Audi A6´05 323 Service
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Audi A6´05 323 Service

Self-study programme 323
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Audi A6´05
Self-Study Programme 323

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Summary of Contents for Audi A6´05 323

  • Page 1 Service Training Audi A6´05 Self-Study Programme 323...
  • Page 2 Preface The new Audi A6 – the most progressive vehicle takes the lead Design and performance are the main driving elements on its way to the top position. Furthermore, the new Audi A6 embodies the consequent continuation of the familiar Audi brand...
  • Page 3 Self-study programmes for the Audi A6´05 SSP 323 Audi A6´05 – Introduction to the vehicle – Body technology – Passenger protection – Air conditioning Order No.: A04.5S00.06.20 323_057 SSP 324 Audi A6´05 Chassis – Front axle technology – Rear axle technology –...

  • Page 4: Table Of Contents

    Contents Chapter 1 Introduction Product highlights..............6 Dimensions.
  • Page 5 Special tools for the Audi A6´05 air conditioning system .......

  • Page 6: Chapter 1 Introduction

    Introduction Product highlights The product features which support the new Audi A6´05 on its way to the top, can be summarised as follows: One wing is the design, the other wing is the car’s performance. Performance Design Power trains Quality –...

  • Page 7: Dimensions

    The vehicle width has been increased by 4.5 cm to 1.86 m. The height of the new A6´05 has been increased by 0.8 cm to 1.46 m. The new Audi A6´05 has grown. For the dimensions, please refer to the diagrams.

  • Page 8: Body Shell / Connection Technology

    The main objectives during the development of the In spite of the greater demands compared with new Audi A6 body design were the realization of the previous model, the body weight has been kept at the same level. high passive safety characteristics and improved rigidity values as a precondition for optimizing vibration damping characteristics.
  • Page 9 Spot welding bonding, using a high-strength In addition to classic resistance spot welding, the structural adhesive, is used for particularly following connecting techniques are used on the crash-relevant and rigidity determining connections new A6´05 body shell: (length of the bonded seam factor 3 compared with –...

  • Page 10: Materials

    Body Materials In addition to conventional deep-drawing steels, the following materials are used in the body structure of the new Audi A6´05: – High tensile sheet steel – Special sheet steel – Aluminium sheets – Aluminium extruded sections and – Plastic-ribbed deep-drawing steel component (hybrid component) High tensile steels (180 - 300 N/mm²)
  • Page 11 Large-volume aluminium extruded sections are High-tensile steel sheets are used especially in used as sill reinforcements to stiffen the cell areas which require strengthening and greater structure in the event of an offset or side crash. impact resistance. The front roof frame is designed as a hybrid Special steel sheets are also used in the body component in order to reduce the weight.

  • Page 12: Blanks

    Body Blanks Blanks with different wall thicknesses and material Laser-welded blanks, so-called tailored-blanks, qualities are used to realize a stress-adapted are used for material distribution for large-area components – the front suspension strut cross member which are subject to high stress. –...
  • Page 13 Tailored-rolled blanks, which have variable rolled In total, a weight reduction of 8 kg (without add-on wall thicknesses, have particular advantages. parts) was realized through the material selection They can be used to produce continuous material being adapted to the respective stress conditions. thickness transitions which meet the local stress An additional weight reduction of 9 kg was realized conditions.

  • Page 14: Assemblies

    Body Assemblies Plenum chamber One application area for special steel is the chassis In addition, a tailored blank is fitted in the plenum connection in the proximity of the spring and shock chamber. absorber seat. This ensures the highest possible energy It was possible to reduce the wall thickness of the absorption in the event of a crash.
  • Page 15 B-pillar Due to the increased requirements regarding the strength of the B-pillar, a combination of different materials is used. – front inner side section (high tensile steels) – rear inner side section, tailored blank (dual-phase steels, high tensile steels) t = 1.35 mm and 0.8 mm –...

  • Page 16: Bumpers

    Body Bumpers Front bumper The bumper on the new Audi A6´05 is painted in the The number plate in the radiator grille is integrated colour of the car. stylishly and harmoniously within the overall It comprises the following components: design.

