Ssp290 AUDI A3

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Ssp290 AUDI A3 Vorsprung durch Technik www.audi.de 290 Service. AUDI A3 ´04 Self Study Programme 290 All rights reserved. Subject to technical modification. © AUDI AG I/VK-35 D-85045 Ingolstadt Fax 0841/89-36367 A03.5S00.01.20 Technical status 02/03 Printed in Germany For internal use only This SSP is intended to give a general outline of the design and operation of the Audi A3 ‘04. Further relevant information can be found in the various Self Study Programmes and other media such as the CAN data bus CDs. V o r s p r u n g d u r c h T e c h n i k Media containing further material on the Audi A3 ‘04 include the CAN data bus CDs Parts 1 and 2. This Self Study Programme deals exclusively with the special features of the Audi A3 ‘04. 2 Contents Page Introduction . 04 Brief outline. 06 Body Body shell . 08 Front bumper . 10 Rear bumper . 13 Passenger protection . 14 Engine 1.6 l 2V engine. 16 2.0 l 4V FSI engine . 17 Oil filter module . 24 Accelerator pedal module . 27 3.2 l V6 engine. 32 Camshaft timing control . 36 Non-return fuel system . 38 Exhaust system. 40 Fuel tank . 42 1.9 l 4-cylinder TDI engine . 46 2.0 l 4V TDI unit injector system engine. 48 Diesel rapid start system . 51 Gearbox Direct-shift gearbox 02E . 52 Automatic gearbox 09G (6-speed) . 54 Running Gear Front axle. 57 Steering . 58 Rear axle . 59 Rear axle for quattro® drive. 60 Electrical System Bus topology . 62 Convenience electronics . 63 Heating/Air Conditioner Design and operation. 66 Mode of operation . 70 Service Special tools . 72 The Self Study Programme contains information on design features and functions. Attention New The Self Study Programme is not intended as a Workshop Manual. Values given are only intended to help explain the subject matter and relate to the software version applicable at the time of SSP compilation. Use should always be made of the latest technical publications when performing maintenance and repair work. 3 Introduction The new Audi A3 ‘04 The new top sports model in the compact created by the sporty body design does not class is raring to go and is to take the place of remain an empty promise. its predecessor of the same name. The use of exclusive equipment and materials In combination with the highly dynamic again guarantees that the high standards running gear, powerful petrol and diesel typical of the large Audi models come into engines up to 177 kW, quattro drive and the play in the compact class as well. new automatic-shift sporty gearbox DSG make sure the image of driving fun Gateway as separate control unit V6 engine Direct-shift gearbox 4 Body shell modifications Individual climate control SSP290_018 Electromechanical steering 5 Introduction Brief outline Principal Audi A3 ‘04 dimensions. The diagrams below illustrate the changes in relation to the predecessor model. Passenger compartment length + 57 mm Shoulder width Front Rear Front head room Knee room + 20 mm + 42 mm + 23 mm + 2 mm -10 mm Volume: ± 0 mm + 56 mm Height/unladen Shoulder width Front Rear Wheelbase + 65 mm + 16 mm + 14 mm Vehicle width + 30 mm Vehicle length + 48 mm Rear ref. SSP290_005 point to centre of rear axle + 8 mm Length 4203 mm Front track 1536 mm Width 1765 mm Rear track 1517 mm Height 1421 mm Gross weight 1835 kg Wheelbase 2578 mm Kerb weight 1275 kg Turning circle 10,70 m Luggage compartment 350 litres volume Tank capacity 55 litres Drag coefficient 0.31 cd 6 The vehicle dimensions indicated are measured in mm at kerb weight. 884 624 871 1421 121 1536 1517 1765 1957 974 935 655 865 2578 760 4203 1511 796 1392 1343 1000 SSP290_006 7 Body Body shell Lightweight body Upper body Bearing in mind the requirements in terms of The strength of the upper body is achieved by – Passive safety employing modern fastening methods. – Torsional rigidity A great deal more use has been made of laser – Vibration damping and bonded seams than in the predecessor – Acoustics model. The weight component of high and vehicle development work focused on ultra-high strength panels in the upper body lightweight construction methods. has been increased to almost 50 %. SSP290_072 Lower body Proportion of high Proportion of high Whilst maintaining the same strength, and ultra-high and ultra-high material weight reductions of around 25 % strength panels in strength panels in were obtained for certain components upper body lower body through the use of tailored blanks and high/ ultra-high strength panels. The weight component of high-strength steel panels in the underbody is 56 % and that of ultra-high strength panels 15 %. 