Service.181Audi A3 - PresentationSelf-Study ProgrammeFor internal use only. © VOLKSWAGEN AG K-VK-12, Wolfsburg All rights reserved. Specifications subject to alteration. 640.2809.9820Technischer Stand: 07/96 Y This paper was produced using cellulose bleached without chlorine.Service DepartmentEcologySafetyMobilitySSP 181/12Audi A3 In brief..................................................................... Audi A3 Environmental protection is.................................. Safety How safe is the A3?................................................ Body The outer skin of the car........................................ Engines The big movers...................................................... Gearbox In forward gear....................................................... Engine and gearbox They make a strong team...................................... Subframe Controlled swinging.............................................. Running gear With the ability to lead........................................... Braking system Power under pressure........................................... Steering Highs and lows....................................................... Heating system Hot and breezy....................................................... Air conditioning system Well-cooled............................................................. Electrical system Issues the command.............................................. Anti-theft warning system The minder.............................................................4 8 10 12 14 18 19 20 22 24 25 26 27 28 30A Self-Study Programme is not a Workshop Manual. Please refer to the Service Literature which contains all the relevant adjustment, inspection and repair instructions.NewImportant/Note3Audi A3In this Self-Study Programme we will introduce you to the Audi A3. The technical details are explained in Self-Study Programme 182.SSP 181/80In briefThe Audi A3 is a car which offers: outstanding quality, a high safety standard, and an emotive design.--SSP 181/3SSP 181/81SSP 181/82SSP 181/834The Audi is sporty and comfortable.In briefTypical A3 drivers are: young, modern, and sportyTo them, driving is an adventure.SSP 181/3SSP 181/84SSP 181/85SSP 181/865Audi A3In briefThe dimensions of the compact Audi (all specified dimensions are in mm.)SSP 181/4SSP 181/5SSP 181/6The Audi A3 has a through-loading width of 1005 mm.SSP 181/66Vehicle aerodynamicsAerodynamics is about investigating how gases flow around solid bodies. Vehicle aerodynamics is about investigating how air flows around the vehicle.SSP 181/8 SSP 181/7As you can see, the shape of a car plays a key role.If the air resistance is low, less force is needed to overcome it. This saves energy. And saves fuel.With its low Cd, the Audi cuts a good figure.Cd= 0.321In briefWhat does Cd stand for? cd = drag coefficient7Audi A3Environmental protection is...only what people make of it.In briefLess environmental pollution: • Use of lighter materials improves fuel economy. • Use of water-based paints means fewer solvents. • Use of recyclable materials saves raw materials. .SSP 181/10SSP 181/98More than just scrap ironIt makes good ecological sense to strip scrap cars of all usable materials and put them back into circulation in a new form as more environmentally-friendly cars.The object of the exercise is the ecofriendly utilisation of all scrap cars. 83% of the Audi A3 is made of recyclable materials.65% Steel and iron 3.7% Lead, copper, zinc 7.5% AluminiumSSP 181/113.4% Plastic 3.4% Glass, tyresSSP 181/489SafetyHow safe is the A3?The Audi also achieves an impressive safety standard. It is the safest car in its class.SSP 181/12SSP 181/1410You will already be familiar with many of the “active and passive safety” features.Here are a few examples: Active safety Passive safetyBodyDriver and front passenger airbagsSSP 181/15SSP 181/88Rear disc brakes with aluminium floating caliperSide airbagSSP 181/16SSP 181/89Seat belt tensionerAnti-lock braking systemSSP 181/17 SSP 181/90Crash concept SteeringInner and side door trim panels with integrated paddingSSP 181/87 SSP 181/9111BodyThe outer skin of the carWhile expressing comfort and taste, the body also provides security and safety.SSP 181/18The Audi A3 has a fully galvanised body.Audi uses only top-quality materials from body construction through to final assembly and vouches for the reliability of every detail.Tried and tested concepts are employed: - Use of aluminium parts - All models come with padding plus aptly lined door sides - Use of laser welding technology in the roof area - Mash-welded panels are used for the side members (panels are of different thickness)12How does the body manage to protect us?Seats with high transverse rigidityInside and side door trim panels with integrated paddingSSP 181/91SSP 181/92SSP 181/19High-strength door side reinforcements made of aluminium which