The Audi A4 ‘The Audi Ad is a car which has been completely re-developed compared to Its predecessor model, the Audi 80. The Audi Ad is characterized by fundamental innovations in its design and by its new ergineering concept. It profits from adopting engineering components which have already proven their success in tne Audi A and Audi Aé models, The five-valve engines and fourlink front suspension set new standards in the mid-class. SSP 167/01© The Audi A4 @ Range of Engines @ Gearboxes B Engines It. Engine ADP . SV Engine ADR 1.8-Itr. 5V Turbo Engine AEB Motronic M 3.2 2.6-Itr. V6 Engine ABC * 2.8-ltt. V6 Engine AAH * 1.9-ltf. TDI Engine 1Z B® Running Gear * The Four-Link Front Suspension The "Imaginary Steering Axis" of the Four-Link Front Suspension The Torsion Beam Rear Suspension The Double Wishbone Rear Suspension Steering Steering Column. Handbrake @® ABS/EDL/TCS (Bosch) 5 B Electrics * Electrical Components * Dash Panel Insert © Immobiliser —___ * Anti-Theft Warning System. * Seat Belt Tensioners in Airbag System —— * Power Windows Triple-Reflector Headlights Radio Systems Body B Test Your Knowledge Note: The Self-Study Programme is not a Workshop Manual! Contents Please always refer to the relevant Service Literature for all inspection, ‘adjustment and repair instructions.The Design + New front styling with large Audi rings and swept down bonnet + Wedge-shaped bodyiine rising to the tail + Smooth transition at the D-pilar * Larger overall width and height as well as wider track + Extended wheelbase with the same overall length + Flush-fitting Integrated bumpers colour-keyed to the body colour + Improved aerodynarrics with a Cd figure of 0.29 SSP 167/02 The Interior + Longer seat runner travel provides greater legroom length at the front Larger dimensions in the interior to provide greater head, shoulder and elbow space + Larger legroom space at the rear + Full-size head restraints at the rear + Rearcentie armrest with fist-aid kit + Larger boot with flat floorThe Engineering 1.8:litre engines with five valves per cylinder Fourlink front suspension Modified multi-link rear suspension for front-wheel drive models Steering column with manual adjustment for reach and rake Immobliser SSP 167/03 The Safety ‘ABS with electronic brake pressure distribution EBPD Disc brakes at front and rear Fulsie alibag for driver and passenger with fully usabie glove box Front pyrotechnical seat belt tensioners Inertia reel belts with child seat lock Crash-optimized body for enhanced eneigy absorption in the case of a front, side and fear collision Side impact bars in all doorsThe range of engines has been thoroughly revised. The new 1.6-Htr. four-cylinder engine with cross-flow cylinder head is the entry-level version. Itis followed by two new 1.8+H”, BV four-cylinder engines with five valves for each cylinder. The range of engines is rounded off by the known V6 engines with 2.6 and 26 litres, displacement and the 1.9-itr TOI engine. 1.6-Itr. engine ADP Displacement: 1595 cms Bore: 81.0 mm. ‘Stroke: 7.4mm, Compression ratio: 10.31 Power output: 74 ew Engine Motronic M 3.2 management: Fuel: 95 RON unleaded premium Not SSP 167/04 The engine may also be operated attemativeyy with 91 RON unleaded regular fuel with a slight reduction in performance. 1.8-Itr. 5V engine ADR Displacement: 1781 ems Bore: 81.0 mm stroke: 86.4 mm Compression ratio: 10.3:1 Power output: 92kW Engine Motronic M 3.2 management: Fuel: 95 RON unleaded 5 premium, SSP 187/05 Note: The engine may also be operated alternatively with 91 RON unleaded regular fuel with a slight reduction in performance.‘SSP 167/07 SSP 167/06 1.8-Itr. 5V turbo engine AEB Displacement: 1781 com> Bore: 810mm Stroke: 864mm. Compression ratio: 93:1 Power output: 10 kW. Engine Motronic M 3.2 management: Fuel: 95 RON unleaded premium Note: The engine may also be operated alternatively with 91 RON unleaded reguiar fusl with a slight reduction in performance. 2.6-Itr. V6 engine ABC Displacement: 2598 cmd Bore: 825mm stroke: 810mm Compression ratio: 10.0: 1 Power output: no kw Engine MPFI management: Fue: 95 RON unleaded premium Note: The engine may also be operated alternatively with 91 RON unleaded reguiar fuel with a sight reduction in performance.SSP 107/07 ~ SSP 167/08 2.8-ltr. V6 engine AAH Displacement: Bore: Stroke: ‘Compression ratio: Power output: Engine management: Fuel: Note: 2771 cms 825mm, 864mm, 10,331 128 kW Met 98 RON unleaded premium The engine may also be operated alternatively with 95 RON unleaded regular fuel with a slight reduction in performance. 1.9-Itr. TDI engine 1Z Displacement: Bore: Stroke: Compression ratio: Power output: Fuel: Mixture formation: 189% ers 795mm 95.5mm 198:1 OO KW 45 CN diesel Direct injection with electronically controlled distributor injection pumpThe familiar 5-speed manual gearboxes for front-wheel drive and 4x4 are used in the Audi Ad, A modified 4-speed automatic gearbox is used together with the 1.8-ltr. 5V engine. 5-speed manual gearbox 012 + Forall models with front-wheel drive 5-speed manual gearbox 01A + Forall quattro (4x4) models 4-speed automatic gearbox 01N The highlights: + ECO/sports switch is no longer fitted. The functions are performed by the ‘automatic gearbox control unit of the inteligent gearbox management. + Torque converter with integrate, siip- controlled lock-up clutch. + New design of multi-plate clutch improves Gearshift quality. Fewer geaishifts necessary. New type of fluid level indicator. Note: You can find detailed information on this 4-speed automatic gearbox in Self-Study Programme 172.New Features . Cross-flow cylinder head with metal cylinder head gasket + Long intake tract + lightweight vaive gear + Modified dynamic oil pressure monitoring + Pneumatically damped thermostatic tensioning pulley for toothed belt + Friction-damped spring tensioner for tlobed V-belt + M3.2 Motronic fuel injection system with hot wire air mass meter + Throttle valve contro! unit with Integrated idling speed stabilisation Output and Torque The newly developed cross-flow cylinder Qutout Tora head ensures a more rapid gas cycle. Km The engine produces an output of 74 kW 80 200 (101 hp) at a speed of 5300 rpm. ‘ fa Maximum torque of 140 Nm is produced at 3800 rpm. 64 joo Performance: ee TT e ae v0 + Acceleration from 0 fo 100 km/h in a 100 11.9 seconds | Top speed of 191 km/h x 0 Consumption of 7.5 Itr./100 km in third oy 7 60. ip ms 16 40 8 20 9 a oT ae a0 Bao Engine speed rpm. SSP 167/12 0Lightweight Valve Gear What lightweight valve gear means: Reduction in the diameter of the valve stems Use of a single valve spring A design which dispenses with the valve spring retainers Hollow-driled camsharts Lightweight bucket tappets Hydraulic Exhaust valve SSP 167/13 Advantages of the lightweight valve gear: Reduction in spring forces as a result of lower valve gear masses and accelerations Quieter engine running as a result of the reduced fiction torces and camshaft input torque: Higher efficiency, Improved cylinder charge, improved output Reduced exhaust emissions The lightweight valve gear is also used on the five-valve and the Vé engines. "Dynamic Oil Pressure Monitoring 4 standard feature of all the engines used in the Audi Ad is that the oil pressure is monitored nthe engine speed range torn 1500 rpm to $000 rpm. Only one oil pressure switch is now required for the dynamic cil pressure monitoring in this, speed range. Advantages: + Simplified oll pressure monitoring + Reduction in the possible erroneous warnings Dash panel insert ll pressure SSP 167/14 The oll pressure warning lamp in the dash panel insert flashes to provide a visual warning and a buzzer sounds three times as. an audible warning in the following conditions: * If the engine stops and the oil pressure switch Is closed. + I the oll pressure switch opens three times for longer than § seconds at an engine speed greater than 1800 rpm; this is stored ana the oll pressure warming also remains active at a speed below 1500 pm and also above 5000 rpm. 12Throttle Valve Control Unit The job of the newly developed throttle valve control unit is 10 stabilise the ding speed of the engine no matter the conditions and engine load, The quantity of idling air required is less as a result of controlling the idling air directly at the throttle valve and not, as before, by means of a bypass. This, Of course, also reduces the quantity of fuel needed. Using this compact component makes it possible to eliminate parts such as the idling stabilisation valve, The throttle valve contro! unit is used in all four-cylinder engines in the Audi A4. Advantages: SSP 