trainerinformation a6pa en–°添加/国产/原厂培训... · v8 4.2l 5v 250/340 420 01l qu. v8...

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Audi A6 Model Improvements 2002>Trainer information

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Contents:External features

Engine overview

Innovations to 3.0 V6 petrol engine

Innovations to 2.5 V6 TDI engine

Innovations to 1.9.PD TDI engine

Innovations to multitronic®

Innovations to running gear

Innovations to electrical system

Innovations to air conditioner

3

4

5

11

12

14

16

20

30

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Larger passengerdoor mirror

Bonnetand

trim grille

Flat-profile wipers New paint colours

Protective trim

Number platemounting

Clear sideturn-signallamps

Rear lights

Parkingsystem withnew optics

Aluminium frame

Headlights

Dynamic headlightlevelling system withBi-Xenon Visible

tailpipe

Audi A6 2002> - External Features

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Engine Overview

01E qu.01V qu.

370132/180V6 2.5l TDI

01E fr.01J fr.

310114/155V6 2.5l TDI

012 fr.01E fr.

285310

96/130R4 1.9l TDI(pump jet)

GearboxMax. torque(Nm)

Power(kW/PS)

Engine

01L qu.420250/340V8 4.2l 5V

01L qu.400220/300V8 4.2l 5V

01E qu.01V qu.

350184/250V6 2.7l5VT

01W fr.01E qu.01J fr.

01V qu.

300162/220V6 3.0l 5V

012 fr.012 qu.01J fr.

01V qu.

230125/170V6 2.4l V5

012 fr.01J fr.

21095/129R4 2.0l 5V

012 fr.01J fr.

210110/150R4 1.8l5VT

GearboxMax. torque(Nm)

Power(kW/PS)

Engine

Petrol engines Diesel engines

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3.0 V6 162 KW Engine

• Identical to 3.0 V6 engine in the Audi A4 2001>

• Additional exhaust flap in rear silencer forfront-wheel drive vehicles

Pow

er o

utpu

t [kW

]

Torq

ue [N

m]

Engine speed [rpm]

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3.0 V6 162 KWExhaust flap

A

Cross section A

The exhaust flap in one of the tailpipes on the rear silencer is designed to ensure that legalnoise restrictions are met at idling speed and atlow engine speeds.

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otherconsumers

Intakemanifold

Control unit Flap open

Intakemanifold

Control unit

otherconsumers

The system becomes avacuum and the flap is closed.

Atmospheric pressure Vacuum

3.0 V6 162 KWOperating principle of exhaust flap

Vacuumreservoir

Vacuumreservoir

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3.0 V6 162 KWExhaust flap functional diagram Exhaust flap control sensors

• G28 Engine speed sender

• G187 Air mass meter

• G22 Sender for speed via J218 dash panelinsert and CAN drive

Exhaust flap control actuator

• N220 Exhaust flap valve

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0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

6500

0 50 100 150 200 250

v [km/h]

n [

1/m

in]

open

closed

traction

overrun

5 km/h

Open: v>5 km/h AND n>2000 rpmClose: v<5 km/h OR n<1800 rpm

3.0 V6 162 KWSwitching diagram of the exhaust flap

n [rp

m]

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3.0 V6 162 KWExhaust flap vacuum circuit diagram

Scope of the exhaust flapH H

G

D

N80

N239

N112FE

C

A

J

I

N220

B B

- Vacuum unit for intake manifold changeover- Vacuum reservoir- Fuel manifold with pressure control valve- Activated charcoal filter- Return valve- Suction jet pump- Brake servo- Combination valve for secondary air- Exhaust flap- Diagnostics pump for fuel system

N80 - Solenoid valve for activated charcoal filter

N112 - Secondary air inlet valveN220 - Exhaust flap valve

Located in boot on left-hand side

N239 - Intake manifold flap changeover valve

A

BC

DEFGH

IJ

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2.5 V6 TDI 114 kW

• Increased power output resulting from software changes in the engine control unit

Pow

er P

eff [

kW]

Tor

que

Md

[Nm

]

Engine speed n [rpm]

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R4 1.9l TDI (pump jet) 96 kW

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• Pistons made from highly heat resistant aluminium alloy withintegrated cooling duct. The piston top land has beenraised from 9 to 12 mm.

• Conrod strengthened.

• Piston pin rigidity increased by reducing the diameter ofthe internal bore and chamfers on both sides.

• Small-end bush replaced by a sputter bearing.

• Crank pin diameter increased and material changed fromC38 to 42CrMoS4.

• Oil pump capacity increased by 25% through use of a broaderrotor set.

• Water pump output increased as a result of changes to theimpeller geometry.

• Turbocharger optimised. More accurate control of the boostpressure by increasing the number of rotor vanes from9 to 11.

• Boost pressure increased from 2100 to around 2300 mbar.

• Fine tuning of the jet orifice geometry resulting in a 25%reduction in particle emissions.

