Removing and installing suction-jet pumps: Audi Q7 (BAR, BHK, BHL, CJTB, …)

🧭 Before you start

Fits: Audi Q7 (4L, 2005–2015)

• Opens: fuel
• Renewed: seals

Don't miss

• Risk of fuel escaping into passenger compartment.The fuel tank must be empty when removing the suction-jet pumps. — Drain fuel tank. Procedure: Rest-of-world vehicles , USA vehicles .
• Disregard (item 3).
• The fuel gauge sender 2G169 is shown without fuel tank for illustration purposes.
• The suction-jet pumps are shown without fuel tank for illustration purposes.
• Renew seals.Check that suction-jet pumps have engaged properly.

🔧 Engine codes this applies to

📋 Procedure

1. Move driver's seat as far back as possible and to highest position, using range of full seat adjustment.
2. ⚠ To prevent irreparable damage to the electronic components when disconnecting the battery:Observe notes on procedure for disconnecting the battery. — Disconnect battery Electrical system27.
3. ⚠ Risk of fuel escaping into passenger compartment.The fuel tank must be empty when removing the suction-jet pumps. — Drain fuel tank. Procedure: Rest-of-world vehicles , USA vehicles .
4. Remove seat frame (right-side) of 2nd row of seats 72.
5. ⚠ Injury risk.Wear protective gloves. — Use a commercially available carpet knife (1) to cut open floor covering (right-side) along perforation (arrows).

6. Fold cut-out section to one side (arrow).
7. Unscrew nuts (1 … 4) and detach cover for flange (right-side).
8. Unplug electrical connector (3) on flange (right-side).
9. ⚠ Risk of injury caused by fuel.To release the residual pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection. — Disconnect breather line (1) from flange (right-side) by pressing release tab.
10. Disconnect fuel supply line (2) from flange (right-side) by pressing release tab.
11. In addition, disconnect fuel supply line leading to metering pump for auxiliary heater by pressing release tab.
12. Unscrew locking ring using wrench T10202.
13. Pull flange (right-side) with seal slightly out of fuel tank.
14. Unplug electrical connectors (1) and (2) on underside of flange (right-side).
15. Press release tab and disconnect fuel line (arrow).
16. Working through fuel tank opening, press release tabs and disconnect supply lines (1) and (4).
17. Disconnect supply line (2) for suction-jet pump by pressing release tab. [Note: Disregard (item 3).]
18. Remove seat cushion (left-side) of 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 cut-out section to one side (arrow).
21. Unscrew nuts (1 … 4) and detach cover for flange (left-side).
22. Unplug electrical connector (1) on flange (left-side).
23. Disconnect breather hose (2) by pressing release tab.
24. Unscrew locking ring using wrench T10202.
25. Pull flange (left-side) together with fuel filter housing and seal slightly out of fuel tank.
26. Unplug electrical connector (arrow) on inside of flange (left-side).
27. Detach fuel lines (1) and (2) from flange (left-side) by pressing release tabs.
28. Working through fuel tank opening, press retaining tab (arrow 1) and at the same time pull fuel gauge sender 2G169 out of guide (arrow 2). [Note: The fuel gauge sender 2G169 is shown without fuel tank for illustration purposes.]
29. Carefully take out fuel gauge sender 2G169 through opening in fuel tank.
30. Working through fuel tank opening, pull fuel supply lines and supply line for suction-jet pump out of left fuel tank opening (arrow).
31. Press retaining tab (arrow 1), and at the same time pull suction-jet pumps out of guide (arrow 2). [Note: The suction-jet pumps are shown without fuel tank for illustration purposes.]
32. Carefully take out suction-jet pumps through opening in fuel tank. [Note: Renew seals.Check that suction-jet pumps have engaged properly.]
33. Insert suction-jet pumps in guide and press down until they click into place.
34. Push fuel supply lines and supply line for suction-jet pump through left fuel tank opening into right fuel tank chamber.
35. Insert fuel gauge sender 2G169 in guide and press down until it clicks into place.
36. Connect electrical connector (arrow) on underside of flange (left-side).
37. Install new seal for flange (seal must be installed dry).
38. Move flange (left-side) to installation position.
39. Fit supply line (2) leading to suction-jet pump so that it engages audibly.
40. Attach supply lines (1) and (4) to fuel delivery unit so that they engage audibly.
41. Fit fuel line (arrow) so that it engages audibly. [Note: Disregard (item 3).]
42. Connect electrical connectors (1) and (2) to underside of flange (right-side).
43. Install new seal for flange (seal must be installed dry).
44. Move flange (right-side) into installation position.
45. Install cover for flange.
46. Insert retaining frame (Electronic parts catalogue) in floor covering 70.
47. Install seat frame and seat cushion of 2nd row of seats 72.
48. Observe notes on procedure for connecting the battery Electrical system27.
49. Let auxiliary heater run with full load for 10 minutes to bleed fuel supply line going to metering pump.

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