167/15 + Better control of Idling speed by direct actuation of the throttle valve and reducing the possible leak air points Insensitive to dirt Reduces exhaust emissions Cults fuel consumption Reduces the number of idling control systems 3The idling speed switch, the throttle valve positioner potentiometer and the throttle valve potentiometer inform the engine control unit of the current position of the throttle valve and of the ttrottle valve positioner. The throttle valve positioner is actuated by the engine control unit in order to operate the throttle valve in the idling speed range. Cable pulley Thiottie valve positioner potentiometer Back-up mode spring Throttle valve positioner SSP 167/16 Idling switch Throttle valve potentiometer IRM Integrated idle speed control Note: The housing with the integrated idling speed control must not be opened. Itis not possible to perform any mechanical adjustment of the potentiometers and switches. These are set by the V.A.G. 1551 as part of the basic setting. You can find further information on the throttle valve control unit in SSP 173 "Throttle Valve Control Unit".Varying engine load This is performed through the accelerator pedal and the Bowden cable in ‘aecordance with the driver's wishes. SSP 167/17 The following functions are performed by the throttle valve control unit: Idling speed control The throttie vaive |s ‘opened or closed by the throttle valve positioner depending on engine load and temperature. The engine thus always Tur at optimal idle speed SSP 167/18 Engine cod Engine warm Closing damping functions Itthe driver releases the accelerator pedal quickly, the throttle valve is intercepted by the throttle valve postioner and slowly moved back until the required iding speed Is feached. Mechanical idling speed backup ssp 167/19 function If no power is supplied to the drive, the backup spring pulls the throttle valve into a defined backup running position. This, therefore, does not affect the adjustment of the throttle valve by the driver. ‘SSP 167/20 Back-up mode 15Output and Torque The 1.6-Itr. five-valve naturally aspirated engine produces its maximum power output ‘of 92 KW (125 hp) at 5800 rpm. The intake manifold has been designed to achieve a good torque curve, which results ina toque of 165 Nm being available at. cn engine speed of 3500 rpm, rising to 173 Nm at 3950 rpm. Performance: * Acceleration from 0 to 100 km/h in 10.5 seconds + Top speed of 205 kmyn * Consumption of 7.8 Itr./100 km in third mix New Features + Cast valve cover in combination with a rubber/metal gasket + Castoil sump in combination with a metal gasket + New type of cylinder nead bolted connection and metal cylinder head gasket + Decoupled intake marifold + Pneumatically damped themnostatic tensioning pulley for toothed belt + Fiiction-damped spring tensioner for ripbed V-belt + Two-mass flywheel + M3.2 Motronic fuel injection system with hot wire air mass meter + Distridutoiless high tension ignition system * Throttle valve control unit with Integrated idling speed stabilisation Qutput Torque = _ pee z 90) | S228 ° et ZT 30 T 75 20 9. °5 2000 4000 om csp gonermeeserFive-Valve Technology The Aucl A4 features engines with flve-valve technology tor the fist time in volume production - these being the 1.8+ltr. SV naturally aspirated engine and the 1.8ttr. 5V turbocharged engine. The highlight of these enginesis the newly developed five-valve cyinder head with the proven 1.8-ltt, cylinder block. In addition to various factors such as displacement and engine speed, the performance which an engine offers is particulary dependent on how rapidly the charge cycle can be completed, The power produced is all the more intensive the more fresh gases flow into the combustion chamber within the same time span. Advantages: + High power yield with small displacement Low fuel consumption as a result of high engine efficiency Good torque patter and high pulling power . * Compact dasign and low engine SSP 167/24 weight + Pleasant engine acoustics and quiet running aso result of low combustion noise The three inlet and two exhaust valves provide a laige flow cross-section. It Is these large flow cross-sections in the cylinder head which make it possible to achieve short valve opening times and thus a narrow overlap of the valve opening. The strokes are thus more clearly separated, which results in a low level of combustion noise, The centrally positioned spark plug ensures short ignition spark travel and thus optimal fuel combustion. This, in tur, resultsin a lower risk of knocking at a high compression ratio and Intensive utllization of the fuel, 2Five-Valve Cylinder Head Despite the compact design, the cylinder head bolts can be removed and inserted with the camshafts installed. This has been made possible by dispensing with cylinder head bolts with large washers. Cylinder head bolt Screw-in sleeve The prestressing force introduced into the cylinder head in this case by means of a heat-treated screw-in sleeve. This has a beneficial effect on the setting characteristics of the gasket. Metal The cylinder head gasket is now qylnder hed! composed of 4 metal single layers, gasket which avoid the gasket settling. It is therefore not necessary to re-fignten the cylinder head bolts. SSP 167/25 The sealing surfaces are treated with a special coating fo ensure good sealing properties. Note: A\ll four-cylinder petrol engines in the Audi A4 feature the metal cylinder head gasket. 22Valve Gear of Five-Valve Engine The five valves are operated directly by two camshafts through hydraulic bucket tappets. The inlet camshaft controls three valves on each cylinder and the exhaust camshaft two. ‘The exhaust camshaft is driven by the crankshaft by means of a toothed belt, Both camshatts are linked by a drive chain for driving the inlet camshatt. Pneumatically damped theime tensioning pulley Exhaust camshaft Diiying chain Hydraulic chain tensioner SSP 167/26 Inlet camshatt The toothed belt for driving the exhaust camshatt is maintained at the proper tension by a pneumatically damped thermo tensioning pulley. A specially shaped mounting bracket at the pneumatically damped thermo tensioning pulley makes it possible to visually check that the belt is correctly set. The drive chain is maintained at the proper tension by a maintenance-free, hydraulic chain tensioner. 23The Intake Manifold The primary aim In developing the intake manifold was to provide a high level of torque at Ielatively low revs. This is achieved by designing the intake manifold in a worm shape, which is then supported at the engine by two rubber bushes, Bubber sleeve Injector carrier Intake manifold The intake arms are designed in a worm shape and are supported at the engine by two rubber bushes. Four rubber sleeves provide the connection between the intake manifold and the injector carrier, which is rigidly attached to the cylinder head. Using such rubber sleeves minimises the transmission of vibrations to attached parts, such as the throttle valve control unit. In addition, it also reduces the heat transfered to the intake manifold and thus prevents it heating up greatly as the result of the heat which would otherwise be transmitted from the cylinder head. 24Suction Jet Pump for Brake Servo Vacuum The suction jet pump with integrated non-return valves boosts the intake manifold vacuum Gnd provides the pressure difference which is required at the vacuum brake servo unit, The alr flow which Is needed for operating the suction jet pump is branched off at a glaphragm vaive, which Is located in the intake air tract. The vacuum servo assistance is required as the throttle valve is opened further at idling speed, particularly during a cold start, and a slight vacuum exists. A second connection at the diaphragm valve is used for crankcase ventilation. Suction jet pump To vacuum brake servo unit To crankcase breather ‘To suction jet pump, Dicphragm valve SSP 167/28 25Schematic Diagram of Coolant Circuit The engine coolant is pumped by the coolant pump into the engine biock and spiit into two. partial flows at the phase end by means of a plastic connector. One partial flow passes through the heating system neat exchanger while the other partial flow is passed along a pipe routed below the intake manifold to the radiator. When the thermostat is open, the coolant flows from the radiator through the thermostat housing integrated in the coojant pump back to the coolant pump. ‘At the same time, coolant is branched off from the radiator feed pipe for preheating the throttle valve control unit and for the oil cooler. ‘The expansion tank Is integrated in the cooling system parallel to the radiator. Heating systern heat exchanger Feed pipe Vent opening Throttle valve control unit Expansion |— tank —~ Oll cooler Coolant pump Radiator SSP 167/29 It has been possible to dispense with a separate bypass circuit as an adequate quantity of coolant flows through the constantly open heating circuit and the common circuit of the throttle valve control unit and cil cooler in the control range of the thermostat. 