Audi A3 Sportback 332 Service
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Audi A3 Sportback 332 Service

Self-study programme 332
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Audi A3 Sportback
Self-Study Programme 332

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Summary of Contents for Audi A3 Sportback 332

  • Page 1 Service Training Audi A3 Sportback Self-Study Programme 332...
  • Page 2 Audi A3 Sportback Audi is defining a new segment in the premium compact class. The A3 Sportback is characterised by the sporting elegance of a coupé and the versatility of a 5-door. The Audi Sportback is deliberately going its own, new way in the compact class.

  • Page 3: Table Of Contents

    Contents Introduction ........4 Body .

  • Page 4: Introduction

    Introduction Overview Dimensions of the A3 Sportback. 332_051...
  • Page 5 Body The 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.

  • Page 6: Body

    Body Materials Bodyshell Ultra-high-strength and higher-strength sheet metal are used in areas which are subjected to high mechanical stresses during a crash. Welded tailored blanks and deep-drawn sheet metal are used in other areas. Ultra-high-strength sheet metal higher-strength sheet metal...
  • Page 7 332_052...
  • Page 8 Body Materials Doors, sills and floorpan Welded tailored blanks and tailored blanks with flexible rolled wall thickness are used in the front floorpan assembly and door areas. The result is a distribution of material which provides optimum stress absorption. The sills are reinforced using rolled profiles. Rolled profiles have a high strength-to-weight ratio.
  • Page 9 Joining technique Various joining techniques are applied to interconnect the individual body elements. Spot welding joining Laser soldering Crash-relevant and Laser-solder joining is used to achieve a better rigidity-defining design and higher rigidity in the area of the joints are spot-weld bonded using a high-strength invisible joint and boot lid.

  • Page 10: Roof Rail

    Body Roof rail Description The Audi A3 Sportback has a roof rail whose new style design accentuates the car's coupe like roofline. It is made from aluminium and is available in two finishes: – high-gloss anodised or – black powder-coated...
  • Page 11 Open Sky roof Description Function The optional Open Sky roof creates a more pleasant Opening is powered by an electric motor. interior climate. It lets more light into the car and When opening, the glass roof moves upwards and allows the occupants a view of the sky above. outwards.

  • Page 12: Occupant Protection

    Occupant protection Safety system 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 ratings for the new Audi A3 Sportback.
  • Page 13 332_004 J220 Engine control unit N153 Driver seat belt tensioner igniter -1- J234 Airbag control unit N154 Front passenger seat belt tensioner igniter -1- J285 Control unit with display in dash panel insert N199 Side airbag igniter, driver side J393 Convenience system central control unit N200 Side airbag igniter, front passenger side...

  • Page 14: Airbag Control Unit J234

    The airbag control unit's hardware and electronics have been modified compared to the control unit in the Audi A3 3-door such that they are also capable of activating the dual-stage front airbags. The airbag control unit has also been modified in such a way that no mechanical safing sensor is required.
  • Page 15 Crash sensors for side protection system Side airbag crash sensors, G179, G180 (in the front doors) For the first time in the Audi A3 Sportback, pressure sensors will be installed in the two front doors. In a side impact, the deformation of the vehicle causes a rapid increase in air pressure in the door cavity.
  • Page 16 Occupant protection Airbag Front airbags Dual-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 of the driver side airbag and by time-staggered ignition of the propellant charges. The airbag control unit controls the time interval between the two deployments depending on the severity and nature of the accident.
  • Page 17 Ignition of the first propellant charge 332_033 Ignition of the second propellant charge 332_034...
  • Page 18 250 bar Side airbags, N199, N200 Like 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.

