SSP332 Audi A3 Sportback - VolksPage
332Vorsprung durch Technik www.audi.deService TrainingAudi A3 SportbackSelf-Study Programme 332All rights reserved.Technical specificationssubject to change withoutnotice.CopyrightAUDI AGI/VK-35Service.training@audi.deFax 49-841/89-36367AUDI AGD-85045 IngolstadtTechnical status: 05/04Printed in GermanyA04.5S00.11.20
Self-Study Programmes on the Audi A3Audi A3 SportbackSSP 279Audi is defining a new segment in the premiumcompact class. The A3 Sportback is characterised bythe sporting elegance of a coupé and the versatilityof a 5-door.––––The Audi Sportback is deliberately going its own,new way in the compact class. It offers theemphatically sporty qualities and the athletic stylingof the three-door version with which it shares itsdrive train, dynamic suspension and wheelbase.In addition to two rear doors, it offers even morespace and variability thanks to its rear end which isa total of 68 millimetres longer than on its threedoorcounterpart.Order number: 240.2810.98.20EngineInjection systemOperating modesExhaust treatment332 084SSP 290 Audi A3 ‘04––––––––The A3 Sportback is immediately recognisable atfirst glance in the rear-view mirror by its strikingsingle-frame radiator grille, the distinctive taperingof the sides and the dynamic shape of the clearglassheadlights.The silhouette of the A3 Sportback when viewedfrom the side becomes flatter towards the rear ofthe car in typical coupé fashion and combines withthe gently rearward sloping roof line and therestyled rear end to give the car its dynamic overallproportions.332 085IntroductionBodyEngineGearboxRunning gearElectrical systemHeating/air conditioningServiceOrder number: A03.5S00.01.20SSP 293 Infotainment––––InfotainmentSound systemRadio moduleNavigationOrder number: 000.2811.13.20332 086SSP 312 Audi A3 ‘04––––Control unitsDistributed functionsInfotainmentOccupant protectionOrder number: A03.5S00.03.20332 087SSP 313 Audi A3 ‘04 Running Gear––––––332 074AxlesSteeringBrake systemESPWheels / tyresHand and foot controlsOrder number: A03.5S00.04.20332 088Excellence in design & performance
ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Running gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Convenience electronics . . . . . . . . . . . . . . . . . . . . . . . . . . 44Infotainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50The Self-Study Programme conveys basic principles with regard to the design and function of new models,new automotive components or new technologies.The Self-Study Programme is not a Repair Manual!All values given are intended as a guideline only, and referto the software version valid at the time of publication of the SSP.For maintenance and repair work, always refer to the current technical literature.ReferenceNote
IntroductionOverviewDimensions of the A3 Sportback.332 0514
BodyThe body of the Audi A3 Sportback has a highly rigid and crash-optimised occupant cell.Special attention was given to the following aspects: the body rigidity, the steering column rigidity, local rigidity in highly stressed areas, interior acoustics and driving comfort, the crash optimised body structure and the hybrid construction of the front end.Front view of the body-in-white332 048Rear view of the body-in-white332 049By using state-of-the-art calculation and simulation methods, new materials and joiningtechniques, and by optimising the joining sequence during the bodyshell assembly process, it was possible toincrease body rigidity by 20% compared to the predecessor model and enhance the crash performance of thebody structure.5
BodyMaterialsBodyshellUltra-high-strength and higher-strength sheet metalare used in areas which are subjected to highmechanical stresses during a crash.Welded tailored blanks and deep-drawn sheet metalare used in other areas.Ultra-high-strength sheet metalhigher-strength sheet metal6
332 0527
BodyMaterialsDoors, sills and floorpanWelded tailored blanks and tailored blanks withflexible rolled wall thickness are used in the frontfloorpan assembly and door areas.The result is a distribution of material whichprovides optimum stress absorption.The sills are reinforced using rolled profiles. Rolledprofiles have a high strength-to-weight ratio.Rolled profileTailored blanksTailored blanksRolled profileTailored blanks332 0538
Joining techniqueVarious joining techniquesare applied to interconnect the individual bodyelements.Spot welding joiningLaser solderingCrash-relevant andrigidity-definingjoints are spot-weld bonded using a high-strengthstructural adhesive.The overall length of the bonded seams is approx.26 m.Laser-solder joining is used to achieve a betterdesign and higher rigidity in the area of theinvisible joint and boot lid.The total length of the laser-soldered joints isapprox. 3.3 mPlasma solderingLaser weldingLaser welding is used in areas which are not easilyaccessible.The total length of the laser welded joints is approx.25 m.Laser-welded jointsLaser-soldered jointsPlasma-soldered jointsTo ensure the high rigidity and good design of thewater channel,materials are joined by plasma soldering.The overall length of the plasma-soldered joints isapprox. 1.1 m.332 0719