28Isolated Lambda Probe with Defined Earth Offset All petrol engines in the Audi A4 now feature an isolated lambda probe. Isolated means: The lambda probe no longer obtains its earth for the signal voltage from the screw-in thread and thus from the exhaust system, but it now features the separate earth wire which runs to the engine control unit, Note: The isolated lambda probe is recognizable from the connector which now has 4 pins instead of the previous 3 pins. The Isolated lambda probe features a separate earth connection. Defined earth offset moans: The control range is raised by 700 mv. which corresponds to the separate earth connection. Advantage: The self-diagnosis is now able to distinguish whether the lamioda probe is at the control limit (fault in injection system) or whether there is a short circuit to earth. Note: The 700 mV to vehicle earth can be measured only at the 4-pin connector. The voltage levels of the control range are displayed in the measured value block of the self-diagnosis, ‘elated to the signal earth (about 1000 mv), Signal wire > Probe heater Signal earth positive Probe heater SSP 167/30 earth mv 3 3g [17 4 22 2 1150-4 38 £3 &5 i © 2 \ 700: , 4 Control limit Separate earth + reached signat_ | connection earth t Short circuit SSP 167/31 toeartn 2SSP 167/06 Output and Torque The 1.8:tr, five-valve turbocharged engine produces its maximum output of 110 kW (150 hp) at 5700 rpm. The maximum torque of 210 Nm is available at an engine speed of only 1750 (pm, and remains constant up to 4600 rpm. Consequently, a high torque is always available particularly in the vehicle and engine speed range at which the caris most tequentiy driven, Performance: + Acceleration from 0 to 100 km/h in 8.3 seconds «Top speed of 222 km/h + Consumption of 7.7 Itr./100 km in third mix 20 New Features Small exhaust gas turbocharger with rapid response Cast valve cover in combination with a tubber/metal gasket Cast oll sump in combination with a metal gasket New type of cylinder head bolted connection and metal cylinder head gasket Pneumatically damped thermostatic tensioning pulley for toothed belt Friction-damped spring tensioner for tibbed V-belt Cast two-piece exhaust manifold Two-mass flywheel M3.2 Motronic fuel injection system with hot wire air mass meter Disttibutorless high tension ignition syste Throttle vaive control unit with integrated idling speed stabilisation Output Torque & . va stb 10 $1275 10) | j250 ae Fe 5 20 2 h75 = hs 3 1B ~ 0 » I 2 0 5 0 os — ey — as Engine speed rpm. SSP 167/33Turbocharging with Intercooling Turbocharging is used in order to achieve a higher filing efficiency of the cylinders with fresh gases. The aim in the case of this engine, however, is not to achieve a peak power output but to provide a high level of torque from low revs over a wide engine speed range. A small exhaust gas turbocharger with a rapid response is used for this purpose. This enables the diiver to shift up sooner and to therefore drive more often and forlongerin a higher gear which thus offers improved fuel economy. Exhaust gas Compressor end turbocharger Intake end Fuel shut-off valve SSP 167/34 Fuel Shut-off Valve The fuel shut-off valve is located in a hose connection between the compressor end and the intake end of the turbocharger. This spring/diaphragm valve is controlled by the intake manifold vacuum, During deceleration, the boost pressure which continues to exist upstream of the closed throttle flap produces a dynamic pressure which would normally sharply decelerate the compressor wheel of the turbocharger. When the engine is again accelerated by the throttle valve opening, the turbocharger would have to regain its speed (turbo lag), This problem is overcome, therefore, by the fuel shut-off vaive biiefly closing the compressor end to the intake end during deceleration as a result of the vacuum in the intake manifold. This maintains the speed of the turbocharger and when the engine Is again accelerated, full boost pressure Is immediately available. a1General The four-cylinder engines feature the Motronic M 3.2, which is basically identical on each of the engines. The Motronic control unit forms the following base functions: Sequential injection with adaptive lambda contiol Map-controlied ignition with cyiinder-selective knock control ‘Adaptive idle speed filing control Fuel shut-off on overrun Fuel tank ventilation system Se'f-dlagnosis with substitute function Immobiliser The highlight of the engine management system is the integration of an electronic immobiliser (see also chapter on immobiliser, page 5). Distinguishing features of the Motronic M 3.2 on the four-cylinder engines: 1.6-Itr, engine (ADP) 1.8+ttr. SV engine (ADR) 1.8+ttr. SY turbo engine (AEB) Hot wire ait mass meter Hot wire cir mass meter Hot flim air mass meter Distributor high tension Distrioutorless high tension _| Distributorless high tension ignition ignition ignition Ignition col with power 2double ignition coils with | 4 ignition coils with integrated output stage cutput stage ina module —_| spark plug connectors 1 knock sensor 2 knock sensors 2 knock sensors Lambda probe with Lambda probe with Lambda probe with 18 W heater 18 W heater 12. W heater * _ Integrated wastegate * Note: The lambda probe is located close to the catalytic converter which allows it to rapidly reach its operating temperature. it has thus been possible to reduce the heating capacity of the lambda probe heater to 12W. This enables the lambda probe heater to be switched on and off by the engine control unit and also by the self-diagnosis, 36Self-Diagnosis The self-diagnoss facilities have been enlarged with the introduction of the new four-cylinder engines. + Display group number 23. Adaptation of throttle valve positioner + Display gioup number 98 Adaptation of throttle valve control unit * Display group number 99 Lambda control Note: With display group 99, the lambda control is switched off in the ‘basic setting’ function. This makes It possible, when dealing with engine performance problems, to check whether any change occurs by switching the lambda control off and on. The additional following new features apply to the 1.8-Itr. 5V turbocharged engin + Display group number 21 Lamoda control operating state * Display group number 25 Boost pressure control (wastegate) + Display group number 26 Idle speed air dernand * Display group number 27 Load reduction by knock control system Note: Please refer to the Workshop Manual for explanatory notes on the display groups. Diagnostic Connection The Glagnostic connection on the Auci Ad is located next 1o the rear ashtiay of the centre console. ‘SSP 167/37 37The six-cylinder engines offered in the Audi Ad are the successful 2.6-t. and 2.8-1tr. Vé engines. New Features Output and Torque The 2.6-Htr. V6 engine produces 110 kW (160 hp) at 8800 rpm. Maximum torque of 225 Nm is aveilable at an engine speed of 3500 rpm, while more than 200 Nm are on tap in the range between 2200 rpm and 8100 rpm. formance: . Acceleration from 0 to 100 km/h in 9.1 seconds Top speed of 220 km/h Consumption of 8.8 It1./100 km in third mix 38 Lightweight valve gear Oil pressure regulated downstream of the oi filter Simplified oil pressure monitoring Viscous fan Output Torque kW Ne 140, 20 0 380 120 ‘3e0 110 320 100 300 o 270 0 240 70 210 0 180 50 160 0 120 2) 0 20 60 0 ° Engine speed pr SSP 167/38New Features + Lightweight valve gear * Oil pressure regulated downstream of the oil fiter + Simplified oll pressure monitoring + Viscous fan Output and Torque This V6 engine with a displacement of 2.8 litres produces its maximum power output of 128 kW (174 hp) at 8500 rpm. Maximum torque of 250 Nmis avaliabie at an Output Torque ‘engine speed of 3000 rpm, while at least aw No 200 Nmis on tap over the wide engine 0 20 speed range from 2000 rpm to beyond 120) 380 5000 rpm. 120 360, ro 30 Performance: 100. 200 ° 270 + Acceleration from 0 to 100 km/h in 0 210 8.2 seconds 2 210 Top speed of 230 km/h a ‘ed Consumption of 68/100 in thie 0 150 mix 120 ‘9 ‘0 30 lo . 