  • Page 17: Trailer Coupling

    Rear bumper Compared to the previous model, the joints on The rear bumper assembly comprises the coating, the A6´05 have been noticeably reduced. spoiler, towing lug cover and closing part Due to a special adjusting/holding part below the components. It is mounted on the vehicle by means rear light, the zero joint between the bumper of fixed guides on the body.
  • Page 18 J345 corresponds to the control unit which has already been in use since the 2001 Audi A4. coupling and indicating this to the driver. To be used in the Audi A6´05, it was upgraded by the control function for the swivelling trailer coupling. F354...
  • Page 19 On pulling the handwheel in the boot, the contact switch on handwheel F354 is closed. On turning the handwheel, the locking bolt on the trailer coupling is unlocked mechanically by a Bowden cable and the contact switch on locking bolt F355 opens. After being unlocked, the trailer coupling can be swivelled out/in mechanically.

  • Page 20: Chapter 3 Passenger Protection

    – Driver and front passenger airbags, two-stage completion User tests, in which the new – Front side airbags Audi A6´05 was to gain a top position in the rating – Sideguards (head airbags) scheme, were only a part of the extensive safety –...
  • Page 21 G283 G284 K145 PASSENGER J623 AIRBAG OFF J285 E224 AIRBAG K75 / K19 AUS EIN J533 N95 / N250 N131 / N132 G179 J234 G180 N199 N200 G128 N251 N252 N154 N153 G256 G257 J393 J655 326_002 J234 Airbag control unit Airbag igniter, driver side J285 Control unit in dash panel insert...

  • Page 22: Airbag Control Unit J234

    – Crash detection (front, side, tail) technician needs access (with password) to the – Defined triggering of the airbags, belt tensioners ”FAZIT” database at Audi. and battery cut-off If the coding or adaptation is not carried out in the – Defined triggering of the second front airbag...

  • Page 23: Data Exchange

    Airbag warning lamp K75 The airbag warning lamp, which is located in dash panel insert J285, is triggered via the bus CAN. If there is no data message from the airbag control unit, the warning lamp is automatically switched on from the dash panel insert.

  • Page 24: Sensors

    326_015 (in the control unit) The mechanical safing sensor in the airbag control unit for the Audi A6‘05 has been replaced by a micromechanical acceleration sensor. This sensor also detects the vehicle's deceleration in the direction of travel (x-axis) and sends this information to the control unit electronics for a plausibility check.
  • Page 25 Both crash sensors for side airbag G256 and G257, which are fitted near the C-pillar (left and right), are conventional acceleration sensors, which were already used for the previous Audi A6 model. How the crash sensors work A crash sensor essentially comprises a housing,...

  • Page 26: Belt Warning

    Passenger protection Belt warning The new Audi A6´05 includes a belt warning function If the driver or front passenger has not fastened for both driver and passenger. the seat belt, a warning is given by means of belt After switching on the ignition, the driver's belt lock...

  • Page 27: Airbag

    Airbag Driver airbag N95 and N250 A two-stage gas generator is used as the driver's airbag. The radial opening of the airbag and the delayed ignition of the propelling charges reduce the loads acting on the driver when the car crashes. Depending on the seriousness and type of accident, the time lapse between the two ignitions can be approx.

  • Page 28: Passenger Protection

    Passenger protection Front passenger airbag N131 and N132 Like the driver airbag, the passenger airbag also comes with a two-stage gas generator. In contrast to the driver's airbag, the gas generator in the front passenger airbag operates according to the hybrid gas technique.
  • Page 29 Propelling charge I is ignited 326_021 Propelling charge I burns off Piston opens the gas cylinder Gas mixes Gas fills the airbag 326_022 Propelling charge II is ignited and burns off 326_023...
  • Page 30 Side airbag NAR Head airbags N251 and N252 Sideguards The policy for the sideguard, like all Audi vehicles, is to cover the entire side window area. New head airbags are used in the Audi A6´05. The hybrid gas generator is no longer fitted in the proximity C-pillar, but in the upper area of the B-pillar.

  • Page 31: Airbag Disabling Key Switch, Front Passenger Side E224

    Seat belts and belt tensioners N153 and N154 The proven compact tensioners are used for the front seats in the Audi A6. The electrically triggered tensioner units operate according to the ”ball and gearwheel” principle. The belt tensioner units are triggered before the front airbags.
  • Page 32 Passenger protection Belt switches E24 and E25 (in the belt locks) A belt lock interrogation procedure is planned for the driver / front passenger belt lock. The switch position can be determined by means of a resistance measurement. The measured resistance value tells the airbag control unit whether the safety belt has been fastened.