  • Page 19: Active Head Restraints

    332_035 332_036 Active head restraints The task and function of the active head restraint Functional unit are described in Self-Study Programme 312, Audi A3 "active head ´04 Electrical System. restraint" For further information, refer to this Self-Study Programme. Lumbar support...
  • Page 20 Occupant protection Battery isolation igniter, N253 The battery isolation igniter has the same task as the battery cut-off relay. This involves disconnecting the starter and alternator leads from the vehicle battery in the event of a crash. The battery isolation igniter is used only on models whose battery is installed in the luggage compartment.
  • Page 21 The seat occupied recognition system for the North American market has been carried over from the 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.

  • Page 22: Engine

    Engine 2.0l 4-cylinder turbo FSI The new turbo FSI engine is a progression on the 2.0l 4-cyl. FSI engine with stratified petrol direct injection which combines the advantages of direct injection combustion with the dynamics of the exhaust turbo technology. The result is an extremely responsive unit which conveys a highly enjoyable driving experience. Reference You will find a description of the design and function of the...
  • Page 23 The engine number can be found at the bottom lefthand side of the engine block in the area of the gearbox flange. 332_029 Torque/power curve Torque in Nm Power output in kW Engine speed in rpm 332_015 Specifications Engine code Type In-line 4-cylinder petrol engine Displacement...
  • Page 24 Engine Crankshaft The crankshaft has been modified to meet the tougher demands of the turbo FSI engine, resulting in higher component strength and enhanced acoustics. The flanges on the main bearings and the conrod journal have been enlarged for greater rigidity. This way, the rigidity specifications have been met despite the 6.4 mm increase in stroke length.
  • Page 25 Decoupled final drive sprocket The higher torsional irregularity in the crankshaft of the turbo engine at the bottom end of the RPM range results in much greater chain forces in the balancer shaft chain drive. The oscillation angle of 2° crank angle in the turbo engine is significantly higher than the relative oscillation angle of 0.8°...
  • Page 26 Engine Toothed belt drive As with all Audi 4-cylinder inline engines, the timing gear is designed as a toothed belt drive and directly drives the exhaust camshaft. The toothed belt tensioning system carried over Function from the naturally aspirated engine has been...

  • Page 27: Cylinder Head

    Cylinder head The following turbo-specific modifications were In addition, the intake port geometry has been made to the cylinder head (in relation to the revised, enhancing the tumble effect along with 2.0l FSI): knock resistance and running smoothness. The high-pressure pump mounted on the cylinder sodium-filled exhaust valves head has been installed rotated through 90°.
  • Page 28 Engine Crankcase ventilation A permanent vacuum is maintained in the cylinder Since a turbo engine requires a more sophisticated crankcase by separate ventilation of the cylinder pressure control system, a two-stage pressure crankcase and cylinder head, since the crankcase control valve which branches off the blow-by gases breather is connected to the intake manifold.
  • Page 29 Exhaust turbocharger/manifold module Due to the constraints on available space, a modular package comprising an exhaust manifold and turbine housing has been developed for the respective longitudinal and transverse mounting drive train variants. Special emphasis was placed on implementing a service solution for the easy removal and installation of the exhaust manifold and the integration of a close-coupled catalytic converter.
  • Page 30 Engine A clamping flange on the cylinder head allows easy removal and installation of the module with a minimum of bolting. The terminal block does not have to be detached. Terminal block 332_025 The exhaust manifold is designed as a split Cylinder 1 manifold.
  • Page 31 Charge air ducting and boost pressure control The boost pressure and intake pressure are converted to a control pressure by the pulsed Note charge pressure control solenoid valve N75. The In the event that the control system fails, applied control pressure acts on the pressure unit the boost pressure will act directly on the which actuates the wastegate flap by means of pressure unit and against its spring...
  • Page 32 Engine Air divert control in overrun If the throttle valve is closed when the engine is in overrun, a back pressure will develop in the compressor housing due to the continuing presence of boost pressure. This back pressure noticeably reduces the speed of the compressor wheel, the net result of which is in a reduction in boost pressure and increased turbo lag.