700 4000, 6000 Engine speed rom ‘SSP 167/039Oil Pressure Regulation The oil circuit for the Vé engines have been modified for their use in the Audi A4. Schematic diagram comparing the two oil pressure regulation systems: NEW OLD End cover Toengine ll pump olfiter pare Oil cooler \ relia valve \ a tJ “ VL. = =a ge Ol pressure Pressure limiting switch | vave Ollintoke Ol pressure switch/sender SSP 167/40 Operation of the modified oil circuit: The oil pressure Is now regulated downstream of the oil filter by the pressure relief valve which is housed in the end cover of the botiom part of the oll sump. The pressure Imiting valve upsiream of the oil fiter sa safety valve and opens if an excessive pressure exists, e.g, at high engine speeds and when the engine is cold. Advantages: * — Constant oil pressure regulation as a result of locating pressure relief valve downstream of oil fiter, * Impurities are trapped before they can reach the pressure relief vaive. 40New Features + Fuel tank sender with reservoir housing SSP 167/08 Output Torque wv Nn 70 20 Output and Torque 4 S The 1.9-ltte direct injection diesel engine Offers a maximum torque of 202 Nm at an 2 ao ‘engine speed as low as 1900 rpm and a Power outpui of 66 kW (90 hp) at 4000 rpm. < 190 formance: 20 ‘ 120 * Acceleration from 0 to 100 km/h in ‘| 0 13.3 seconds Top speed of 183 km/h 10 ED ‘Consumption of 5.1 Itt./100 km in third mix ol 0 ° ligne speed rom SSP 167/41 rsFuel Tank Sender with Reservoir Housing ‘The fuel pump draws the fuel out of a reservoir housing which at the same time is filled by the return pipe. This makes a major contribution to ensuring that the fuel pump is able to provide an uninterrupted supply of fuel even when comering or negotiating inclines and descents. Reservoir housing 5a FER, 167/42 42The "Imaginary Steering Axis" of the Four-Link Front Suspension The four aluminium links are each arranged in pairs in an upper and a bottom link plane. The extensions of links 1 and 2 produce an intersection point in the upper link plane. A second intersaction point in the lower link plane is formed by extending the links 3 and 4, If these intersection points are then connected, this results in an imaginary steering axis ground which the wheel rotates when the car is steered. The wheel suspension system is designed so as to produce a given movement of this imaginary steering axis with the aim of achieving a small distance between the steering axis and the wheel centre in all criving states, When driving straightahead, for example, this distance, which Is termed the road kickback lever arm, is about 10 mm (Audi 80 = 66 mm). The consequence is that any disturbances, such as those which result from accelerating, braking and cornering forces, scarcely make themselves felt at the steering wheel, Advantages: small road kickback lever arm + more spacious interior as a result of the reduced space needed for the wheels when tearing Wheel in straightahead postion i Wheel centre ® Road kickback lever arm (@@) __ Extensions of links Full lock position of right link | Fulllock position of left linkThe Torsion Beam Rear Suspension Front-wheel drive Audi Ad models feature a modified and e-tuned torsion beam rear suspension. Axle beam Anti-tol bar shackle Balancing weight Anttroll bar Guide bush Mounting bracket The axle beam of the torsion beam rear suspension is attached to the body by two guide bushes which are connected to the mounting bracket. The large guide bushes contribute to ensuring minimal body roll, The result is enhanced directional stability combined with feduced selt-steering characteristics, The guide bushes in the vertical and longitudinal direction of body travel have been designed to have different compliances in order to optimize ride comfort, ‘The mounting brackets feature slots to enable the axle beam to be properly aligned in the transverse direction. A balancing weight is bolted to the axle beam in order to minimize vibrations and to improve acoustics, In addition, the anti-roll bar is braced relative to the oxle beam by means of a shackle. Further features of the torsion beam rear suspension: Brake disc with integrated wheel hud: + Gas-filled shock absorbers (standard for all suspension versions) . Welant savings through the use of narrower wall thickness at the V section of the axle am. Note: When performing repairs on the torsion beam fear suspension, avoid slackening the bolted joints of the mounting bracketsto the body. If these bolts are slackened this alters the overall wheel toe and necessitates re-setting the suspension. a7The Double Wishbone Rear Suspension Four-wheel drive Audi A4 models feature the successful double wishbone rear suspension from the Audi 80 predecessor model. + Large bonded rubber bushes and * gas-filled shock absorbers with lighter coil springs tuned to match the characteristics of the car ensure enhanced ride comfort and acoustics. Bonded rubber bush SSP 167/46 Bonded rubber bush Gas¢fil shock absorber( Steering ! The standard hydraulically assisted steering systern in the Audi Ad is composed of the folowing components: Power-assisted steering gear with track rods and steering damper Mechanical vane pump: Supply pipes for feed and retuin Ol cooler and expansion reservoir Track tod Power steeting gear Damper element Track rod end Steering damper | Rack and piston fod SSP 187/47 aN The main components of the power-asssted steering gear are the combined rack and piston fod, a pinion and the supply pipes. A piston is attached fo the combined rack and piston rod. Depending on whether the steering is tuined to full lett or full right lock, the hydraulic fluid is pumped to the lett or right piston face and assists the steeting effort of the driver, The hydraulic fluid is controlled by a rotary side valve which is ikewise housed in the power steering gear. The vane pump supplies the hydraulic fluid to the steering system. An orifice in the restrictor port of the vane pump is designed so that maximum steering assistance Is available at a low engine speed and that this power assistance decteases as Vehicle speed rises. This type of speed-responsive control ensures an optimal feel for the road no matter the driving situation, 1 Damper elements in the track rod endsisolate the power steering gear trom the front suspension and prevent vibrations and noises being transmitted. Note: ‘Only models with Vé engines are equipped with a steeiing damper. 49Steering Column The steering column in the Audi Ad can be adjusted manually 50 mm fore and aft and 28 mm for height. Fore-and-aft adjustment is made possible by means of a telescopic shaft with a splined section. Slotted ting Mounting bracket with siding guide NN | ‘Clamped connection Power steering gear Locking lever for foward-and-back! height adjustment Damper element Double universal joint The steering column is supported directly at the power steering gear by means of a double universal joint and is linked to the power steering gear by means of a clamp connection. A damper element above the double universal joint separates the steering column from the power steering gear and prevents vibrations and noises being transmitted, A mounting bracket with sliding guide forms the top attachment of the steering column to the body and ensures that the steering column is able to deflect forward in the event of a front-end collision. 50A plastic moulding with shear pins fixes the carriage in postion in the guide of the mounting bracket. In the event of a crash, the shear pins shear off first. If this occurs, the carriage is braked in Its forward movement by a wire clamp which Is wound around two bolts in the bearing bracket. This enables part of the impact eneigy to be absorbed. In addition, the shat telescopes and ensures that the steering column does not penetrate Into the passenger compartment, or anly slightly. Note: If the car has been involved in a crash, itis important to always inspect the gap between mounting bracket and side. ILihis gop ls greater than 0.6 mm, tne steering colurnn hos been damaged and should be replaced, Carriage Wire clomp ‘Mounting bracket SSP 167/49 Slip coupling at steering lock The slotted ring into which the pin of the steering lock engages, is prest-fitted onto the steering column with two metal rings, ‘AS a result, itis no longer possible for the steering lock to break open becatse the steering lockis rotated in the slotted ring with a defined force. In this case, itis only possible to steer the car with considerably greaier physical effort, which acts as an anti-theft deterrent. Advantages: + The steering lock and the steering stak are not damaged. + Minimal repair costs. 