SSP 181 Audi A3 Presentation

7/26/2019 SSP 181 Audi A3 Presentation

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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



2

SSP 181/1

Ecology

Safety

Mobility



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



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



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



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

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



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



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



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



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



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



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



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



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



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 .



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



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



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 .



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



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



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

• • • • •



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 )



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



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



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



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



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



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



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



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



Technical

Details, see

Self-Study

Programme182

The eng-

ineering

Documents

SSP 181 Audi A3 Presentation