Download - SSP 181 Audi A3 Presentation
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 1/32
Self-Study Program
Service Department
Service.
For internal use only.
© VOLKSWAGEN AG K-VK-12, Wolfsburg
All rights reserved. Specifications subject to alteration.
This paper was produced
using cellulose bleached
without chlorine.
❀
Audi A3 -
640.2809.9820Technischer Stand: 07/96
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 2/32
2
SSP 181/1
Ecology
Safety
Mobility
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 3/32
3
New
Important/Note
A Self-Study Programmeis not a Workshop Manual.
Please refer to the Service Literature whichcontains all the relevant adjustment, inspection
and repair instructions.
Audi A3In brief..................................................................... 4Audi A3
Environmental protection is.................................. 8SafetyHow safe is the A3?................................................ 10BodyThe outer skin of the car........................................ 12EnginesThe big movers...................................................... 14GearboxIn forward gear....................................................... 18
Engine and gearboxThey make a strong team...................................... 19SubframeControlled swinging.............................................. 20Running gearWith the ability to lead........................................... 22Braking systemPower under pressure........................................... 24SteeringHighs and lows....................................................... 25
Heating systemHot and breezy....................................................... 26Air conditioning systemWell-cooled............................................................. 27Electrical systemIssues the command.............................................. 28Anti-theft warning systemThe minder............................................................. 30
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 4/32
4
In brief
The Audi A3 isa car which offers:
- outstanding
quality,
- a high safetystandard,
- and an emotive
design.
In this Self-Study Programme we willintroduce you to the Audi A3.
The technical details are explained
in Self-Study Programme 182.
SSP 181/3
Audi A3
SSP 181/80
SSP 181/81 SSP 181/82 SSP 181/83
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 5/32
5
The Audi is sporty and comfortable.
In brief
TypicalA3 drivers are:
- young,
- modern,
- and sporty
To them, driving is anadventure.
SSP 181/3
SSP 181/86 SSP 181/85 SSP 181/84
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 6/32
6
Audi A3
SSP 181/6
The dimensions of the compact Audi(all specified dimensions are in mm.)
The Audi A3 has a through-loading
width of 1005 mm.
In brief
SSP 181/6
SSP 181/4 SSP 181/5
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 7/32
7
With its low Cd, the
Audi cuts a goodfigure.
= drag coefficientcd
What does Cd stand for?
= 0.321
Vehicle aerodynamics
Aerodynamics is about investigating how
gases flow around solid bodies.
Vehicle aerodynamics is about investigatinghow air flows around the vehicle.
Cd
SSP 181/7
As 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.
In brief
SSP 181/8
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 8/32
8
Audi A3
In brief
Less environmentalpollution:
Environmental protection is...only what people make of it.
SSP 181/9
Use of lighter
materials improvesfuel economy.
Use of water-basedpaints means fewer
solvents.
Use of recyclablematerials saves raw
materials..
•
•
•
SSP 181/10
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 9/32
9
It makes good ecological sense to strip scrap
cars of all usable materials and put them backinto circulation in a new form as more
environmentally-friendly cars.
More than just scrap iron
SSP 181/11
The object of theexercise is the eco-friendly utilisation of
all scrap cars.
83% of the Audi A3is made of recyclable
materials.
SSP 181/48
65%Steel and iron
3.7%Lead, copper, zinc
7.5% Aluminium
3.4%Plastic
3.4%Glass, tyres
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 10/32
10
Safety
How safe is the
A3?
The Audi also achievesan impressive safetystandard.It is the safest car in itsclass.
SSP 181/12
SSP 181/14
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 11/32
11
You will already be familiar with many of the“active and passive safety” features.
Here are a few examples:
Active safety Passive safety
Rear disc brakes withaluminium floating
caliper
Anti-lock brakingsystem
Crash concept
Steering
Driver and frontpassenger airbags
Side airbag
Seat belt tensioner
Body
Inner and side door
trim panels withintegrated padding
SSP 181/15
SSP 181/16
SSP 181/17
SSP 181/87
SSP 181/88
SSP 181/89
SSP 181/90
SSP 181/91
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 12/32
12
Body
Audi uses only top-quality materials from
body construction through to final assemblyand 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)
The outer skin of the car
While expressing comfort and taste, the body
also provides security and safety.
The Audi A3 has a fully galvanised body.
SSP 181/18
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 13/32
13
How does the bodymanage to protect us?
