Audi A6 Avant '05 344 Assembly instructions

344

Technical specifications

subject to change without

notice.

AUDI AG

I/VK-35

Service.trai[email protected]

Fax +49-841/89-36367

AUDI AG

D-85045 Ingolstadt

Technical status: 02/05

Printed in Germany

A05.5S00.13.20

The New Audi A6 Avant ´05

Self-Study Programme 344

Vorsprung durch Technik www.audi.de Service Training

Audi is adding a new chapter to the success story of

the Avant.

The new Audi A6 Avant '05 represents a unique

blend of design and dynamism, driving pleasure

and functionality.

Here is a car that exhibits a unity and harmony of

design.

Measuring 4.93 metres in length, 1.86 metres in

width, and 1.46 metres in height, the new

Audi A6 Avant ´05 visibly sets a new standard in

terms of its proportions.

The lines of the car combine the clear architecture

typical of Audi with other core elements of the

brand's progressive design.

The already classic proportions of the Avant's

silhouette, with its high shoulder line, narrow

windows all round, coupé-like roofline and shallow

sloping tail end, have been infused with added

dynamism.

The New Audi A6 Avant ‘05

Into the lead: With Design & Performance

Self-study programmes on the Audi A6 Avant

344_056

344_057

SSP 324 Audi A6 ´05 Running Gear

–Frontaxletechnology

–Rearaxletechnology

–Steering system

–ESP

–ElectromechanicalParking Brake EPB

Order number: A04.5S00.07.20

SSP 326 Audi A6 ´05 Electrical Systems

–Networking

–Bustopologies

–Convenienceelectronics

–Infotainment

Order number: A04.5S00.09.20

SSP 323 Audi A6 ´05

–Introduction to the vehicle

–Bodyengineering

–Occupant protection

–Airconditioning

Order number: A04.5S00.06.20

SSP 325 Audi A6 ´05 Engines and

Transmissions

–3.0V6TDI Common Rail

–3.2V6FSI

–Manualtransmissions 01X, 02X, 0A3

–6-stepautomatic transmission 09L

–Multitronic 01J

Order number: A04.5S00.08.20

323_057

323_058

323_059

323_056

NoteReference

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

The self-study programme provides introductory information regarding the design and function of new

models, automotive components or technologies.

The self-study programme is not a Repair Manual!

All values given are intended as a guideline only and refer

to the software version valid at the time of publication of the SSP.

For maintenance and repair work, always refer to the current technical literature.

Table of contents

Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Running gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Infotainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Convenience electronics . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Overview

Dimensions of the Audi A6 Avant ´05.

Introduction

344_062

Tailgat e

In the new Audi A6 Avant ´05, an inner tailgate hinge

is implemented for the first time.

The hinge is attached to the upper roof crossrail at

the rear so that it is located behind the tailgate seal,

and thus inside the occupant cell.

When the tailgate is closed, the hinge is concealed

behind the trim panel and is not visible from the

interior.

This hinge arrangement and function has the

following advantages:

–nocorrosion,

–nosealingproblems,

–internal wiring,

–nogrommets are needed to seal through-holes

in the body,

–largercargo area

possibility for electric tailgate drive.

Body

344_046

344_047

344_048

Occupant protection

Reference

For further information on the safety

system, please refer to Self-Study

Programme 323 - Audi A6 ´05.

Front passenger front airbag

–Airbagigniter 1, front passenger side N131

–Airbagigniter 2, front passenger side N132

The front passenger airbag consists of a casing in which are housed two pyrotechnic gas generators

separated by a partition. A propellant in the form of tablets and hollow tabs is used.

Safety system

The goal was to implement a protection system that offers a very high level of safety, thereby raising still

further the high safety standard set by the current Audi fleet.

The many safety requirements for the new Audi A6 Avant ´05 included meeting all current legislation, as well

as achieving a top rating in consumer tests.

