly.
46. Install new seal (1) for flange (seal must be installed dry).
47. Fit flange (4) into fuel tank.
48. Move flange (right-side) into installation position:
49. Remove locking ring for flange (right-side) using wrench T10202.
50. Attach fuel return line (1) and fuel supply line (2) to flange (right-side).
51. Plug in electrical connectors (3) and (4) on flange (right-side).
52. Install covers for flanges .
53. Insert retaining frame (Electronic parts catalogue) in floor covering 70.
54. Install individual seats or 2/3 section of seat bench in 2nd row of seats 72.
55. Put at least 5 litres of fuel into tank after installing fuel delivery unit.

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