  • Page 33: Active Head Restraints

    A blocking of the mechanics in the event of a frontal impact, as in the case of the Audi A8‘03, is not necessary, due to the lower mass of the head Lumbar support restraints.

  • Page 34: Battery Cut-Off Relay J655

    Passenger protection Battery cut-off relay J655 The Audi A6‘05, like the Audi A8‘03, will also be equipped with the battery cut-off function in the event of a crash. The battery cut-off relay disconnects the starter and generator lines from the vehicle's battery (located in the boot) in the event of a crash.
  • Page 35 J655 326_018 Terminal Input / output Description input Battery + (screw-type terminal) output Output and starter (screw-type terminal) input Switched + (clamp-type terminal) input Chassis ground (clamp-type terminal) Crash signal input Activation from (clamp-type terminal) airbag control unit J234 Diagnosis Input and output Diagnosis line from (clamp-type terminal)

  • Page 36: Seat Occupied Recognition, Not For Usa

    Passenger protection Seat occupied recognition, not for USA Seat cushions Seat occupied sensor, front passenger side, G128 is a plastic foil, which covers the rear part of the front passenger seat. It consists of several individual pressure sensors. This ensures that the relevant part of the seat is sensed.

  • Page 37: Seat Occupied Recognition For Usa Market

    PASSENGER AIRBAG OFF warning lamp and a corresponding message in the dash panel insert. This type of seat occupied recognition in the Audi A4 will now be used for the USA (new). The system comprises the following components: – Seat cushions –...
  • Page 38 Passenger protection Pressure sensor for seat occupied recognition G452 Pressure sensor for Protective foil seat occupied recognition Pressure sensor for seat occupied recognition G452 is connected to the mat for seat occupied recognition by means of a hose. The mat, which is filled with a silicone-like gel is fitted below the seat cushion.
  • Page 39 Wearing belt recognition switch E24 and E25 The wearing belt recognition switch is fitted directly in the belt lock. Two resistors are integrated within the switch. The measurement is effected via one or both of the resistors, depending on the switch position.

  • Page 40: Seat Occupied Recognition Control Unit J706

    Passenger protection Seat occupied recognition control unit J706 The control unit evaluates the signals coming from The data from the sensors is continuously evaluated the pressure sensor and the belt force sensor. The when the ignition is switched on. This ensures that seat occupied recognition control unit uses the the control unit recognizes any seat occupancy information it receives from the seat belt force...
  • Page 41 Data exchange between the seat occupied recognition control unit and other vehicle systems is effected via the airbag control unit (by means of the LIN bus). The airbag control unit is thus the master control unit and the seat occupied recognition control unit (J706) the slave.

  • Page 42: Chapter 4 Diagnosis

    Diagnosis Diagnosis As in the case of the Audi A8´03 and Audi A3´04, communication in the Audi A6´05 between the VAS tester and the vehicle is effected via CAN-Bus, CAN-Diagnosis. The main Diagnosis modification is the Diagnosis tester online connection.

  • Page 43: Vas 5051

    VAS 5051 The VAS 5051 A tester will be replaced by the VAS 5051 B in 2004. The hardware and design of the VAS 5051 have been revised and updated. The 15" screen is the most noticeable feature of the VAS 5051 B. The main objective of the revision was being able to use it on the existing instrument waggon and with the existing test cables.

  • Page 44: Vas 5053/20

    Diagnosis VAS 5053/20 The VAS 5053/20 wireless Diagnosis interface permits wireless communication between the Diagnosis socket in the vehicle and the VAS 5051 B, VAS 5052 and VAS 5053 Diagnosis testers. 326_034...

  • Page 45: Recording The Working Time Using The Vas 5051/5052

    Workshop code: Version: 02211 123 12312 Basic V06.02.00 19/06/2003 Audi V06.50.00 07/08/2003 Company code: Registration no.: VK-31 AB-CD 1234 Vehicle Ident. No.: WAUZZZ.....

  • Page 46: Overview Of Available Engine / Gearbox Combinations

    Engine / Gearbox Overview of available engine / gearbox combinations V6 3.0l TDI V6 3.2l FSI V8 4.2l 2.4l...
  • Page 47 Reference: For information on the engines and gearboxes, refer to SSP 325 09L/to 450Nm 0A3/450Nm 01X/02Xqu 01J/330Nm 330Nm 09L/to 450Nm 01J/330Nm 01X/02Xqu 330Nm...