Inside and side
door trim panelswith integrated
padding
Seats with high transverse rigidity
High-strength door side reinforcements madeof aluminium which support one another
inside the door sill during a crash
Wide door overlap at
door pillar and in doorsill area
Aluminium cross membersin bumpers
SSP 181/92
SSP 181/91
SSP 181/21
SSP 181/19
SSP 181/20
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 14/32
14
Engines
We 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 pollutantemissions even further. This was achieved
by shedding weight, and by employing newtechnologies and different materials.
omitting the intermediate shaftfitting an aluminium oil pan
using plastic componentsusing lightweight valve gear in all engines
cylinder block made of aluminium (1.6 ltr.)
••
••
•
Engine weight was reduced by:
Aluminium oil panReplaceable oil filter insert made of paper
(in 1.9 ltr. TDI engine)
Auxiliary component holders made ofaluminium
Coolant pump impeller made of plasticPlastic twin-path intake manifold
••
•
••
New oil pump chain-driven by crankshaftNew oil circuit
New water pump in cylinder block driven
by rib beltThermostat in cylinder block
Engine management system with 16-bitcomputer
Engine control units with identical housingsand two-part connector
••
•
•
•
•
The big movers
New engineering: Different materials were used to make thesecomponents:
SSP 181/30
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 15/32
15
2000 4000 6000
0
48 125
15060
72
36
24
12
84
175
100
75
50
0
200
0
96 220
Displacement:
Output:Engine management:
Fuel:
1595 cc
74 kW (100 bhp)Simos 2
Premium unleaded,95 RON
1.6 ltr. engine
The 1.6 ltr. engine develops 74 kW (100 bhp) atan engine speed of 5600 rpm.
Peak torque is 145 Nm at 3800 rpm.
Aluminium cylinder block withinternal vent pipe
Press-fitted cast iron cylindersPlastic twin-path intake manifold
Simos 2 engine managementsystem
Static high-voltage distributor
•
••
•
•
Output
kW
Torque
Nm
Engine speed rpm
Engine code AEH
SSP 181/31
The engine may also run on regular unleaded
fuel (91 RON), but this reduces max. power.
SSP 181/32
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 16/32
1
. 8 l t r . 5 - v a l v e e n g i n e
7 2
8 4
1 7 5
2 0 0
9 6
2 2 0
E n g i n e s
D
i s p l a c e m e n t :
O
u t p u t :
E
n g i n e m a n a g e m e n t :
F
u e l :
1 7 8 1
c c
9 2 k W
( 1 2 5 b h p )
M o t r
o n i c 3 . 8 . 2
P r e m
i u m u n l e a d e d
( 9 5 R
O N )
H y d r a u l i c i n l e t c a m s h a f t
a d j u s t m e n t , e l e c
t r o n i c a l l y
c o n t r o l l e d
M o t r o n i c 3 . 8 . 2 e n g i n e
m a n a g e m e n t s y s t e m
S t a t i c h i g h - v o l t a g e d i s t r i b u t o r
• • •
O u t p u t
k W
T o r q u e N m
E
n g i n e c o d e A G N
S S P 1 8 1 / 3 3
T
h e e n g i n e m a y a l s o r u n o n r e g u l a r u n l e a d e d
f u e l ( 9 1 R O N ) , b u t t h i s r e d u c e
s m a x . p o w e r .
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 17/32
6 0
7 0
2 5 0
8 0
2 7 5
3 0 0
D i s p l a c e m e n t :
O u t p u t :
M i x t u r e p r e p a r a t i o n :
F u e l :
E x h a u s t g a s t r e a t m e n t :
1 . 9 l t r . T D I e n g i n e
1 8 9 6 c c
6 6 k W ( 9 0 b h p )
D i r e c t i n j e c t i o n , w i t h
e l e c t r o n i c a l l y
c o n t r o l l e d p i l o t
i n j e c t i o n p u m p
D i e s e l ; c a n a l s o b e
r u n o n b i o d i e s e l .
E x h a u s t g a s
P r e s e t i n j e c t i o n p u m p w i t h t w o -
p a r t r i b b e l t
w h e e l
L i g h t w e i g h t
v a l v e g e a r
V e r t i c a l o i l fi
l t e r w i t h r e p l a c e a b l e
p a p e r i n s e r t
C a m s h a f t - d r i v e n v a c u u m p u m p
• • • •
O u t p u t
k W
T o r q u e N m
E n g i n e c o d e A G R
S S P 1 8 1 / 3 5
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 18/32
G e a r b o x
I n f o r w a r d g e a r
Y
o u s h o u l d a l r e a d y b e f a m i l i a
r w i t h t h e 4 -
s
p e e d a u t o m a t i c g e a r b o x .
A l l g e a r b o x e s a r e t r a n s v e r s e l y m o u n t e d
i n p e n d u l u m s u p p o r t s .