  • Page 33: Cooling System

    Cooling system To prevent carbon build-up on the turbine shaft in the turbocharger, an auxiliary water pump provides additional water circulation for up to 15 minutes after the hot engine is shut off. The pump transports the lower-temperature coolant against the direction of flow. The coolant, which is taken in by the auxiliary water pump, flows from the radiator through the turbocharger to the engine block and back to the cooler to dissipate stored heat.
  • Page 34 Engine Tumble flaps As the engine is operated in homogeneous-charge They are actuated: mode only, tumble flaps are used to improve – to improve idling quality when the engine is cold mixture formation inside the engine. – to improve charging efficiency at engine start-up –...

  • Page 35: Fuel Supply

    Fuel supply The new direct-injection petrol engines are supplied by a demand-controlled fuel pump. This demand control was developed to minimise the energy demand of the fuel pump and save fuel. The fuel pump supplies only as much fuel as is required by the engine while maintaining the required system pressure.
  • Page 36 Engine Actuators and sensor diagram Air mass meter G70 Charge air pressure sender G31 intake manifold pressure sender G71 Engine speed sender G28 Hall sender G40 Altitude sender F96 Motronic control unit J220 Throttle valve drive angle sender -1- (electric power control) G187 Throttle valve drive angle sender -2- (electric power control) G188 Throttle valve control unit J338...
  • Page 37 Fuel gauge sender G Fuel pump (pre-supply pump) G6 Fuel pump control unit J538 Injector, cylinder 1 N30 Injector, cylinder 2 N31 Injector, cylinder 3 N32 Injector, cylinder 4 N33 Ignition coil 1 with output stage N70 Ignition coil 2 with output stage N127 Ignition coil 3 with output stage N291 Ignition coil 4 with output stage N292 Throttle valve control unit J338...

  • Page 38: Running Gear

    Running gear Axles Front axle The front axle of the A3 Sportback is identical in design and function to the A3 3-door. The spring/shock absorber set-up has been adapted to suit the Sportback. 332_075 Rear axles The rear axles for front-wheel drive and quattro all-wheel drive are identical in design and function to the A3 3-door.
  • Page 39 Suspension alignment The suspension alignment procedure and setting values are the same as for the A3 3-door version. Steering system The electromechanical steering system (EPS) used on the A3 3-door is also used in the A3 Sportback. As before, the steering has been adapted to the various front axle loads by two different characteristic curves in the power steering control unit J500.

  • Page 40: Steering Wheels

    Running gear Steering wheels The steering wheel and airbag are identical in design to the steering wheels in the A6 and A8. The following steering wheels are available: 332_082 332_083 Basis Option Option Attraction Steering wheel in 4-spoke design Sport steering wheel in 3-spoke Multifunction sport steering wheel for design with shift paddles telephone and radio operation...
  • Page 41 Operating principle When a tyre loses air, its rolling circumference decreases. This increases the number of revolutions necessary to cover a specific distance. This information is acquired by the wheel speed sender and evaluated by the ESP control unit. In this way, the control unit recognises changes in tyre pressure. The ability of the control unit to precisely evaluate measurement data is limited in certain dynamic operating conditions, such as cornering at high speed, driving on rough roads, driving away and braking.
  • Page 42 Running gear System overview 332_046 Service work System faults are indicated by the continuous illumination of the TPM warning lamp and registered in the fault memory of the ESP control unit. Control units with TPM capability have additional measured value blocks for system diagnosis.

  • Page 43: Wheels And Tyres

    Wheels and tyres Two new wheels will be featured on the A3 Sportback. A cast aluminium wheel in size 6.5J x 16" is available as an option on models with the "Attraction" trim. 332_079 A cast aluminium wheel in size 7.5J x 17 is available as an option on all models.