  • Page 48: Chapter 6 Chassis

    Chassis Overview The basic version of the Audi A6´05 is equipped with a steel spring chassis. There are three different types of running gear: Normal chassis: Designation 1BA Sports-style running gear: Designation: 1BE, vehicle trim is positioned 20 mm lower than on...

  • Page 49: Rear Axle

    Rear axle The rear axle represents a further development of The axle struts are now longer compared with the trapezoid link axle, with which you may be the A4`00 in order to guarantee a larger toe width. familiar from the A4’00. Because of the geometric For vehicles with the V8 TDI engine with quattro and kinematic changes compared with the drive, the rear axle track width will be reduced in...

  • Page 50: Wheel Brake

    Chassis Wheel brake Front-axle overview Engine 3.0 litre V6 TDI 3.2 litre V6 FSI 4.2 litre V8 MPI Minimum wheel size 16” 16” 17” Brake type FNR-G 60 16” FNR-G 60 16” FNR-G 60 17” Number of pistons Piston diameter (mm) Brake disc diameter (mm) x 321 x 30 321 x 30...

  • Page 51: Esp

    A new ESP generation from Bosch in the form of The basic functionalities of the subfunctions EBD, ESP 8.0 is used in the Audi A6'05. The familiar basic ABS, TCS, EDTC, EDL, ESP and ECD are the same as functions already available in the other Audi models in the predecessor version 5.7.

  • Page 52: Steering System

    A newly developed three/four-spoke steering-wheel predecessor model. The speed-dependent generation is used. Servotronic servo-support is available as standard. Servotronic II, which was already used in the Audi A8, is used (set-up and mode of operation: see SSP 285). Steering gear Oil reservoir Suction hose...

  • Page 53: Wheels / Tires

    A new generation of the tyre pressure monitoring It is modular in design and is significantly different system is available for the Audi A6´05. from the systems used up to now at Audi from the point of view of functionality and design.

  • Page 54: Bus Topology

    Electrics Bus topology Distance control J428 Control unit in dash panel insert J285 Diagnosis interface for data bus J533 Data link connector Door control unit, Power sensor Engine electronics 1 driver’s side management J583 J623 J386 J644 Door control unit, Rotation rate sensor ABS with EDL Auxiliary heating...
  • Page 55 Transmitter and transmitter and for telephone Handset Display and Telephone/telematics for telephone operating unit for J526 front information J523 Navigation with CD drive J401 TV tuner CD changer Digital Radio module Voice input sound package J507 J525 MOST bus CAN Instrument cluster Switch for Antenna read-in access and...

  • Page 56: In/Outputs On Control Units J393, J519 And J520

    Electrics In/outputs on control units J393, J519 and J520 This overview shows all load modules in the convenience system with their in/outputs. You thus have all 3 control units and their basic E1 Light switch functions at a glance. For further details, please E3 Hazard warning light switch F4 Switch for reversing lights refer to the function plans in self-study...
  • Page 57 E316 Glove compartment button J520 Control unit 2 for on-board power supply N119 Solenoid valve for Servotronic V1 Motor for sliding roof: – Speed signal – Convenience opening – Convenience closing V327 Motor for glove compartment release J9 Relay for rear window heater L106 Lighting for footwell, rear left L107 Lighting for footwell, rear right M2 Lamp for tail light, right...

  • Page 58: Chapter 8 Air Conditioning

    Air conditioning Overview The new Audi A6´05 is equipped with an air During the development process, particular conditioning system as standard. A differentiation attention was paid to weight and space-saving is made between automatic air conditioning and but output-optimized) components.
  • Page 59 Audi A6´05 air conditioning unit In the case of the 4 and 6-cylinder engines, it is The new Audi A6´05 – like the Audi A2 and Audi A3´04 – will be equipped with the familiar driven via a plastic belt pulley and in the case of the 8-cylinder engine, via a shaft.

  • Page 60: Convenience Automatic Air Conditioning And Convenience Automatic

    Air conditioning Convenience automatic air conditioning and convenience automatic air conditioning plus The new Audi A6´05 will still use an automatic air The control for the optional seat heating and conditioning system with two-zone temperature ventilation is integrated within both variants of control as standard equipment.