Y o u w i l l fi n d a d e s c r i p t i o n o f t h e
d e s i g n a n d f u n c t i o n
o f t h e 4 - s p e e d
a u t o m a t i c g e a r b o x i n S S P 1 7 2 .
T
h e 0 2 J 5 - s p e e d m a n u a l g e a
r b o x i s a m o r e
a
d v a n c e d v e r s i o n o f t h e 0 2 A
m a n u a l
g
e a r b o x .
T h e 0 2 K 5 - s p e e d m a n u a l g e a r b o x i s a m o r e
a d v a n c e d v e r s i o n o f t h
e 0 2 0 m a n u a l
g e a r b o x .
S S P 1 8 1 / 2 2
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 19/32
C O M B I N A T I O N
E n g i n e a n d
g e a r b o x
T h e y m a k e a s t r o n g t e a m
o r
o r
0 2 K
A G 4
0 2 J
A G 4
1 . 6 l t r .
1 . 8 l t r .
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 20/32
A s s e m b l y
m o u n t i n g
T h e s u b f r a m e c o m p r i s e s t h e f o l l o w i n g :
C o n t r o l l e d s w i n g i n g ?
I n t h e A u d i A 3 , t o o , t h e
a s s e m b l i e s ( e n g i n e a n d
g e a r b o x ) d o n o t s w i n g
- t h e y o s c i l l a t e .
I n o t h e r w o r d s , t h e e n g
i n e a n d g e a r b o x a r e
i n s t a l l e d a c c o r d i n g t o t
h e p r i n c i p l e o f t h e
p e n d u l u m .
G e a r b o x m o
u n t
E n g i n e m o u n t
P e n d u l u m s u p p o r t
S S P 1 8 1 / 3 8
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 21/32
T h e g e a r b o x m o u n
t
i s a r u b b e r / m e t a l m
o u n t c o m p r i s i n g m o d i fi e d
r u b b e r e l e m e n t s .
T h i s f a c i l i t a t e d fi n e
t u n i n g o f t h e 3 f o r c e
c o m p o n e n t s i n t h e
d e s i g n p r o c e s s .
T h e 3 f o r c e c o m p o
n e n t s a r e :
W e i g h t
E n g i n e t o r q u e
C e n t r i f u g a l f o r c e w h e n c o r n e r i n g
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 22/32
S i n g l e - b o l t c l a m p i n g
A n t i - r
o l l b a r
T r a c k
r o d
S u s p e n s i o n s t r u t
W i t h t h e a b i l i t y t o
l e a d
T h e b a s i s o f t h e f r o n t a
x l e i s t h e 1 5 “ r u n n i n g
g e a r w i t h s u s p e n s i o n s
t r u t a n d a n A - a r m .
R u n n i n g g e a r
P o w e r S t e e r i n g a s s t a n d a r d
C a s t w h e e l b e a r i n g
h o u s i n g w i t h
“ s i n g l e - b o l t c l a m p i n g “
T h e t w o t r a c k r o d s
a r e a d j u s t a b l e
P l a s t i c c o u p l i n g r o d
R o u t i n g o f a n t i - r o l l
b a r
• • • • •
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 23/32
W i t h t h e a b i l i t y t o l e a d
T h e r e a r a x l e i s a t o
r s i o n b e a m a x l e . T h e s h o c k
a b s o r b e r s a n d s p r i n g s a r e l o c a t e d s e p a r a t e l y .
T h e s h o c k a b s o r b e
r s a r e s e c u r e d i n t h e
w h e e l h o u s e , i n c r e a s i n g t h e t h r o u g h - l o a d i n g
w i d t h a n d r e d u c i n g d r i v i n g n o i s e i n t h e
i n t e r i o r .
W h e e l b e a r i n g
: t w i n b a l l r a c e s ( n o
a d j u s t m e n t n e e d e d )
R e a r a x l e b e a r i n g w i t h 2 5 °
i n c l i n a t i o n
A n t i - r o l l b a r a s
s t a n d a r d
• • •
W h e e l b e a r i n g :
t w i n b a l l r a c e s ( n o
a d j u s t m e n t
n e e d e d )
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 24/32
B r a k i n g s
y s t e m
P o w e r u n d e r p r e s s u r e
T h e b r a k i n g s y s t e m h a s a d i a g o n a l d u a l - c i r c u i t
d e s i g n .