  • Page 44: Convenience Electronics

    Convenience electronics Bus topology...
  • Page 45 The bus topology is based on the Audi A3 3-door. The Sportback has two additional door control units as well as the optional infotainment systems, such as the Navigation Plus system (RNS-E) incl. TV tuner and satellite radio for the North American market.
  • Page 46 Convenience electronics New features of the convenience electronics...
  • Page 47 The combined sensor is already known from the A3 Sportback to the new function "rain and light Audi A6´05, and is connected via the LIN data bus detector sensor G397" as well as the modified to the onboard power supply control unit J519.
  • Page 48 Convenience electronics Control unit with display in dash panel insert J285 The A3 Sportback and 3-door for model year '05 will come with an upgraded version of the dash panel insert. It has the same basic functions as the dash panel insert known from the A3 3-door. 332_009 New and modified warning lamps Further warning lights have been added to the modified dash panel insert for the new vehicle functions,...
  • Page 49 Onboard computer The optional Driver Information System (FIS) will be extended to an onboard computer. In the onboard computer, the following functions can be AUXILIARY programmed: HEATER – auxiliary heating/ventilation /VENTILATION – clock CLOCK – computer (FIS menu) COMPUTER – speed alarm (speed warning) SPEED ALARM –...

  • Page 50: Infotainment

    As before, the new Navigation Plus system is designed for installation in a 2-DIN slot in the dash panel. Apart from the Audi A3, the new Navigation Plus system is available in the A4´04, Allroad´04 and Audi A6´04 Avant. As different front panels are available for the respective models, there are several variants with different part numbers.
  • Page 51 Like in the Audi A6 and Audi A8, there are four so-called softkeys located around the rotary/pushbutton control. If you are in a function menu, e.g.
  • Page 52 DVD drive, SD card drives), address book (NAME), telephone and navigation system. A Help function is also available. Unlike in the Audi A6 and A8, the voice-operated system is integrated in the operating electronics control unit, navigation J402, and not installed in the vehicle as a separate module. The system is operated using the controls on the multifunction steering wheel.
  • Page 53 Available sound systems The new Navigation Plus system (RNS-E) for the Audi A3 ´05 comes with a choice of two different sound system options. Firstly, the standard sound system, whereby the two front channels are amplified directly by the power amps of the RNS-E...
  • Page 54 Universal mobile phone preparation II Pressing the TEL key opens the menu for controlling the mobile telephone in the optional universal mobile phone preparation II (See SSP 312, Audi A3 ´04 Electrical System). 332_068 DVD navigation The NAV key opens the control menu of the DVD-based navigation system.
  • Page 55 System overview The new Navigation Plus system is fully integrated into the CAN bus architecture of the Audi A3. Only the optional CD changer exchanges data with the operating electronics control unit, navigation J402 via a separate bus port (Panasonic bus, See SSP 312). The distance signal is sent from the ABS control unit J104...
  • Page 56 Convenience electronics Diagnosis Most diagnosis procedures for the new Navigation Plus system can be performed using the diagnostic tester. In addition to the extended control unit identification, the following functions are available: data blocks, coding and adaptation functions as well as sequential and selective final control tests. The control unit identification contains two different part numbers, one for the hardware and one for the software.
  • Page 57 Tyre circumference in millimetres. If the input value is "0", then the system in the Audi A3 ´06 will calibrate itself after several kilometres and input the corresponding value automatically. Pulses per wheel revolution. If the input value is "0", then the system in the Audi A3 ´06 will calibrate itself after several kilometres and input the corresponding value automatically.
  • Page 58 Notes...
  • Page 59 – Control units – Distributed functions – Infotainment – Occupant protection Order number: A03.5S00.03.20 332_087 SSP 313 Audi A3 ‘04 Running Gear – Axles – Steering – Brake system – ESP – Wheels / tyres – Hand and foot controls Order number: A03.5S00.04.20...
  • Page 60 Vorsprung durch Technik www.audi.de All rights reserved. Technical specifications subject to change without notice. Copyright AUDI AG I/VK-35 Service.training@audi.de Fax +49-841/89-36367 AUDI AG D-85045 Ingolstadt Technical status: 05/04 Printed in Germany A04.5S00.11.20...

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