R4 1.9l TDI (pump jet) 96 kWDevelopments

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multitronic ®Developments

• Stronger material used for pulley shaft 1

• Diameter of pulley shaft 1 increased

• Toroidal roller bearing in the rear bearingassembly of pulley shaft 1 (see next slide)

• Chain strengthened and minorimprovements made

• Pressure level in the starting clutches andcontact pressure of the pulley sets increased

• Gold-plated plug contacts from calendar week 23/2000

• Control unit run-on function

• Tip - change gear in “D”

Original bearing assemblyPulley set 1

New bearing assembly

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multitronic ®Toroidal roller bearing

• Single-row roller bearing. The profile radius of the outerrace describes a circle which has a centre point outsidethe inner race.

• Increased radial load-bearing capacity

• Accommodates:

- axial displacements

- alignment tolerances

- pendulum movements

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Running gear

Extended range of wheels/tyres

16” FNR60 brakes for V6 3.0l and V6 2.7l 5VT

PAX system including tyre pressure checking

17” sports running gear

Spring/damperrematched

Servotronic II

Electronicstability program

ESP 5.7

8”/9” brake servo

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Teves FNR 60 Brakes

Innovations to FNR 60 brake

• Piston diameter: 60 mm

• Brake disc diameter: 321 mm

• The braking power is comparable with the HP2 brakes (A8, A6 V8).

• Procedure for replacing brake padschanged.

for V6 3.0l and V6 2.7l

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Servotronic IIServotronic 2

Centring lugs (piston stroke always in thesame direction regardless of the relativerotation direction of the valve) • only one feedback chamber• increased surface area of feedback piston• simpler hydraulic switching• more resistant to dirt• increased spread of characteristic curve possible

Ball screw (piston stroke in twodirections, depending on the relativerotation direction of the valve)

• 2 feedback chambers required

Feedback mechanism

Conversion of the relativerotation of the valve

into an axial movement ofthe feedback piston by

means of

active hydraulic feedback via feedback mechanism

• valve resistance increases with speed• no limit to maximum steering power at high speeds

Characteristic curvevariation principle

proven steering valve, rotary valve in steering box with roller bearingBasic valve

Servotronic 1

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Servotronic II

G22

C D

E

F

Torsion bar

Centring unit

G22 J285 C D E F

Sender for speed sensor G22Dash panel insert

Torsion barRotary slide valvePumpElectrohydraulic converter

J285

Steering box

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Bi-Xenon headlights

Enhancedacoustic parking system

New GPS/GSM roof aerial

Seat memory function

New sounder foranti-theft alarm

Electrical system

2nd diagnostic wire

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J285

J220

G85

J104J554(only allroad)

J197(only allroad)

J217

E85

J502

J446

R (vehicle without FIS)

R99

J507

J453

J526

J401

RR94

J402

CAN Network

E85 Air conditioner

G85 Sender for steering angle

J104 ESP

J197 Level control

J217 Automatic gearbox

J220 Motronic

J285 Dash panel insert

J401 Navigation system

J402 Navigation system plus

J446 Parking aid

J453 Multifunctional steering wheel

J507 Voice control system

J526 Telephone/Telematics

J554 Additional shift stage

R Radio

R94 Navigation interface

CAN Drive CAN Display

CA

N C

onve

nien

ce

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2nd Diagnostic WireDiagnosis - Components

J220 J217 J104 J234 J197 J499/J526 J507

J453 J136 J431 J502 J162 J379 J446 R J401 J402 J415 E87

J285

VAS 6017

K wire

L wire

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Bi-Xenon Headlights

Turn signal Gas-discharge lamp(Dipped and main beam)

H7 lamp(additional main beam,

headlight flasher)Ballast

The headlight module consists of:

• the electronic ballast (EVG)• the servomotor for the headlamp levelling system• normal bulbs• the gas discharge module• the housing with the laminated clear glass lens

When travelling in countries which drive on the leftboth headlamps can be switched from asymmetrical to symmetrical dipped beam.

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Bi–Xenon Headlights Functional principle

Lens ScreenElectromagnet

Reflector

Gas discharge lamp

Main beam

The whole light cone is effective. In addition the H7 lamp is switchedon.

Dipped beam

The screen is adjusted electromagnetically,to block out part of the light cone.

(Border between light and dark)

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Enhanced trailer recognition

Vehicle innormal operation

Vehicle withtow bar

Vehicle withtrailer Vehicle in normal operation

The APS indicates obstacles in the pale orange area by an intermittent horn sound. In the area closest to the vehicle (darker orange), this is becomes a continuous tone.

Vehicle with tow barThe two central sensors on the back of the vehicle recognise the tow bar. The warning area closest to the vehicle (continuous tone) is extendedaccordingly.

Vehicle with trailer The APS recognises the presence of the trailer when the microswitch in the tow bar socket is operated.Monitoring at the back of the vehicle is switched off.