V e n t i l a t e d d i s c b r a k e s a t f r o n t a s
s t a n d a r d
D i s c b r a k e w i t h a l u
m i n i u m fl o a t i n g
c a l i p e r a t r e a r a s s t
a n d a r d
B r a k e p i p e w i t h a l u
m i n i u m / p l a s t i c
c o v e r i n g , i m p r o v e d
c o r r o s i o n
p r o t e c t i o n
A B S a s s t a n d a r d , 2
0 G I s y s t e m
( I T T a u t o m o t i v e E u
r o p e ,
a m a l g a m a t i o n w i t h
T e v e s )
• • • •
D
i s c b r a k e
B r a k e p i p e s
A B S m o d u l e
D i s c b r a k e
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 25/32
S t e e r i n g
L o n g i t u d i n a l a d j u s t m e n t : 4 5 m m ,
v i a c l a m
p i n g .
H i g h s a n d l o w s
T h e s t e e r i n g w h e e
l i s m a n u a l l y a d j u s t a b l e f o r
r e a c h a n d h e i g h t .
H e i g h t a
d j u s t m e n t : 4 4 m m , w i t h
i n d e x i n g m e c h a n i s m .
• •
4 5
m m
S S P 1 8 1 / 4 4
4 4 m m
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 26/32
26
Heating system
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 isadmitted.
The air recirculation button is not functional in
Defrost setting.
The heating system with air
recirculation flap is operatedelectronically via a servo motorThe other air flaps are actuated
mechanically via Bowden cables
•
•
Hot and breezy
The heating system with air recirculation
mode is controlled at the air intake end.
What does air recirculation mode mean?
Servomotor
Air recirculation flap
Air recirculation button
SSP 181/45
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 27/32
27
Well-cooled
The air conditioning system of the Audi A3 is
controlled automatically. You should alreadybe familiar with the function and operation ofthe air conditioning system, since it is identical
to that of the Audi A4.
Air conditioning system
The 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.
The ventilation flap and air
recirculation flap are controlled viaa common servo motorThe air flap is controlled via servo
motors and 2 temperature sensorsPlate evaporator
•
•
•
Ventilation flap
Servo motor
Control unit
SSP 181/46
Temperature sensor
Air recirculation flap
Refrigerant
Air
Lamella
SSP 181/73 SSP 181/74
Laminar tube evaporatorPlate evaporator
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 28/32
28
SSP 181/55
Electrical system
The electrical system is, technically, identicalto that of the Audi A4.
The overview shows you the fitting locationsof the control units and connection stations.
Issues the command
SSP 181/66
SSP 181/64
SSP 181/65
SSP 181/53
SSP 181/77
SSP 181/93
Engine control unit
Control unit AG 4
Air conditioning
control unit
Coupling
station of
A pillar
Airbag control unitMain fuse box
SSP 181/79
When repairing the wiring harness,use Wiring Harness Repair Kit VAS
1978.This kit can be used for all VW and
Audi vehicles.
ABS control unit
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 29/32
29
The dash panel insert has self-diagnosiscapability and can be read with Service Tester
V.A.G. 1551/1552.
Dash panel insert with integratedimmobiliser
Pneumatic central locking withradio wave remote control
•
•
1
2
3
4
5
6
7
1/min x 1000 km/h
90
°C
1/2
1/1R
4D0000190
13
8.8km
220
260
180
140100
60
20
40
80
120160
200
240
0
!
PABS
AIRBAG
50 120
SSP 181/58
SSP 181/78
SSP 181/63
SSP 181/54
SSP 181/71
SSP 181/62 SSP 181/56
Dash panel
insert with
integrated
immobiliser
Diagnosis plug connection
Micro central electrics
Coupling station
Control unit
Interior monitoring
Fuse-box
Control unit
Anti-theft warningsystem/central locking
SSP 181/55
Coupling
station of A
pillar
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 30/32
30
Anti-theft warning system
The minder
You should also already be familiar with theanti-theft warning system with interiormonitoring, since the same system is used in
the Audi A4.The overview shows you the fitting locations
of the control units and sensors.
SSP 181/59
SSP 181/70
SSP 181/72
SSP 181/68
SSP 181/67
SSP 181/70
Interior sensor
Servo motor for fuel filler flap
Interior LED
Interior
switchInterior LED
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 31/32
31
Servo motor
Central locking/
left and right doors
SSP 181/71
SSP 181/62
SSP 181/60
The design and function of the anti-theft warning system and interior
monitoring are described in Self-
Study Programme 185.
SSP 181/61
Control unit
Anti-theft warning
system/central locking
Servo motor
Central locking/Tailgate
Control unit
Interior monitoring
7/26/2019 SSP 181 Audi A3 Presentation
http://slidepdf.com/reader/full/ssp-181-audi-a3-presentation 32/32
Technical
Details, see
Self-Study
Programme182
The eng-
ineering