Audi A3 Sportback 332 Instrucciones de montaje

332

Technical specifications

subject to change without

notice.

AUDI AG

I/VK-35

Service.t[email protected]

Fax +49-841/89-36367

AUDI AG

D-85045 Ingolstadt

Technical status: 05/04

Printed in Germany

A04.5S00.11.20

Audi A3 Sportback

Self-Study Programme 332

Vorsprung durch Technik www.audi.de Service Training

Audi is defining a new segment in the premium

compact class. The A3 Sportback is characterised by

the sporting elegance of a coupé and the versatility

of a 5-door.

The Audi Sportback is deliberately going its own,

new way in the compact class. It offers the

emphatically sporty qualities and the athletic styling

of the three-door version with which it shares its

drive train, dynamic suspension and wheelbase.

In addition to two rear doors, it offers even more

space and variability thanks to its rear end which is

a total of 68 millimetres longer than on its threedoor

counterpart.

The A3 Sportback is immediately recognisable at

first glance in the rear-view mirror by its striking

single-frame radiator grille, the distinctive tapering

of the sides and the dynamic shape of the clearglass

headlights.

The silhouette of the A3 Sportback when viewed

from the side becomes flatter towards the rear of

the car in typical coupé fashion and combines with

the gently rearward sloping roof line and the

restyled rear end to give the car its dynamic overall

proportions.

Audi A3 Sportback

Excellence in design & performance

SSP 290 Audi A3 ‘04

–Introduction

–Body

–Engine

–Gearbox

–Runninggear

– Electrical system

– Heating/air conditioning

–Service

Order number: A03.5S00.01.20

SSP 279

–Engine

– Injection system

–Operatingmodes

– Exhaust treatment

Order number: 240.2810.98.20

SSP 293 Infotainment

– Infotainment

– Sound system

–Radiomodule

–Navigation

Order number: 000.2811.13.20

Self-Study Programmes on the Audi A3

332_084

332_074

332_085

332_086

SSP 313 Audi A3 ‘04 Running Gear

–Axles

– Steering

– Brake system

–ESP

– Wheels / tyres

– Hand and foot controls

Order number: A03.5S00.04.20

SSP 312 Audi A3 ‘04

– Control units

– Distributed functions

– Infotainment

– Occupant protection

Order number: A03.5S00.03.20

332_087

332_088

NoteReference

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

The Self-Study Programme conveys basic principles with regard to the design and function of new models,

new automotive components or new 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.

Contents

Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Running gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Convenience electronics . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Infotainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Overview

Dimensions of the A3 Sportback.

Introduction

332_051

By using state-of-the-art calculation and simulation methods, new materials and joining

techniques, and by optimising the joining sequence during the bodyshell assembly process, it was possible to

increase body rigidity by 20% compared to the predecessor model and enhance the crash performance of the

body structure.

Front view of the body-in-white

Rear view of the body-in-white

332_048

332_049

Body

The body of the Audi A3 Sportback has a highly rigid and crash-optimised occupant cell.

Special attention was given to the following aspects:

●the body rigidity,

●the steering column rigidity,

●local rigidity in highly stressed areas,

●interior acoustics and driving comfort,

●the crash optimised body structure and

●the hybrid construction of the front end.

Materials

Bodyshell

Ultra-high-strength and higher-strength sheet metal

are used in areas which are subjected to high

mechanical stresses during a crash.

Welded tailored blanks and deep-drawn sheet metal

are used in other areas.

Body

Ultra-high-strength sheet metal

higher-strength sheet metal

332_052

Materials

Doors, sills and floorpan

Welded tailored blanks and tailored blanks with

flexible rolled wall thickness are used in the front

floorpan assembly and door areas.

The result is a distribution of material which

provides optimum stress absorption.

The sills are reinforced using rolled profiles. Rolled

profiles have a high strength-to-weight ratio.

Body

Rolled profile

Tailored blanks

Tail ored bl ank s

Rolled profile

Tailored blanks

332_053

Joining technique

Various joining techniques

are applied to interconnect the individual body

elements.

Spot welding joining

Crash-relevant and

rigidity-defining

joints are spot-weld bonded using a high-strength

structural adhesive.

The overall length of the bonded seams is approx.

26 m.

Laser welding

Laser welding is used in areas which are not easily

accessible.

The total length of the laser welded joints is approx.

25 m.

Laser soldering

Laser-solder joining is used to achieve a better

design and higher rigidity in the area of the

invisible joint and boot lid.

The total length of the laser-soldered joints is

approx. 3.3 m

Plasma soldering

To ensure the high rigidity and good design of the

water channel,

materials are joined by plasma soldering.

The overall length of the plasma-soldered joints is

approx. 1.1 m.

332_071

Laser-welded joints

Laser-soldered joints

Plasma-soldered joints

Roof rail

Description

The Audi A3 Sportback has a roof rail whose new

style design accentuates the car's coupe like

roofline.

It is made from aluminium and is available in two

finishes:

–high-gloss anodised or

–blackpowder-coated

Body

Mounting

The roof rail is mounted to the

roof side member using four bolts.

Rivet nut

Roof side member

exterior

Roof

To l e ra n c e

compensation

element

Bolt

Nut-and-washer assembly

Head airbag

Mounting bolts

332_047

332_019

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