BodyRoof railDescriptionThe Audi A3 Sportback has a roof rail whose newstyle design accentuates the car's coupe likeroofline.It is made from aluminium and is available in twofinishes:– high-gloss anodised or– black powder-coatedMounting bolts332 019MountingRoofThe roof rail is mounted to theroof side member using four bolts.Rivet nutRoof side and-washer assemblyHead airbag332 04710
Open Sky roofDescriptionFunctionThe optional Open Sky roof creates a more pleasantinterior climate. It lets more light into the car andallows the occupants a view of the sky above.The front glass segment can be opened completelyand slid back.Two separate sun blinds protect against the glare ofthe sun and can also be used when the glass roof isopen.Opening is powered by an electric motor.When opening, the glass roof moves upwards andoutwards.Operation is by pushbutton. The glass roof halts inthe position in which the pushbutton is released.Open Sky roof open332 055Open Sky roof closed332 05411
Occupant protectionSafety systemLike the system in the Audi A3 3-door, the safety system in the Audi A3 Sportback is built to the higheststandards. The long list of safety requirements includes full compliance with legislation currently in force, aswell as consumer tests with the aim of achieving class-leading car safety ratings for the new Audi A3Sportback. Audi's internal requirements often present the development team with additional challenges.Special emphasis was placed on a high level of occupant protection in accidents and on compatibility. Audi's"safety first" approach to vehicle design complements the information derived from scientific analysis ofactual accidents and their impacts. To this end, the Audi Accident Research Unit ( AARU) analyses the datafrom accidents involving recent Audi vehicles. The task of the research team is to analyse and reconstructaccidents, and to identify areas where there is potential for improvement. In addition to this, the AARUevaluates the information stored in the respective accident databases.The differences to the Audi A3 04 are highlighted on the following pages.The safety system in the Audi A3 Sportback consists of the following components:–––––––––––Airbag control unitDual-stage driver and front passenger airbagsFront side airbagsSideguards (head airbags)Side impact detection sensors on the C-pillarSide impact detection sensors in the front doorsCrash sensors for differentiated head-on collision detection, otherwise known as "upfront" sensorsFront belt tensionersBattery disconnector, only for models with battery in luggage compartmentSwitches in the front seat-belt bucklesSeat occupied sensor, front passenger sideThe vehicle can also be equipped with rear side airbags and a keyswitch with associated warning lamp fordeactivating the front passenger airbag.The active head restraints in the front seats round off the safety system in the Audi A3 Sportback.LegendNoteFollow the safety instructions in the repairmanual before performing any work on theairbag system!12E224E24E25Front passenger side airbag deactivation key switchDriver side belt switchFront passenger side belt switchG128G179G180G256G257G283G284Seat occupied sensor, front passenger sideSide airbag crash sensor, driver side (front door)Side airbag crash sensor, front passenger side (front door)Rear side airbag crash sensor, driver side (C-pillar)Rear side airbag crash sensor, front passenger driver side (C-pillar)Driver side front airbag crash sensor (frontend left)Front passenger side front airbag crash sensor (frontend right)
332 004J220J234J285J393J533Engine control unitAirbag control unitControl unit with display in dash panel insertConvenience system central control unitData bus diagnostic interface (Gateway)K19K75K145Seat belt warning system warning lampAirbag warning lampFront passenger side airbag deactivated warning lamp(PASSENGER AIRBAG OFF)Airbag igniter, driver sideDriver side airbag igniter -2Front passenger side airbag igniter 1Front passenger side airbag igniter 2N95N250N131N132N153N154N199N200N251N252N253Driver seat belt tensioner igniter -1Front passenger seat belt tensioner igniter -1Side airbag igniter, driver sideSide airbag igniter, front passenger sideDriver side curtain airbag igniterFront passenger side curtain airbag igniterBattery isolation igniterT1616-pin connector, diagnosis connection13
Occupant protectionAirbag control unit J234The airbag control unit's hardware and electronics have been modified compared to the control unit in theAudi A3 3-door such that they are also capable of activating the dual-stage front airbags. The airbag controlunit has also been modified in such a way that no mechanical safing sensor is required.The airbag control unit is integrated in the drive train CAN bus.The airbag electronics basically have the followingtasks:– collision detection (front, side, rear)– defined deployment of the airbags or frontairbag stages, belt tensioners and batterydisconnector– activation of the belt-on indicator– evaluation of all input information– continuous monitoring of the entire airbagsystem– capacitor-based independent power supply fora defined period of time(approx. 150 ms)– fault display by failure warning lamp– storage of fault/ andcollision information– notification of a collision event to other systemcomponents via the drive train CAN-bus ora discrete collision output (conventionally wired)Information about the occurrence of a crash isutilised by other control units for opening thecentral locking system, shutting off the fuel supplyand activating the hazard warning light system, etc.Rear collision detectionIf the airbag control unit recognises a rear collision whose severity exceeds the predefined deploymentthreshold, then it ignites the belt tensioners and, where fitted, the battery isolation igniter.14332 005