51Handbrake The adjustment of handbrake cables is new. An adjustment mechanism on handbrake cable makes it possible to form a coarse and fine adjustment of the tension of the handbrake cables. The location of the adjustment mechanisms on tlont-wheel and 4-wheel drive models differs because of the different routing of the handbrake cables. Ifthe cables are replaced, they are attached to the equalizer, which is now positioned directly at the handbrake lever. Equalizer SSP 167/50 Adjusting mechanism as Note: Please refer to the Workshop Manual for the procedure for adjusting the handbrake. 52The Audi A4 features a control unit with the functions of ABS with EBPD and also EDL and ICs, the latter two functions being available only on cars fitted with this optional equipment. ‘SSP 167/51 ABS: The Anti-lock Brake System prevents the wheels locking up during brake applications. EBPD: The Electronic Broke Pressure Distribution allocates the brake prossure to the rear Wheels through the hydraulic system of the ABS. This eliminates the need for a mechanical brake pressure regulator. EDL: The Electronic Differential Lock brakes wheels which spin when setting off. The input torque is diverted in this case to the wheels which have good grip. ‘On 4WD models, the manually operated differential lock for the rear wheels is no longer necessary. This function is performed by the EDL control, TCS: The Traction Control System reduces the input torque if both driven whee's begin to sip by reducing the engine output. Note: You can find additional information regarding this system in Self-Study Programme 162 "ABS/EDL/TCS (Bosch) 5 In the Auci", You can find detailed descriptions of the functions of ABS with EDL (Bosch) in Self-Study Programme 148, 53Electronic Brake Pressure Distribution EBPD The electronic brake pressure distribution has been integrated in the ABS control unit. The EBPD allocates and controls the brake pressure to the rear wheels on front-wheel and 4- wheel drive cars. The EBPD control makes use of the hydraulic components of the ABS, which eliminates the need for the mechanical brake pressure regulator. rake application with EBPD control Car steerable Carnot steerable “Braking force Braking and comering force 0. Brake slip Wheel rotating freely Wheel locked up ‘SSP 167/52 Operating Principle of the EBPD The EBPD is activated even during slight brake applications, particularly when cometing, The speed sensors detect the differences in speeds between the front and rear wheels and also between the right-hand and left-hand sides of the car, Itan excessive difference in speed exists when braking between the front and rear wheels during comering, the ABS inlet valves close off the brake pipes to the rear wheels by pulsed ‘operation. AS.Q result, the increase in the brake pressure to the rear wheels is limited sufficiently to avoid the rear wheels being excessively braked. The EBPD contiol ensures high cometing forces ‘and good transmission of braking pressure. The car remains in line and steerability and directional stability are further enhanced. 54EDL and TCS Control The diagrams on this page and overleat show the operating ranges of the EDL and TCS control. Depending on the particular driving situation, either the EDL and/or the TCS control are, activated. Driving situation: FWD with difference in speed between front wheels 9g mex, 3 2 a : = 2 8 e s 2 a 0 about 40kmih Speed of car SSP 167/53 Ifthe caris being driven at less than 40 km/h, the EDL contio\ is activated, ‘When this happens, the front wheel which is spinning Is decelerated by the brake system. tthe cars being driven at a speed in excess of 40 km/h, the speed of the wheels is equalized by activating the TCS control. This reduces the engine torque by switching off the Injectors for certain periods or be altering ‘the ignition timing. Consequently, the input torque at the front wheels is reduced and the wheels are prevented from sipping. 55Driving situation: FWD with difference in speed between front wheels and rear wheels 2 Difforonce in wheel speod SSP 167/54 Speed of car In this driving situation, it is the TCS control alone which is activated in order to equalize the speed of the wheels over the entire vehicle speed range. Driving situation: FWD with difference in speed between front wheels and between the front wheels and the rear wheels mmm TES mm EDL Difference in wheel speed 0 ‘about 40 km/h SSP 187/55 Speed of car In this driving situation, the EDL and the TCS control are activated If the car Is being driven at less than 40 km/h. The EDL control equalizes the speed between the front wheels. The engine torque is reduced sufficiently by the TCS control so as to prevent any excessive wheel slip at the driven wheels. If the car is being driven at more than 40 km/h, the speed compensation between the wheels is performed solely by the TCS control. 56The electiical centre |s located below the dash panel close to the steering column. The ‘cuxilary relay cartier with connector station |s positioned behind the electiical centre, Cars with a wide range of optional equipment have a further relay carrier installed above the electrical centre. SSP 187/57 Relay cartier Additional relay cartier with connector station Electrical centro The fuse box is located behind a cover on the side of the dash panel Fuses of reduced dimensions (mini-fuses) are used for protecting the electrical circuit, Mini-tuse Advantages: * Greater number of fuses within the same space Extended protection of circuits Specific pinpointing of any circuits which ore the cause of faults Note: eter fo the sticker on the Inside of the cover for the fuse assignment. The numbering of the fuse sockets can be found as follows: * For the mini-fuses, beiow the fuse. * For the little fuses, on the left next to the fuse, SSP 167/58The battery is housed in the plenum chamber, irrespective of the engine and the equipment fitted to the particular model, Advantages: * Installation point outside of the crash zone Extended life as a result of installation Position shielded from heat SSP 167/59 The hazard waming signal relay is now integrated in the hazard warning light switch, ‘SSP 167/60 The boot light is operated by a tit angie switch with ball mechanism. The boot light is switched off as soon as the boot lid is only half-closea. Advantage: + If the boot lid is not fully closed, this does not result in the batiery being discharged by the boot light, SSP 167/81 61Coolant temperature gauge Fuel gauge Revolution counter Main beam Indicator light Indcator/waminglights | | Indicator/ warning lights @ ein Cx a > 8 LO Je OL, > 2%, \ me 1 ymin xioo07 {|| WS) Cd om yoo 120/77. 80 140 “2 ) 160% SSP 167/62 / Analogue clock Mini check display Odometer with sevice interval dplay \ + Button for adjusting instrument lighting Rese! button for Speedometer + Test button for ‘tip counter ‘Auto Check System + The speed indication in the speedometer begins at 0 km/h. * Revolution counter with small integrated analogue clock is part of standard equipment. * The indicator/warning lights (except main beam) are integrated in the dial of the speedometer and revolution counter. + The coolant temperature and fuel gauges are positioned in the midalle of the dash panel insert. The coolant temperature needle Is positioned at 90°C if the coolant jemnperature is between 60°C and 100°C. The coolant temperature is indicated exactly if it is less than 80 °C ore more than 100 °C, + Anengine oll temperature gauge and a voltmeter for indicating the battery voltage gre available as optional additional instruments in the dash panel insert, ‘On models fitted with automatic gearbox, an outside temperature display is now also available as optional equipment. 62Auto Check System The Auto Check System constantly monitors certain functions and car components when ‘the ignition is switched on and when driving. Particularly major operational faults, such as low oil pressure level or insufficient coolant, aie displayed by red symbols (initial priority warning) in the on-board computer display. At the same time a warning signal sounds three times. Information regarding first priorty warnings can be displayed in clear text by pressing the test button of the Auto Check Systern. Other warnings such as less than 8 litres in fuel tank, are displayed by yellow symbols (second Priority warming) and a single warning signal. On-board computer display ens eh PRN@32 1 2nd priority Ist priority 7 minx 1000. PRN#321 SSP 167/63 Test button for Auto Check Sysiem In addition to the check function, the Auto Check System also features a toad speed warning system for two different speed thresholds, The one speed threshold Is erased each time the ignition is switched "Off", while the other speed threshold Is retained unti it is programmed. In addition, the Auto Check System also displays the information of the radio display, such as ‘the name of the station, if the car hasa factory-fitted gamma or delta radio system. 