Audi A3 Sportback 332 Instrucciones de montaje
332
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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
4
Overview
Dimensions of the A3 Sportback.
Introduction
332_051
5
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.
6
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
7
332_052
8
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
9
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
10
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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