Self-Study Program 990203 The 2012 Audi A7 Vehicle Introduction Audi of America, LLC Service Training Printed in U.S.A. Printed 1/2011 Course Number 990203 ©2011 Audi of America, LLC All rights reserved. Information contained in this manual is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, LLC., its affi liated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, nor may these materials be modifi ed or reposted to other sites without the prior expressed written permission of the publisher. All requests for permission to copy and redistribute information should be referred to Audi of America, LLC. Always check Technical Bulletins and the latest electronic service repair literature for information that may supersede any information included in this booklet. Table of Contents Introduction . 1 Body . .2 Dimensions and Specs . 2 Materials . 4 Body Structure . 6 Occupant Protection . 8 Overview . 8 Components . 9 Engine . .10 3.0L V6 TFSI Engine . 10 Innovative Thermal Management . 15 Fuel Delivery Unit . 18 Exhaust System . 19 Power Transmission . .20 Overview . 20 8-Speed Automatic Transmission 0BK . 22 0BK Specifi cations . 23 Suspension System . .26 Overview . 26 Axles . 27 Adaptive Air Suspension . 28 Steering System . 29 Brake System . 30 Torque Vectoring . 31 Adaptive Cruise Control (ACC) . 32 Wheels and Tires . 32 i Table of Contents Electrical System . .33 Head-Up Display . 33 Audi Active Lane Assist . 35 Audi Drive Select . 36 Operating Modes . 37 Characteristics . 38 System Integration . 39 Topology . 40 Climate Control . .42 Overview . 42 Operation . 43 Infotainment . .44 Control Module Locations . 44 Radios and Navigation Systems . 45 MMI Display . 46 Sound Systems . 47 Service . .48 Special Tools and Equipment . 48 Self-Study Programs for the 2012 Audi A7 . .50 Knowledge Assessment . .51 The Self-Study Program provides introductory information regarding the design Reference Note and function of new models, automotive components, or technologies. The Self-Study Program is not a Repair Manual! All values given are intended as a guideline only. ! For maintenance and repair work, always refer to current technical literature. ii Introduction Audi is once again breaking new design ground The Audi A7 is three vehicles in one: a with the A7, combining athleticism and elegance comfortable and prestigious sedan with the on a grand scale. excitement of a coupe and the functional utility The sleek fi ve-door coupe measures 16.31 ft (4.97 of a station wagon. It features a lightweight body meters) in length and 6.27 ft (1.91 meters) in comprised of numerous aluminum components, width, but only 4.66 ft (1.42 meters) in height. Its a powerful and highly effi cient V6 engine, a long hood, fl owing C-pillars, and sharply sloping sport chassis, and advanced assistance and roofl ine result in a dynamic overall design. multimedia systems. 478_028 The 2012 A7 offers great long-distance driving The interior of the A7 reveals workmanship on comfort without sacrifi cing its substantial sport a craftsman level. Layered wood veneers are characteristics. Interior noise levels are very low a treat for the senses, with optional ambient even at high speeds, with the engine providing lighting adding subtle highlights to the interior. subtle acoustic feedback as its power unfolds. Making these excellent acoustics possible are new structural design methods and high-end materials. These materials include microfi ber fl eeces and multifunction parts, such as acoustically active wheel well shells and underbody panels. 1 Body Dimensions and Specs 55.9 in (1420 mm) 64.7 in (1644 mm) 478_029 64.3 in (1635 mm) 75.2 in (1911 mm) 84.2 in (2139 mm) 478_030 27.1 in (689 mm) 27.1 in (689 mm) 36.8 in 44.0 in 114.7 in (2914 mm) (936 mm) (1119 mm) 195.6 in (4969 mm) 478_031 2 447.17.1 iinn ((11971197 mmm)m) 557.17.1 iinn 555.95.9 iinn 336.06.0 iinn ((14521452 mmm)m) ((14211421 mmm)m) ((916916 mmm)m) 478_032 Length 195.6 in (4969 mm) Front internal width 57.1 in (1452 mm) Width 75.2 in (1911 mm) Rear internal width 55.9 in (1421 mm) Height 55.9 in (1420 mm) Front headroom 40.4 in (1028 mm) Front track width 64.7 in (1644 mm) Rear headroom 37.1 in (944 mm) Rear track width 64.3 in (1635 mm) Loading width 36.0 in (915 mm) Wheelbase 114.7 in (2914 mm) Load sill height 27.1 in (689 mm) 18.8 cu ft / 34.0 cu ft Trailer load 4629.7 lb (2100 kg) Trunk capacity (535 l / 965 l) Curb weight 4067.5 lb (1845 kg) Fuel tank capacity 17.1 gal (65.0 l) Maximum 5114.7 lb (2320 kg) Drag coeffi cient 0.29 gross weight 3 Materials The body of the 2012 A7 is a hybrid construction The body shell uses mild, high strength, modern of steel and aluminum components. high strength, and ultra high strength steel parts. There are also four cast aluminum parts for the front strut and tailgate hinge mounts. 