63Self-Diagnosis The dash panel insert is equipped with comprehensive self-diagnosis, The addiess word for the dash panel insert is 17. The following functions can be performed: 02 Intetrogating fault memory 03 Final control diagnosis 05 Erasing faut memory 06 Ending output 07 Coding control unit 08 Reading measured value block 10 Adaptation 07 Coding control unit The engine version, the number of cylinders and the national version are advised to the dash panel insert by entering a five-digit numerical code, SSP 167/64 08 = Reading measured value block The following readouts can be displayed with this function: Vehicle speed Engine speed Oil pressure switch 2 Odometer reading (0 is always displayed as the last digit) Fuel level Outside temperature (only on mode's with vehicle information system) Coolant temperature 10 Adaptation This function enables the folowing operations to be performed and stored: Adaptation of fuel gauge Adaptation of fuel consumption display of on-board computer Adaptation of language versions for driver information of Auto Check System Limits of service interval display (SID) Kilometre input of odometer Note: Adaptation of the kilometre reading can be performed only ones if the dash panel Insert is replaced. 64The immobIliser prevents unauthorized persons operating the car by intervening in the engine management system. The immobiliser consists of the following components: Car key with transponder Reader coil Immobilser control unit Engine control unit with programmable code Indicator light in dash panel insert Indicator ight in dash panei insert KIT Immobiliser control unit J362 Ignition lock with teader coll D2 SSP 167/65 oyThe Transponder The transponder is integrated in the car key and Isa receiver and transmitter unit which operates without o battery, When the ignition is switched on, an electromagnetic altemating field transmits energy from the reader coil to the transponder. The resutt ls that the transponder 's activated and it transmits back its programmed cade to the reader col. Each car key and thus each transponder has ¢ different programmed code. The Reader Coil The reader coll surrounds the mechanical ignition lock and is used for transmitting the energy to the transponder. Following this, it receives the programmed codes from the transponder and posses it on to the immobiliser control unit. The Indicator Light When the ignition is switched ‘ON’, the indicator light comes ‘on for3 seconds. itacar key with the incorrect programmed code &s inserted into the ignition lock, the indicator light flashes, The indicator light aiso flashes if the immobiliser self-diagnosis has recognized a fautt. 66 SSP 167/66 SSP 167/67 SSP 167/68Operation of the Immobiliser Tne immobiliser is activated when the \gnttion is switched on. The immobiliser control unit begins checking the programmed code in the car key. Energy is transmitted from the immobiliser control unit through the reader coil to the tansponder, Engine contiol unit SSP 167/69 SUAS) Innmoblser control unit o7The activated transponder now transmits its programmed code through the reader coll to the Immobiliser control unit. The code which is received by the immobiliser control unit is compared with the programmed codes of the authorized car keys stored in the Immobiliser control unit. Engine control unit Immobiliser control unit SSP 167/70 Following this, the immobiliser control unit checks the programmable code transmitted by ‘the engine contiol unit which was generated cfter the engine was last started. If the programmable and programmed code of the transponder agree, the engine continues Tunning. If they do not agree, the engine is switched off after 2 seconds. The programmable Code is fe-generated each time the engine is started on the random selection piinciple and stored in the engine control unit and in the immoblser control unit. Engine control unit immobiliser __control unit Transponder a SsP 167/71 Note: The Immobiliser has a self-diagnos’s capability. it*Engine control unit inhibited’ appears in the display of V.A.G 1551 during self-diagnosis, the Cause of the fault Is in the immobiliser system, 38Secret Number and Ident Number in older to authorize up to 8 possible keys for starting the engine, the relevant programmed code of the transponder must be entered in the immobiiser control unit using fault reader V.A.G 1651. tt, for exampie, two car keys have been already authorized for use and you wish to add a third one, itis then necessary to enter the programmed codes of all three keys in the immobiiser control unit. In o1der to prevent any misuse, It is not possible to enter the programmed codes until after entering a secret number by using fault reader V.A.G 1851. On new cars, the secret number is affixed concealed fo the key fob (Tub to make number legible). fan ertor is made when entering the ident number, a second attempt is possible; after this, the immobiliser control unit 's blocked. The ignition then has to be switched on for about 30 minutes in order to make a further two attempts. Note: A fault when entering the programmed codes is displayed by the indicator light flashing rapidly. Secret number Ident number _ SSP 167/72 The Ident number of the immobilser control unit is provided on the key fob, but it can also be tead by using the fault reader V.A.G 1551. The ident number is displayed by selecting the immobiliser control unit with addiess word 25. The ident number can then be used to obtain the secret number from the Sales Centre or the Importer. 69Interior Monitor The familiar anti-thett warning system is ennanced in the Audi A4 with the adaition of the “interior monitor function. This consists of the ultrasonic sensors control unit and two ultrasonic sensor modules. The ultiasonic sensors are positioned on the left and right inthe top trim panel of the B-pillar. They act as transmitters and receivers and are aimed at the side windows. The ultrasonic sensois contol unit is located below the rear seat and is connected to the anti-theft warning system control unit. Ultrasonic sensor module with ultrasonic sensors Rear fog light switch) SSP 167/73 Ultrasonic sensors control unit Triggering with the interior monitor: + ifaside window is smashed in Switching off interior monitor: + bystarting the fan motor (e.g. solar roof) + manually, by completely covering over one of the front ultrasonic sensors for about 3 seconds with a door open (e.9. if children are to remain in the car) until the indicator light in the tear fog light switch comes on. Diagnostics of interior monitor: + Fault display and operational check by alaim system indicator light K95 in the rear fog light switch Note: Please refer to the Workshop Manual for the fault display and operational check. 70The Audi A4 Is fitted as standard with two pyrotechnical seat belt tensioners for the driver and passenger sides. The operating mechanism of the seat belt tensionersis integrated in the alibag system, The belt tensioners are activated electrically together and simultaneously with the two fullsize airbags by the airbag control unit. Passenger belt tensioner Airbag contiol unit \ Passenger citbag belt tensioner SSP 167/74 aitbag Note: The airbag system has a self-diagnosis capability. Please refer to the Workshop Manual "Audi A4 > Electrical System’ for the safety precautions relating to work on the airbag oF seat belt tensioner system and for disposal of these systems. nSystem Overview Reed contact Piezo crystal Airbag control unit J237 Diagnostic connection Indicator ight K9S SSP 167/75 Actuators Coll spring for airbag F138 Igniter for airbag N95, (Giver side) Igniter 1 for airbag N131 (Passenger side) Igniter 1 for belt tensioner N153. (liver side) Igniter 2tor belt tensioner N154 (Passenger side) The sensors, a piezo crystal and a Reed contact, are integrated in the airbag control unit. Piezo crystal lan accident occurs, forces act on the piezo crystal as a result of which vibrations are produced in the crystal which generate an electrical voltage. The airbag control unit analyses this voltage and takes the decision to ignite the system. Reed contact The Reed contact is a Mechanical safety switch which Is open in the normal state. In the event of a frontal collision, a ting magnet is Pushed against the force of a spiing in the direction of the contact and closes the contact, If the Reed contact remains closed for @ certain time, the system is then ignited. Housing with piezo crystal SSP 167/76 Ring magnet Inert gas SSP 167/77 Reed contacis Aitoags and seat belt tensione's are ignited only if a sgnal is supplied simultaneously by both sensors, 2The seat belt tensioner consists of the reeling device, the piston, the gas generator, a cable ana the cylinder. It forms a compact unit together with the inertia reel seat belt. Operation: Cylinder Piston Reeling device Cable Gas generator with SSP 167/78 propellant ‘SSP 167/79 Note: Ifa certain deceleration threshold isexceeded during a frontal collision, the airbag control unit is supplied simultaneously with a signal by the two sensors integrated in the airbag control unit. The propellant in the gas generator Is ignited by an electrical pulse from the airbag control unit: The gas which is produced pushes the piston in the cylinder up and tensions the wire cable, Asa result, the reeling device is totated together with the belt shaft to take up the belt slack, The belt is thus tensioned. The bel! tensioner units must clways be replaced If the fullsize airbags have inflated. 