Other Fuel System Hoses Lines/piping, And Fittings Problems of Audi Q7

2012 Audi Q7 3. 0t s line prestige, 91k miles! started as small gasoline smell becoming stronger throughout the next couple days. Smelled really strong around rear left door area and inside cabin. Investigated fuel leak and notice underneath the SUV, fuel dripping down the side of one of the two fuel tanks. Disconnect battery, remove rear seat to access fuel pump panel on the floor, discovered lots of fuel leak near pump and electrical connectors. Noticed that the fuel filter housing already had "Audi's quick fix" (protective film) covering the area but it was still leaking. Not to mention the pump's electrical connectors was soaked in the fuel that had the fuel puddle! this issue should have been found when I had a recent safety recall code 20w9 done at an Audi dealership just a couple weeks prior. In order to fix the leaking issue, I had to buy a new fuel filter w/ flange, "protective film", and a some seal ring.

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Noticed a strong gasoline smell in the enclosed garage where the vehicle is kept. Researched the issue online and discovered several instances where the pressurized fuel filter assembly on top of the fuel tank (left side, beneath second row rear seat) develops cracks in the plastic and emits a fine spray of fuel. I removed the second row seat and discovered a pool of liquid gasoline on top of the pressurized fuel filter. Audi has an existing recall under NHTSA campaign number: 16v660000, which merely "installs a butyl rubber band to protect the pump" and which I have already had performed at the dealership. This is a different issue in that the fuel filter itself develops cracks and fissures that allow pressurized fuel to escape. In the picture you can see that the electrical connector appears to be immersed in liquid gasoline.

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2013 Audi Q7 tdi - catastrophic high pressure fuel pump failure. Second incident within approximately 20,000 mi on same vehicle. Was driving approximately 30 mph on city street. Car began shaking violently and losing power rapidly, glow plug light came on. Driver began pulling over to the side of the street but vehicle stalled before safely on shoulder. Attempted to restart engine after approximately 1 minute. Car would not start and had to be towed to dealer. The first incident occurred at approximately 50,000 mi. The entire fuel system except tank was replaced including high pressure fuel pump (hpfp), fuel lines, fuel filter, common rail, fuel injectors. Repair was covered by Audi. Second incident happened at approximately 69,000 mi. Exact same behavior experienced by the car. Car shook, glow plug light came on, lost power rapidly, and stalled. Engine would not restart and had to be towed to the dealer. The vehicle is currently at the Audi dealer. Audi has requested a fuel sample and we are waiting for Audi to determine if they will cover the repair.

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2013 Audi Q7 tdi - catastrophic high pressure fuel pump failure. Was driving approximately 30 mph on city street. Car began shaking violently and losing power rapidly, glow plug light came on. Driver began pulling over to the side of the street but vehicle stalled before safely on shoulder. Attempted to restart engine after approximately 1 minute. Car would not start and had to be towed to dealer. First incident happened at approximately 50,000 mi. Car shook, glow plug light came on, lost power rapidly, and stalled. Engine would not restart and had to be towed to the dealer. The entire fuel system except tank was replaced including high pressure fuel pump (hpfp), fuel lines, fuel filter, common rail, fuel injectors. Repair was covered by Audi.