support one another inside the door sill during a crashWide door overlap at door pillar and in door sill areaSSP 181/20Aluminium cross members in bumpersSSP 181/2113EnginesThe big moversWe will introduce you to the new engines of the Audi A3 on the following pages. The objective during development was to reduce fuel consumption and pollutant emissions even further. This was achieved by shedding weight, and by employing new technologies and different materials. Engine weight was reduced by:• • • • •omitting the intermediate shaft fitting an aluminium oil pan using plastic components using lightweight valve gear in all engines cylinder block made of aluminium (1.6 ltr.)SSP 181/30New engineering:Different materials were used to make these components: • • • • • Aluminium oil pan Replaceable oil filter insert made of paper (in 1.9 ltr. TDI engine) Auxiliary component holders made of aluminium Coolant pump impeller made of plastic Plastic twin-path intake manifold• • • • • •New oil pump chain-driven by crankshaft New oil circuit New water pump in cylinder block driven by rib belt Thermostat in cylinder block Engine management system with 16-bit computer Engine control units with identical housings and two-part connector141.6 ltr. engineEngine code AEH • • • • • Aluminium cylinder block with internal vent pipe Press-fitted cast iron cylinders Plastic twin-path intake manifold Simos 2 engine management system Static high-voltage distributorSSP 181/31Output kW96Torque Nm220Displacement: Output: Engine management: Fuel:1595 cc 74 kW (100 bhp) Simos 2 Premium unleaded, 95 RON8420072175The engine may also run on regular unleaded fuel (91 RON), but this reduces max. power.60 150481253610024751250The 1.6 ltr. engine develops 74 kW (100 bhp) at an engine speed of 5600 rpm. Peak torque is 145 Nm at 3800 rpm.0 0 2000 4000 60000Engine speed rpmSSP 181/3215Engines1.8 ltr. 5-valve engineEngine code AGN • • • Hydraulic inlet camshaft adjustment, electronically controlled Motronic 3.8.2 engine management system Static high-voltage distributorSSP 181/33Output kW96Torque Nm220Displacement: Output: Engine management: Fuel:1781 cc 92 kW (125 bhp) Motronic 3.8.2 Premium unleaded (95 RON)8420072175The engine may also run on regular unleaded fuel (91 RON), but this reduces max. power.60 150481253610024751250The 1.8 ltr. 5-valve engine develops 92 kW (125 bhp) at an engine speed of 5900 rpm. Peak torque is 173 Nm at 4000 rpm.0 0 2000 4000 60000Engine speed rpmSSP 181/34161.9 ltr. TDI engineEngine code AGR • • • • Preset injection pump with twopart rib belt wheel Lightweight valve gear Vertical oil filter with replaceable paper insert Camshaft-driven vacuum pumpSSP 181/35Output kW80Torque Nm300Displacement: Output: Mixture preparation:70275Fuel:60 2501896 cc 66 kW (90 bhp) Direct injection, with electronically controlled pilot injection pump Diesel; can also be run on biodiesel.5022540200Exhaust gas treatment: Exhaust gas recirculation system and two-way catalytic converter3017520150101000 0 1000 3000 50000Engine speed rpmThe 1.9 ltr. TDI engine develops 66 kW (90 bhp) at an engine speed of 4000 rpm. Peak torque is 210 Nm at 1900 rpm.17SSP 181/36GearboxIn forward gearAll gearboxes are transversely mounted in pendulum supports. You should already be familiar with the 4speed automatic gearbox.SSP 181/22You will find a description of the design and function of the 4-speed automatic gearbox in SSP 172.The 02 K 5-speed manual gearbox is a more advanced version of the 020 manual gearbox.The 02 J 5-speed manual gearbox is a more advanced version of the 02 A manual gearbox.SSP 181/23SSP 181/2418Engine and gearboxThey make a strong team02 KC O M B I N A T I O N Sor1.6 ltr. AG 402 J or1.8 ltr. AG 402 J or1.9 ltr. TDISSP 181/52AG 4SSP 181/2519Assembly mountingControlled swinging?In the Audi A3, too, the assemblies (engine and gearbox) do not swing - they oscillate. In other words, the engine and gearbox are installed according to the principle of the pendulum.Gearbox mountEngine mountPendulum supportSSP 181/38The subframe comprises the following: - The gearbox mount = Rubber/metal mount- The engine mount = Hydraulic rubber/ metal mount - The pendulum support = Rubber/metal mount A description of the pendulum support is given in Self-Study Programme 166 “Polo“.20The gearbox mount is a rubber/metal mount comprising modified rubber elements. This facilitated fine tuning of the 3 force components in the design process.The 3 force components are: Weight Engine torqueCentrifugal force when corneringSSP 181/39Fine tuning improved the vibration response of the engine and gearbox, thereby enhancing ride comfort even more.21Running gearWith the ability to leadThe basis of the front axle is the 15“ running gear with suspension strut and an A-arm. • Power Steering as standard • Cast wheel bearing housing with “single-bolt clamping“ • The two track rods are