73The power windows have been enlarged fo incorporate the ‘roll-back" function. This prevents objects being jammed when the windows are closed. The sensois and analysis electronics required for this rolkback facility are incorporated in the power window motor. SSP 167/60 Power window motor The power windows now include 4 functions: + Central closing + One-touch closing for front side windows + One-touch opening * Rollback 14Roll-back “wo Hall sensors are Integrated in the motor housing of the power window lifter, which detect the revolutions of the motor shaft by means of a magnetic ting. The analyss electronics computes the position of the window on the basis of the signal fram the Hall sensor, Ifa certain force prevents the window from. closing, the closing operation is stopped and she window is opened 125 mm. The operating range of this roll-back facility extends from the top edge of the window 200 mm down, The roll-back facility is not active during the last 4 mm fromthe top edge of the window in order to ensure that the window Is properly inserted into the weatherseal, Note: When performing repails, the power window motor must be teplaced complete and a bas setting performed. One-touch closing/opening electronics SSP 167/61 4mm 209 mm ssP 16782 “SS” The power windows at the front feature one-touch closing/opening while the power windows at the rear are fitted only with one-touch opening for safety reasons. The side windows can be fully closed or opened by simply touching the power window switch once (< 0.5 seconds) The closing of opening operation can be stopped in any desired position by again briefly pressing the switch. Central closing All the side windows can be closed centrally when the driver or front passenger door is locked. This is done by holding the car key orthe infrared remote control button in the close position until all the windows Nave closed. 75A triple-reflector headlight with a new reflector design is used for the first time in Audi Ad models fitted with fog lights. The reflectors for the fog light, dipped and main beam are integrated Ina headlight housing. The individual reflector is composed of computer-calculated sub-reflectors, each of which illuminates a particular partial area of the road. SSP 167/63 The new shape of the reflector for dipped beam now enables the entire surface area of the reflector to be used without dazzling oncoming traffic. Ina conventional design of reflector it was necessary to mask off the bottom area of the reflector in order not to dazzle oncoming traffic, Advantage: * Dipped beam with 50% greater luminous efficiency with the same optimal illumination haw Conventional reflector design retlector design SSP 167/84 76H7 Bulb The new refiector design of the triple- reflector headlight makes even greater demands on the bulb. Tighter geometry tolerances of the oulb, for example at the socket, are necessary in order to maintain the light-dark cutoff. The H7 bulb is a further development of the HI bulb. Advantages: + 30% less dazzle as a result of tighter geometry tolerances * 20% improved luminous density + longer tife + lower energy consumption Note: The H7 bulb is used for main and dipped beam in the triple-reflector headlight. The fog light equipped with a H1 bulb, 7The Audi A4 features the latest generation of Audi radios. The Audi A4 can be equipped with following radio systems: beta CC radio system gamma CC racio system delta CC radio system delta BOSE radio system The delta CC and delta BOSE radio systems can be combined with a CD changer. A.30 mm wider front panel with larger control buttons enhance this operating convenience. ‘The new size of the front panel |s an obstacle for installing the radio system in other cars, which makes it uninteresting for a thiet. Possible components of the radio systems Rear sheit Rear screen aerial See CD changer Radio- cassette set BOSE- sound amplifier \ amplifier SS = Sd Front door SSP 16786 speaker The output amplifier for the speakers of the gamma CC and delta CC radio systernsis housed in the rear shelf at the left-hand speaker. The tight-hand speaker Is also supplied by the stereo amplifier of the left-hand speaker. The new release tool V.A.G 3344 Is required for removing the radio-cassetie player. Note: Please 1efer 10 the operating insttuctions for more precise Information regarding operation of the radio system. 78Body The Highlights of the Audi A4 Body The ptincipal elements in developing the A4 body-in-white were: «A design which will look fresh even several years from now. The design must remain attractive and classy for many years. SSP 167/87 + Longlife quality (full inc-coated pane's) witha body protection ensuring long Ife. + Enhanced comfort demands with a further improvernent in active and passive safety. + Reduced weight. + New designs in respect of lightweight construction, such as high-strength panels. + Adcitional body strength through the combination of spot welds and bonding of sheet metal joints, 80Compact outer dimensions, but with lots of space for the passengers on the inside. ‘Comparison of interior dimensions Ebow width at front Ebow width at rear Etfective legioom at fiont Effective legioom at rear Maximum seat adjustment Head room at front without siding root Head room at front with siding roof Head room at rear without sliding roof Head room at reat with sliding roof Shoulder room ot front Shoulder room at tear Luggage compartment volume (VDA) SSP 167/88 Audi Ad 1,389 mm 1,357 mm 440 litres: Audi 80 7126079 [wr srr ati —| 186. SSP 167/89 81Vehicle Safety The Audi A4 features numerous measures to provide a reliable survival space for the ‘occupants and to minimise the risk of injuries. Measures: + Higher-strength panels at areas relevant for vehicle safety. + A-,B- and C-pillars integrated into door sills and into seat cross membels at front and } fear over a large area (large overap). / + Windscreen and rear window are bonded to the body with a high-modulus adhesive | (high shear and tensile stengtn). Aluminium ross members in the bumpers and Impact absorbers at the front and rear | ends ensure eneigy adsorption up to 15 km/h | * The large overlapped areas of the doors, the door impact beams and the door component carriers for the side windows with the intermediate moulded pelvis and rib Padding offer the necessary level of safety in a side impact. 82Vehicle safety from front to rear: ‘SSP 167/91 Aluminium cross members integrated in the Dumper absorb minor damage up to 8 km/h. Impact absorbers and Bumpers together absorb damage up to 15 km/h. se eonesceanns: Inrojor collisions, the side members at the front begin theit precisely defined crumpiing, Impact absorber Bumper with integrated Glurrinium cross member SSP 167/92 83,Body Side Impact The A4 body displays a high degree of stability and optimal occupant protection in a side impact. SSP 187/83 The A- and B-pillars are integrated into the side sils over a wide area (large overlap) which, together with the stable seat cross members at the front and rear, help in better absorbing the forces produced in acollision. The foot frame features reinforcements which, together with the shear-resistant bonded windshield and rear window (high shear modulus), contribute to enhanced safety in a side impact. 