  • Page 61: Can Networking

    CAN networking The air conditioning system in the new Audi A6´05 is The personalization of the air conditioning settings integrated within the convenience CAN (see table). is effected by importing the respective code In addition to the air conditioning master control,...
  • Page 62 The rear window heating is activated from The air conditioning system (both variants) in the Climatronic control unit J255. A message is sent new Audi A6´05 uses the MMI display to display to convenience system control unit J393 via relevant information. The current MMI display switches over to the air conditioning menu on CAN-Convenience.
  • Page 63 On actuating an air conditioning function, the This in turn converts the incoming signals into data MMI display switches back to its original menu to be displayed on the respective display (J685) after a certain waiting time. which is connected. The information required for this is sent from Climatronic control unit J255 to the CAN-Convenience, converted into messages for...

  • Page 64: Components In The Audi A6´05 Air Conditioning Unit

    Air conditioning Components in the Audi A6´05 air conditioning unit Control motors Driver’s side Front left chest vent control motor, V237 Control motor for indirect ventilation flap, V213 Control motor for central vent, V102 Left footwell flap control motor, V107...
  • Page 65 Passenger’s side Control motor for cold air flap V197 Front right chest vent control motor, V238 Right footwell flap control motor, V108 Control motor for defrost flap V205 Control motor for passenger compartment vent, V112 323_019...

  • Page 66: Replacing Components

    Air conditioning Replacing components The air conditioning unit in the new Audi A6´05 does After fitting the new evaporator, the air conditioning not have to be completely removed from the vehicle unit housing is closed by means of a service flap to replace components.
  • Page 67 323_022 Using the special tool ”Suction nozzle T40073” to change the pollen filter in the vehicle 323_029 Two-part pollen filter in the new Audi A6´05...

  • Page 68: Control Motor Versions

    Control motor versions The redesigned air conditioning unit in the In the basic version, the control motors for the left Audi A6´05 uses modified kinematics for the chest vent, V237, are installed in the position of the individual control motors.

  • Page 69: In/Output Signals At Climatronic Control Unit J255

    In/output signals at Climatronic control unit J255 CAN-Convenience output signals Information on the status ... displays whether the compressor is switched on or off. Switched on means of the compressor that the compressor is within the control range, in other words, a current of 300 –...
  • Page 70 Air conditioning CAN-Convenience input siganls Vehicle speed The vehicle speed is used for the calculation "Setting the air congestion flap". Engine speed Start recognition: the program defines "Engine off", if n < 200 rpm (below starter speed) "Engine on", if n > 500 rpm is read. Terminal 58d Dimming value for the display and function lighting in %.

  • Page 71: Additional Electric Air Heater

    J255 sends an appropriate message containing versions of the new Audi A6´05. The operating the required output level to CAN-Convenience. This principle of the additional air heater is, as with the...

  • Page 72: Auxiliary / Additional Heating

    Air conditioning Auxiliary / additional heating The auxiliary heating which is available ex-works is Climatronic control unit J255 decides on the installed on the longitudinal member, front right auxiliary heating or auxiliary ventilation mode, the under the headlight. It is incorporated into the respective symbol is shown as a function display on CAN-Convenience via auxiliary heating control the display unit in dash panel insert J285 after the...
  • Page 73 Switch-on conditions: Switch-off conditions: no tank warning Auxiliary heating active longer than 60 min no crash signal from airbag control unit VAS diagnosis tester function basic setting no cut-off level from control unit for power management Heater units error in operational mode no message "Transport mode active"...

  • Page 74: Air Conditioning Diagnosis

    (complete performance of all actuator tests) and selectively (selection of functionality. In contrast to the current Audi A8 and Audi A3, individual actuator tests) possible. The following conditions must be met before the actuator test can during a recoding of a Climatronic control unit J255, no information on the networking is taken from the be performed.

  • Page 75: Special Tools For The Audi A6´05 Air Conditioning System

    Special tools for the Audi A6´05 air conditioning system Puller T40072 Ratchet spanner T40083 323_027 323_026 Suction nozzle with brush T40073/1 and hose T40073/2 323_028...
  • Page 76 Vorsprung durch Technik www.audi.co.uk All rights reserved. Subject to technical change. Copyright AUDI AG I/VK-35 Service.training@audi.de Fax +49-841/89-36367 AUDI AG D-85045 Ingolstadt Technical release 01/04 Printed in Germany A04.5S00.06.20...

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A6 2005

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