adjustable • Plastic coupling rod • Routing of anti-roll barSuspension strutSingle-bolt clampingTrack rod Anti-roll barCoupling rodSSP 181/4122With the ability to leadThe rear axle is a torsion beam axle. The shock absorbers and springs are located separately. The shock absorbers are secured in the wheelhouse, increasing the through-loading width and reducing driving noise in the interior. • Wheel bearing: twin ball races (no adjustment needed) • Rear axle bearing with 25° inclination • Anti-roll bar as standardWheel bearing: twin ball races (no adjustment needed)Rear axle bearingSSP 181/4223Braking systemPower under pressureThe braking system has a diagonal dual-circuit design. • Ventilated disc brakes at front as standard • Disc brake with aluminium floating caliper at rear as standard • Brake pipe with aluminium/plastic covering, improved corrosion protection • ABS as standard, 20 GI system (ITT automotive Europe, amalgamation with Teves)Brake pipes ABS module Disc brakeDisc brakeSSP 181/43Brake servo: Left-hand drive ø 10“ Right-hand drive ø 7“/ 8“ Because there is less space in righthand-drive vehicles, a 7“/ 8“ diameter tandem brake servo is fitted. ABS, see SSP 171!24SteeringHighs and lowsThe steering wheel is manually adjustable for reach and height.• Height adjustment: 44 mm, with indexing mechanism.44mmSSP 181/44• Longitudinal adjustment: 45 mm, via clamping.45mmSSP 181/75Simultaneous height and longitudinal adjustment are possible.SSP 181/7625Heating systemHot and breezyThe heating system with air recirculation mode is controlled at the air intake end. • The heating system with air recirculation flap is operated electronically via a servo motor • The other air flaps are actuated mechanically via Bowden cablesAir recirculation flapAir recirculation buttonServomotorSSP 181/45What does air recirculation mode mean? When you press the Air Recirculation button, the air recirculation flap is closed via the servo motor. When the air recirculation flap is closed, the air in the interior is recirculated. No outside air is admitted. The air recirculation button is not functional in Defrost setting.26Air conditioning systemWell-cooledThe air conditioning system of the Audi A3 is controlled automatically. You should already be familiar with the function and operation of the air conditioning system, since it is identical to that of the Audi A4. • The ventilation flap and air recirculation flap are controlled via a common servo motor • The air flap is controlled via servo motors and 2 temperature sensors • Plate evaporatorControl unitAir recirculation flap Ventilation flap Temperature sensor Servo motorSSP 181/46The shape is what matters While having the same cooling capacity and cooling area as the laminar tube evaporator, the plate evaporator is 40% smaller than the latter.Plate evaporatorLaminar tube evaporatorRefrigerant Lamella AirSSP 181/74SSP 181/7327Electrical systemIssues the commandEngine control unitThe electrical system is, technically, identical to that of the Audi A4. The overview shows you the fitting locations of the control units and connection stations.Coupling station of A pillarSSP 181/64SSP 181/55Control unit AG 4SSP 181/65Air conditioning control unitSSP 181/53 SSP 181/77Airbag control unit Main fuse box ABS control unitSSP 181/93SSP 181/66When repairing the wiring harness, use Wiring Harness Repair Kit VAS 1978. This kit can be used for all VW and Audi vehicles.SSP 181/7928Dash panel insert with integrated immobiliser901/2 120 °C R 1/14 3 2 5 65010080120ABS140P16018020060!AIR BAGThe dash panel insert has self-diagnosis capability and can be read with Service Tester V.A.G. 1551/1552.40220km/h0km171/min x 10002024026013 8.84D0 000 190SSP 181/58Control unit Interior monitoringDiagnosis plug connectionSSP 181/71SSP 181/63Control unit Anti-theft warning system/central locking Coupling station of A pillar Coupling station Fuse-boxSSP 181/54SSP 181/55SSP 181/56SSP 181/62Micro central electrics•Dash panel insert with integrated immobiliser Pneumatic central locking with radio wave remote control•SSP 181/7829Anti-theft warning systemThe minderInterior sensorYou should also already be familiar with the anti-theft warning system with interior monitoring, since the same system is used in the Audi A4. The overview shows you the fitting locations of the control units and sensors.SSP 181/68Servo motor for fuel filler flapSSP 181/67Interior LEDSSP 181/70SSP 181/59Interior LEDInterior switchSSP 181/70SSP 181/7230Servo motor Central locking/TailgateSSP 181/61Control unit Interior monitoringSSP 181/71Control unit Anti-theft warning system/central lockingServo motor Central locking/ left and right doorsSSP 181/62The design and function of the antitheft warning system and interior monitoring are described in SelfStudy Programme 185.SSP 181/6031The engineeringTechnical Details, see Self-Study Programme 182SSP 181/9232