84The principal reinforcing panels for a side impact: pillar Root frame. reinforcing Avpillar reinforcing C-pillar B-pillar Bm 4 f reinforcing A-pillat ond sill reinforcing rear Seat cross memberDoors The consequent lightweight construction is continued with the Ad doors, Additional to the large overlap the doors have an aluminium tubular frame. (pace frame technology) SSP 167/95 Special pei and ib padding between the alurinium carters greatly Increase occupant protection. 86Safe In a Rear Collision Minor impacts at the rear are absorbed by the bumper and also by the impact SSP 167/06 absorber, in the same way as at the front. \ Impact absorber compressed Bumper with integrated Gluminium cioss member SSP 167/97 Major colisions at the rear are absorbed by the side members which are designed to deform specifically in a crash. The most important aspect here is to ensure that the fuel tank remains undamaged and that the doors can easily be opened by hand atter the accident. oe Side bumper mounting, 87-Higher-Strength Body Panels Higher-strength panels are used in the folowing areas of the body: + Wings : + Qutér panels of bonnet and boot lid + Outer panels of doors Attached parts - Bolted parts SSP 167/98 Highor-strongth body panel is: A generic term for a variety of incividual grades of steel in which the yield limit Is increased in a variety of different ways. These may be carbon steels with good deformation properties. ‘Comparison: The yield point of normal body sheet is some 190 N/mm*, a figure which is increased to about 350 N/mrr# in the case of higher-strength steel sheets. Compared with normal body sheet and the same lines of force, the higher-strength sheet Offers a significantly reduced deformation than normal body sheet. 88The side members at the front and fear are composed of 2 sheets of different thickness. In this case, the ends are manufactured from high-strength, thin material and the inner part from normal, thicker sheet. Welded parts: 8 SSP 167/99 What are the important points to note when performing repairs? When performing panel beating work, the sheet has a greater cent stiffness. The sheet is more resilient and greater force is required. The material may fracture if subject to excessive stress, If the material is heated too rapidly and to an excessively high temperature (about 200 °C) with a drying radictor during a partial respray, the sheet will be misshapen. The result is a dent. 89Please enter a cross in the appropriate box or boxes! Several answers may also be correct. 1. Which statements are correct in respect of five-valve technology? AQ High output with smail displacement B Q Good torque characteristics and high pulling power C Q Compact design and low engine weight DQ High output in the upper engine speed range 2. lightweight valve gear means: ‘A Q_ Reduction in the diameter of the valve stems 8 O Use of double valve springs © Q Dispensing with valve spring retainers D Q Reducing the diameter of the camshaft 3. Which statements are correct regarding the throttle valve control unit? A Q The idling switch, the throttle valve positioner potentiometer and the throttle valve potentiometer are Integrated in the throttle valve housing, 8 Q The housing of the throttle valve control unit must not be opened, C Q The basic setting of the throttle valve control unit can only be performed with the fault reader V.A.G 1851. 4. The throttle vaive control unit performs the functions of AQ Electronic load adjustment 8 Q Idle speed control © 0 Closing damping DQ Backup running mode oh). For dynamic oil pressure monitoring all the engines in the Audi Ad need A Q anol pressure switch. B Q anol pressure switch and an oll pressure sender, C Q two oil pressure switches. .. Which components are fitted in conjunction with the Motronic M 3.2 on the four-cylinder ‘engines? A @ 1.641. engine: hot wire air mass meter, distributor high tension Ignition, ignition col with power output stage, 1 knock sensor 8 O 1.84tr. SV engine: hot wire air mass meter, distributorless high tension ignition, 2 double ignition coils, 2 knock sensors C QO 1.84tr, SV turbo engine: hot fim ait mass meter, distiibutorless high tension ignition, 4 single ignition coils, 2 knock sensors. Design features of the four-link front suspension are: A Q Each wheel Islocated by four aluminium links, the track rod and the suspension strut. 8 Q The guide link is hydraulically damped in order to minimise longitudinal vibrations. © Q The road kickback lever arm is minimised in all driving states as a result of the specific layout of the aluminium links. DQ The distance from ‘steering axis" to wheel centre is called the road kickback lever am. A short road kickback lever arm minimises the disturbances felt at the steering wheel, such as A Q accelerating forces, BQ braking forces, C Q steering torces, D Q cotnering forces, 91a 92 Which statements regarding the torsion beam rear suspension are correct? A Q Improved directional stability is achieved by the different design of the gomplances ot the guide bushesin the vertical and longitudinal direction of the ody. 8 Q Abalancing weight is bolted to the axle beam in order to minimise vibrations and improve acoustics. C Q The suspension alignment nas to be checked if the bolted connections of the mounting brackets have been siackened. ). The electronic brake pressure distribution distributes and controls the brake pressure at the rear wheels. When does such a control cycle take place? A Q_ During braking, particulary when cornering. 8 Q If differences exist in the speeds between the front and rear whee's. C Q During a slight brake application, particularly when cornering and if a difference in speed exists between the front wheels and the rear wheels, In which type of driving situation is the TCS control activated? A Q A difference in speed between the front wheels and the car travelling at about 40 km/h or more 8 Q Adifference in speed between the front wheels and the car travelling at less than about 40 km/h C Q Adifference in speed between the front wheels and rear wheels DQ A difference in speed between the front wheels and between the front and rear wheels . What advantages do the "mini-fuses" offer? A Q A greater number of fuses in the same space as a result of the smaller size. 8 Q Improved protection of the electrical circuits. C Q itis possible to select a lower amperage.13. Which statements regarding the immobiliser are correct? A The transponder is activated by an electromagnetic alteinating field, BQ The reader coll transmits the programmed code from the transponder to the engine control unit. © Q Each car key with a transponder has the same programmed code. D Q The indicator light in the dash panel insert flashesif the self-diagnosis of the immobiliser has detected a fault. 14. Which number is used in the case of the immobiliser for programming the car key? A Q Ident number B Q Secret number CQ Keynumber 15. The interior monitor ... ag is@ function of the anti-thett warning system. 8 Q. ...is performed by means of ultrasonic sensors. CC 2 ...ischecked for faults and proper operation by the indicator light for the alarm. system K95 in the rear fog light switch. 16. Ifan accident occurs, when does the airbag control unit ignite the airbag and seat belt tensioner units? AQ Ifthe piezo crystal generates a voltage 8 Q If the Reed contact closes and a major deceleration is measured by the vehicle speed sender, © Q Ifthe piezo crystal generates a certain voltage and the Reed contact closes fora certain time 9317. Whenis it necessary to replace the seat belt tensioner units? A Q Always if an accident has occurred. B @ Ifthe fulsze airbags have been ignited. © 0 They do not have to be replaced at all, 18. The 4 functions of the power window litters include: AQ Rol-back 8B Q One-touch closing for the front windows © @ One-touch opening D O Central ciosing 19. The triple-reflector headlights with a new design of reflector offer the following features: A Q Foglight, dipped and main beam are integrated in a single housing. B Q S0%greater luminous efficiency with the same optimal illumination, CO Use of a newlens. 20. Which measures adopted for the A body enhance vehicle safety? AQ Higher-strength sheets at areas relevant for vehicle safety. 8 O A-and B-pillars integrated into the doorsils over a wide area, C Use of a door impact beam. 21. At what points are higher-strength body sheets used? AQ Wings 8 Q Floorassembly C Q Outer panels of bonnet and boot lid D Q Outerpanels of doors 94Answers: 1.A,.B,C/2.A,C/3,A,B,C/4.B,C,D/ 8.4/6.4, B,C/7.A,B,C,0/8.A,8,0 9A, B,C/10.C/ 11.4, C, D/12,A,B/ 13, A,D/ 14.8 /15.A, 8, C/16C/ 17.8 18.4, B,C,D/19.A,B/ 20.A, B,C / 21.4, C,D