Crash sensors for side protection systemSide airbag crash sensors, G179, G180(in the front doors)For the first time in the Audi A3 Sportback, pressuresensors will be installed in the two front doors.In a side impact, the deformation of the vehiclecauses a rapid increase in air pressure in the doorcavity. This increase in pressure is detected by thesensor and signalled to the airbag control unit.Rear side airbag crash sensors,G256, G257(C-pillar)The two rear side airbag crash sensors G256 andG257, which are installed in the C-pillar area on theleft and right hand sides, are conventionalacceleration sensors which are already being usedin the Audi A3 3-door.Side impact sensors for the sideairbag are integrated in the frontdoor332 006NoteThe airbag control system uses sensors integrated in the front doors, etc. To avoid anyimpairment to the function of the side airbags, no modifications should be made to the doorsand door trims (e.g. retrofitting of loudspeakers).Damage to the front doors can cause impairment of system functions. All work on the frontdoors should be referred to a specialist workshop.Belt-on indicatorThe new Audi A3 Sportback has the belt-on indicatorfunction for driver and front passenger as knownfrom the Audi A6 05.For further information, refer to Self-StudyProgramme 323, Audi A6 05.Seat belt warning system warning lamp332 00715
Occupant protectionAirbagFront airbagsDual-stage gas generators are employed in the front airbags.The impact load acting on the driver and front passenger during an accident is reduced by radial inflation ofthe driver side airbag and by time-staggered ignition of the propellant charges. The airbag control unitcontrols the time interval between the two deployments depending on the severity and nature of the accident.The time interval can vary between approx. 5 ms and 40 ms.In any event, both propellant charges are ignited. This ensures that no propellant charge remains active afteran airbag deployment.Driver airbag, N95, N250The driver airbag uses two pyrotechnic propellant charges.The airbag control unit activates the electrical detonator of the first propellant charge. The detonator ignitesthe priming charge, which in turn detonates the actual propellant charge through nozzle holes in the gaschamber. The combustion of the propellant charge produces a pressure inside the gas generator. If the gaspressure exceeds a defined threshold, then the gas generator housing deforms and allows the gas to flowthrough the metal filter to the airbag. The airbag unfolds and is inflated by the gases resulting fromcombustion of the propellant charge. After a preset time delay, the airbag control unit energises the secondelectrical detonator, which directly ignites the secondary propellant charge. When a preset pressure isreached, the developing gas lifts the cap off the second-stage chamber and flows into the first-stagecombustion chamber. From here, the gas flows through the filter to the airbag.HousingCapPropellant charge 1Propellant charge 1Metal filterNozzle holesPropellant charge 2Priming chargeDetonator 1Detonator 2332 03216
Ignition of the first propellant charge332 033Ignition of the second propellant charge332 03417
Occupant protectionFront passenger airbag, N131, N132Unlike the driver airbag, the gas generator in the front passenger airbag works by the hybrid gas principle.The gas generator consists of two pyrotechnic propellant charges which are integrated in a pressurised gasbottle.The detonator activated by the airbag control unit ignites the first propellant charge by means of the primingcharge. Should the pressure developing inside the gas bottle exceed a preset value, the rupture disc willexplode and the gas mixture will inflate the airbag. The airbag is further inflated by the combustion of thesecond propellant charge .The coil springs ensure that the propellant charges burn as intended.Detonator 1Priming charge 1Propellant charge 1Coil springFilter332 013Detonator 2Priming charge 2Propellantcharge 2Coil springRupture discPressurised gas bottleGas:argon approx.98%helium approx.2%Pressure:approx. 250 barSide airbags, N199, N200Like the airbags used in the Audi A6 05, the side airbags used in the Audi A3 Sportback are modules.For further details, refer to Self-Study Programme 323, Audi A6 05.So-called pyrotechnic tubular gas generators are used as gas generators.If the airbag control unit detects a side impact which meets the criteria for deployment, then it energises therelevant side airbag detonators. The primary charge is ignited by means of the priming charge. Thedeveloping gas flows through the metal filter into the airbag.Air outletMetal filterPriming charge332 027Air outlet18Propellant chargeDetonator