4 478_094 Mild steel High strength steel Modern high strength steel Ultra high strength steel Ultra high strength steel (hot formed) Cast aluminum 5 Body Structure The use of ultra high strength hot-formed B-Pillar components improves body rigidity and crash safety. The following components and The B-pillar with striker plate is partially assemblies are made from ultra high strength tempered during the forming process. The steel: component assembly is very hard at the top end and softer below a narrow transition zone. – Front side member reinforcement This enables side impact forces to be absorbed – Bulkhead effectively. – A-pillar and roof frame side – B-pillar – Chassis rail (sill) – Front seat cross member – Tunnel reinforcement – Rear longitudinal member Body Attachments Side Member To reduce vehicle weight, the front and rear Manufactured from two tailored blanks, the side bumper mounts, fenders, strut brace, doors, and member is high strength sheet metal at the rear fl aps are made from aluminum. and hot-formed ultra high strength sheet metal at the occupant cell. Both sheet metal blanks are butt joined by a laser weld prior to forming. Aluminum panels Aluminum castings Extruded aluminum sections Ultra high strength steel (hot-formed) High strength areas in B-pillar and side member Steel 478_067 6 Aluminum Castings The aluminum castings in the vehicle structure Specifi c repair procedures have been developed are joined to adjacent sheet metal parts with for repairing damage to the aluminum castings punch rivets and structural adhesive. The and adjacent sheet steel parts. adhesive between these two materials also acts Straightening or reshaping of steel components as an insulator and prevents contact corrosion. can cause external and internal cracks in This method of joining was also used on the aluminum castings, which may not be easily 2007 Audi TT and 2011 Audi A8. detected. Structural integration of front end and strut mount Side member, top of wheel arch (fender stay) Strut mount Adhesive Punch rivet 478_107 Side member, bottom Reference For further information about punch riveting, refer to Self-Study Program 994703, The 2008 Audi TT Body. 7 Occupant Protection Overview Due to different statutory provisions and requirements in the worldwide marketplace, occupant protection equipment is subject to change. This applies to the North American market in particular. Reference For further information about the occupant protection system of the A7, refer to Self-Study Program 990603, The 2012 Audi A7 Occupant Protection, Infotainment, Climate Control, and Head-Up Display. 8 Components The following components are used in the 2012 A7 occupant protection system for the North American market: – Airbag control module – Door-integrated pressure type sensors for side – Adaptive driver and front passenger airbags impact detection – Front side airbags – Acceleration-type sensors for side impact detection on the C-pillars – Audi Sideguard (side curtain airbags) – Front inertia-reel seatbelts with pyrotechnic – Driver and front passenger knee airbags and electrically reversible belt tensioners and – Up-front airbag crash sensors active belt force limiters – Battery interrupt igniter – Seatbelt reminder for driver and front passenger – Seatbelt switch, driver and front passenger – Seat occupancy sensor in front passenger seat (PODS) – Driver and front passenger seat position recognition 478_108 9 Engine 3.0L V6 TFSI Engine Technical Features 478_090 New spark plugs Data Bus On Board Diagnostic Interface J533 478_084 Energy effi cient engine oil pump Friction reduced chain gear with: – Modifi ed camshafts – Camshaft adjusters modifi ed for less leakage 478_086 Reference For further information about the design and operation of the 3.0L V6 TFSI engine, refer to Self-Study Program 925803, The Audi 3.0L V6 TFSI Engine with Roots Blower. 10 Innovative Thermal Management system with active coolant pump Adapted belt drive (without power steering pump) 478_085 Improved high pressure injectors 478_091 478_009 11 Specifi cations 335.2 hp (250 kW) 368.7 lb ft (500 Nm) 301.7 hp (225 kW) 331.9 lb ft (450 Nm) 268.2 hp (200 kW) 295.0 lb ft (400 Nm) Power.