Acoustic Parking System (APS)

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Acoustic Parking System (APS)New warning sensors

• improved seal to protect against dirt and moisture

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Functional diagramAcoustic Parking System (APS)

V signal

CAN bus (convenience)

CAN H

CAN L

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Anti-theft alarm Sounder • Adoption of Thatcham principles as used on

the Audi A4 2001>

• New active sounder

• Previous warning horn discontinued

• Identical to sounder in the Audi A4 2001>

• Charging cycles for the in-built battery

- after the alarm has been activated

- after the power supply has been disconnected

The battery charges until it reaches fullcapacity, but for a maximum of 14 hours.The charging current is 16mA.

After this the maintenance charge isalternately:

1 min 16 mA

59 min < 1mA

Please take note of this when measuringthe no-load current!

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GSM/GPS Aerial

• New duplex roof aerial for phone/GPS for Saloon

• Radio aerials are completely integrated into the rear window

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Air conditionerInnovations

• The air quality sensor is fitted as standard.

• In the 2.0 and 3.0 petrol engines the radiator fan is actuated bythe engine control unit (drive data bus). The speed of

the radiator fan is infinitely variable.

• In the 2.0 and 3.0 petrol engines, and the 1.9 and 2.5 TDI engines (not allroad) data is exchanged between the air

conditioner control system E87 and the engine controlunit via the drive data bus.

• There is an additional servomotor V113 which operates thefresh/recirculated air flap.

• Left-hand drive vehicles are not equipped with an air flow flap, and therefore they do not have the servomotor -V71.

• The following engines have the compressor with thecontrol valve -N280:

– 2.0 and 3.0 petrol

– 1.9 and 2.5 TDI (not allroad)

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Air conditionerInnovations in diagnosis

Control element diagnosis:

• Check points:

– Air conditioner control valve -N280

– In vehicles with 2.0 and 3.0 petrol engines, the radiator fans -V7 are infinitely variable from the off position to

maximum speed.

– The fresh air blower -V2 is infinitely variable from theoff position to full speed within 5 seconds.

– The blower for the temperature sensor -V42 is switched on and off in a 5 second rhythm.

– The servomotor for the recirculated air flap -V113opens and closes the flap.

– The servomotor for the air flow flap -V71opens and closes the flap.

– The idling speed regulation check point is no longerused.

– The heated rear window is switched on for 10 seconds.

– The heated windscreen is switched on for 10 seconds.(not currently available)

L wire

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L wire


Coding:

• It is no longer necessary to select the engine version.

• Entry of a modified heated windscreen

• The compressor version must be selected

– Compressor with magnetic clutch -N25

– Compressor with control valve -N280

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L wire


Measured value blocks:

• Control current and signal ratio of the compressor N-280control valve.

• Signal ratio of the pressure signal from the high pressuresender -G65

• Calculation of pressure in refrigerant circuit based on the signalfrom the high pressure sender -G65

• Measured value block 007 for the servomotor for therecirculated air flap -V113

• Evaporator output temperature -G263

• Signal inputs from wiper switch -E22

• Actuation of the refrigerant fan -V7

• Signal from the air quality sensor -G238

• Request function for fresh or recirculated air via air qualitysensor -G238

• Changes to the display group numbers

(more information in the current workshop manual)

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L wire


Fault memory:

• Supply voltage - signal too weak

This entry occurs when the code for a compressor with amagnetic clutch is entered for a vehicle with a compressor witha control valve -N280.

• Reference voltage (5V external)

- Short to earth

- Short to positive

Monitoring of the supply lines to the potentiometers andsunlight penetration photosensors.

• Servomotor for recirculated air flap -V133

- blocked or no voltage

• Potentiometer -G143 in servomotor -V133

- Short to earth

- Open/short circuit to positive

- Adaption limit exceeded

• Sender for evaporator output temperature -G263

- Short to earth


This entry also occurs if the code is incorrect.

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L wire

Air conditionerInnovations in diagnosis Fault memory:

• High pressure sender -G65

- Short to earth

(signal ratio 5% or lower)


(signal ratio 95% or higher)

- Signal too weak

(signal ratio 5 - 12%)

- Signal too strong

(signal ratio 92 - 95%)

• Rear window heater -Z1

- Does not switch off/short to positive

- Does not switch off/short to earth

• Control valve for air conditioner compressor -280

- Open/short circuit to earth

- Short to positive


• Compressor magnetic clutch -N25

- Open/short circuit to earth

- Short to positive


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L wire

Air conditionerInnovations to diagnosis Fault memory:

• Drive data bus

- Please read fault memory

Request to read all fault memories as a control unitconnected to the drive data bus cannot output the

requested data as a result of a fault.

- Defective

• Engine control unit/Dash panel insert

- Please read fault memory

Request to read the fault memories. The control unitscannot output the requested data as a result of a fault.

- No communications

• Air quality sensor -G238

- Electrical fault in power circuit

- Defective


trainerinformation a6pa en–°添加/国产/原厂培训... · v8 4.2l 5v 250/340 420 01l qu. v8...

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