Head airbags, N251, N252SideguardsThe sideguard covers almost the entire side windowarea. With these modules, the hybrid gas generatoris installed in the rear roof area and inflates theairbag through a gas lance.ConnectorGas lanceThe support is mechanically propelled out of itsmount through the detonation of the propellantcharge.The helium stored in the pressurised gas bottle at600 bar now breaches the rupture disc.The gas flows through the filter into the gas lancewhich connects the airbag to the gas generator.Gas generator332 037Gas lanceFilterSupportRupture discPropellant chargePressurised gasbottle332 035332 036Active head restraintsThe task and function of the active head restraintare described in Self-Study Programme 312, Audi A3 04 Electrical System.For further information, refer to this Self-StudyProgramme.Functional unit"active headrestraint"Lumbar supportplate326 02419
Occupant protectionBattery isolation igniter, N253The battery isolation igniter has the same task asthe battery cut-off relay.This involves disconnecting the starter andalternator leads from the vehicle battery in the eventof a crash. The battery isolation igniter is used onlyon models whose battery is installed in the luggagecompartment.The battery isolation igniter is activated andmonitored for diagnosis by the airbag control unit.Every time the airbag is deployed, the batteryisolation igniter is activated and must besubsequently replaced.When the pyrotechnic propellant charge is ignited,the developing gas pressure displaces the boltlocated on a piston and breaks the connectionbetween the two battery terminals.332 014Battery isolation igniterBattery isolation igniter activatedPin and pistoncombinationPinConnectingelement withterminalsDetonator332 03020Connectingelement withterminalsDetonator332 031
Seat occupied recognition systemfor the North American marketThe seat occupied recognition system for the North American market has been carried over fromthe Audi A6 05.However, the individual components have been adapted to suit the Audi A3 Sportback.The system is described in Self-Study Programme 323 Audi A6 05.The system has the following component parts:––––––––Seat squabSensor mat for seat occupied recognitionPressure sensor for seat occupied recognition , G452Seat occupied recognition control unit, J706Front passenger side belt switch, E25Seat belt force sensor for seat occupied recognition, G453Front passenger side airbag deactivated warning lamp, K145 (PASSENGER AIRBAG OFF)Airbag control unit, J234Front passenger side airbagdeactivated warning lampSeat squabBelt-fastened sensorswitchAirbag control unitBelt force sensor forseat occupancySensor mat for seat occupiedrecognitionPlug connectionbelow the seatPressure sensor for seatoccupied recognitionSeat occupied recognitioncontrol unitDisconnection point326 01921
Engine2.0l 4-cylinder turbo FSIThe new turbo FSI engine is a progression on the 2.0l 4-cyl. FSI engine with stratified petrol direct injectionwhich combines the advantages of direct injection combustion with the dynamics of the exhaust turbotechnology. The result is an extremely responsive unit which conveys a highly enjoyable driving experience.ReferenceYou will find a description of thedesign and function of the2.0l FSI engine inSSP 279.332 00122
The engine number can be found at the bottomlefthand side of the engine block in the area of thegearbox flange.* AXX123 4 5 6*332 029Torque/power curveTorque in NmPower output in kWEngine speed in rpm332 015SpecificationsEngine codeAXXTypeIn-line 4-cylinder petrol engineDisplacement1984 cm3Power output147 kW (200 bhp)Torque280 Nm at 1800-4700 rpmBore82.5 mmStroke92.8 mmCompression ratio10.5:1Weightapprox. 152 kgFiring order1-3-4-2Engine managementBosch Motroni
Like the system in the Audi A3 3-door, the safety system in the Audi A3 Sportback is built to the highest standards. The long list of safety requirements includes full compliance with legislation currently in force, as well as consumer tests with the aim of achieving class-leading car safety rating
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66% UK 22% G: UK G: G Audi Audi: e-tron MPV: 1% 25%G: BE H: Audi Audi e-tron Sportback: MPV 1%: 26%G BE: H Audi: Audi A3 PC: 0% 50%G: 26%H G: H G (AWD) Audi Audi: A3 PC 0%: 47%G 30%H: G H: G (FWD) Audi: Audi S3 PC: 0% 61%G: G G (AWD) Audi Audi: RS 3 PC 0%: 45%G 37%H: GH: Audi Audi: A4 PC 1%: 52%G G: H G(AWD) Audi Audi: A4 PC 1%: 52%G 17%H: G H .
Audi Centre Thailand 02 7658888 ฅ Audi New Petchburi 02 0234888 Audi Service Chiang Mai 052 081188 ฅ Audi Pattaya 038 197888 ฅ Audi Phuket 076 646666 www.audi.co.th AudiThailand �บันเทิง A5 Sportback 40 TFSI S line A5 Sportback 45 TFSI quattro S line Black Edition
Audi drive select as standard - the state-of-the-art technologies in the Audi A5 Sportback are pretty impressive. The same goes for its self-assured elegant look. Accentuated by coupé-style frameless doors, sporty chrome trim around the windows and the carefully sculpted rear section with elongated luggage compartment lid. 6
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