62 % "Tailored blanks" are panels manufactured to size with different material thicknesses. Steel panels SSP290_071 8 Roof zero-gap joint The roof and side wall frames are seamlessly The overall length of the laser soldered joint joined by way of laser soldering. is 3 metres. A-A section Roof Laser-soldered zero-gap joint Outer side panel A-A section SSP290_069 Body components This robust upper body structure helps to Major factors in this were optimised joints increase the overall bending strength and and a modified joining sequence. torsional rigidity in the trimmed body by 20 %. Right side wall section Floor panel Left side wall section two-part view SSP290_011 9 Body Front bumper The bumper of the Audi A3 ‘04 is painted It comprises the following components: entirely in the same colour as the vehicle. – Bumper cover – Cover for towing eye – Side end plate – Radiator grille – Centre grille – Side air inlet grilles and – Bumper bracket SSP290_012 10 The bumper bracket takes the form of an Connection to the longitudinal members is aluminium cross member. provided by the so-called steel crash boxes. Radiator Air conditioner condenser Front end Front longitudinal member Air deflector unit Crash box SSP290_014 Bumper cross member The zero-gap joint between bumper and This connects the wing to the bumper cover. wing is guaranteed by a zero-gap joint bolt. Securing strip Fitted bolt Wing SSP290_061 Bumper cover 11 Body With a view to achieving optimum crash In the model damage test, the bumper safety, the development work for the entire bracket strikes the front end carrier and bumper system was coordinated from the breaks it out of its bolted connections to the outset with that for the front end and its add- body. on components (air-conditioner condenser This produces a larger crumple zone for the and radiator. bumper bracket and avoids damage to the air conditioner condenser and radiator. Success was thus achieved in considerably reducing damage to these components, The transverse forces acting on the particularly in the 15 km/h model damage and longitudinal member in the model damage 64 km/h Euro NCAP* tests. and Euro NCAP* tests are reduced and robust deformation properties result. Radiator Air conditioner condenser Air deflector unit Front longitudinal member Crash box Bumper cross member Securing strip Offset deformation barrier 40 % vehicle cover Fitted bolt Wing SSP290_015 To avoid wing damage in the model damage test, the bumper cover detaches itself from the wing and breaks away to the side. SSP290_062 Bumper cover * New Car Assessment Programme Association of government agencies, institutes and organisations at a European level, e.g. TÜV, ADAC, insurers, aimed at providing consumers with transparent vehicle safety standards. 12 Rear bumper The bumper bracket and support bracket are produced as aluminium extruded sections. The bumper comprises the following components – Bumper cover – Spoiler – Cover for towing eye and – End plate SSP290_068 The zero-gap joint between bumper and side panel takes the form of a clipped rather than a bolted joint. The clipped joint is fastened by a bolt which is accessible after removing the rear light. SSP290_074 13 Body Passenger protection Safety systems Key: The safety system in the new Audi A3 ‘04 has E224 Airbag disabling key switch, been revised and adapted accordingly to front passenger side meet with current and future demands in terms of occupant safety. G179 Side airbag crash sensor, driver side (B-pillar) The system essentially consists of familiar G180 Side airbag crash sensor, components such as: airbag control unit, front passenger side (B-pillar) driver's and front passenger's airbag, front G256 Rear side airbag crash sensor, side airbags, front belt tensioners, driver side sideguards (head airbags) and side impact G257 Rear side airbag crash sensor, recognition sensors. front passenger side G283 Front airbag crash sensor, New features are the external front airbag driver side crash sensors (so-called upfront sensors for G284 Front airbag crash sensor, detection of head-on collisions) and battery front passenger side deactivation in the event of a crash on vehicle models with the battery fitted in the luggage J220 Engine control unit compartment. J234 Airbag control unit J285 Control unit with display in dash Vehicles can optionally be equipped with a panel insert key switch for front passenger's airbag J393 Convenience system central control deactivation and the corresponding warning unit lamp. J533 Data bus diagnostic interface (gateway) The Audi A3 ’04 safety system is rounded off J655 Battery cut-off relay by the active head restraints in the front seats. K75 Airbag warning lamp K145 Airbag disabled warning lamp, front passenger side For the first time use is made in the Audi A3 ‘04 of airbag modules which are not N95 Airbag igniter, driver side subject to any replacement intervals. N131 Airbag igniter 1, front passenger side N153 Belt tensioner igniter 1, driver side N154 Belt tensioner igniter 2, front passenger side N199 Side airbag igniter, driver side N200 Side airbag igniter, front passengerside N251 Curtain airbag igniter, driver side N252 Curtain airbag igniter, front passenger side T16 Connector, 16-pin diagnostic connection Always heed the corresponding safety regulations outlined in the Workshop Manuals before working on the airbag system.
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