Audi's internal specifications often increase the challenges to the development team.

This was the case with the Audi A6 saloon introduced to the market in the 2005 model year; likewise with the

new Audi A6 Avant ´05.

The occupant protection system in the Audi A6 Avant ´05 was largely adopted from the saloon. Due to the

modifications to the body, however, several components were adapted to the new parameters.

A new gas generator with dual threshold deployment for the front passenger front airbag will be implemented

in the Audi A6 saloon in early 2005. This module will be fitted to all models world-wide.

The new Audi A6 Avant ´05 will be equipped with this airbag from rollout.

Rupture disc

344_001

Metal filter Partition Metal filter

Outlets

Priming charge 2

Rupture disc

Priming charge 1

Igniter 2 Igniter 1

Housing

Metal filter Metal filterPropellant charge 2

Outlets

Propellant charge 1

Compensating material

344_001

Airbag igniter 2, front passenger side N132

The airbag control unit defines the time interval between the deployment of airbag igniter 1, front passenger

side N131 and airbag igniter 2, front passenger side N132 according to the type and severity of the accident.

The task of the second gas generator is to inflate the airbag to its full size.

The second gas generator has exactly the same function as the first gas generator.

Airbag igniter 1, front passenger side N131

If igniter I is electrically activated by the airbag control unit J234, it ignites priming charge I. Under the

resulting pressure, the flame passes through the rupture disc and ignites propellant charge I.

On account of the hollow propellant tabs, the complete propellant charge ignites more quickly.

The metal filter cools and treats the developing gas before it flows through the outlets to the airbag.

The task of the first gas generator is to inflate the airbag.

Outlet

Partition

Metal filter

Propellant charge 2 Outlet Compensating material

344_005

Metal filter

Rupture disc

Outlet

Compensating material

344_004

Rupture discMetal filter

Metal filterOutlet Propellant charge 1

Partition Igniter I

Housing

Priming charge 2

Igniter 2

344_004

The 3.0l V6 TDI was modified in several respects to

fill the gap between the 2.5l V6 TDI with distributor

injection pump and the 3.0l V6 TDI with common rail

injection. A wide range of diesel engines in various

sizes is therefore available to the customer.

Engine

The 2.7l V6 TDI with common rail

344_011

The engine number is located on the cylinder block

at the front right adjacent to the vibration absorber.

Specifications

Engine code BPP

Typ e of en gine V6 diesel engine

Displacement 2698 cm3

Power output 132 kW (180 bhp)

Torq u e 380 Nm at 1400-3300 rpm

Bore 83 mm

Stroke 83.1 mm

Compression ratio 17:1

Weight 220 kg

Firing order 1 - 4 - 3 - 6 - 2 - 5

Engine management Bosch EDC-16CP+ common rail injection system

with max. 1600 bar operating pressure and 8-port piezo injectors

Exhaust emission control Oxidising catalytic converter, maintenance free diesel particulate filter

(optional), lambda probe and cooled exhaust gas recirculation

Exhaust emission standard EU 4

344_012

Torqu e/p owe r cur ve

Max. torque in Nm

Max. power output in kW

Engine speed in RPM

–Thestrokewas reduced from 91.4 mm to

83.1 mm by modifying the crankshaft, con-rod

and piston

–Castexhaust manifold and steel compensator

without air-gap insulation

–Deletion of the shield plates above the manifolds

–Piezoinjectors with eight-port nozzles instead of

seven-port nozzles

–Aninletrestrictor has been integrated into the

fuel rail for each injector

Engine

Modifications to the 2.7l engine

The basis is the 3.0l V6 TDI CR engine, i.e. the engine

block with 90 mm cylinder spacing was adopted,

likewise the 83.0 mm cylinder bore.

The crankshaft, the con-rod and the pistons were

modified so that a swept volume of 2698 cm3was

obtained by changing the stroke.

Crankshaft drive

344_003

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