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Self Study Programme 627 For internal use only Audi A3 Sportback e-tron Audi Service Training (Type 8V) < Back The Audi A3 Sportback e-tron is a plug-in hybrid engineered to provide a fully integrated mobility solution There is no need for drivers to change their driving habits because the Audi A3 Sportback e-tron is designed to allow simple use of e-mobility Forwards > Ξ Contents The Audi A3 Sportback e-tron brings together the best of both worlds - an electric motor for emission-free driving and an economical internal combustion engine for long range It therefore combines both driving enjoyment and environmental awareness It has an all-electric driving range of up to 50 kilometres and is driven by a 75 kW (102 HP) electric motor with a top speed of 130 kph At high speeds and under heavy acceleration, the internal combustion engine is automatically activated to provide additional power 627_042 Contents Introduction Vehicle distinguishing features _ In brief Safety instructions Electrical safety rules Warning signs Drive unit Specifications 10 Internal combustion engine _ 12 Fuel system 13 Power transmission Overview _ 14 Gearbox modules _ 16 Suspension Overview _ 20 Electro-mechanical brake servo _ 22 Brake system pressure accumulator VX70 _ 24 High-voltage battery Overview of hybrid components _ 26 Hybrid battery unit AX1 28 Electric drive power and control electronics module JX1 _ 32 Charging _ 34 High-voltage lines _ 39 Electrical AC compressor V470 40 High-voltage heater (PTC) Z115 _ 40 Maintenance connector TW 41 Hybrid manager _ 42 Air conditioning Cooling systems, air conditioning and thermal management 44 Stationary air conditioning _ 53 Infotainment Overview of versions 54 Audi connect (depending on market) _ 56 Audi connect e-tron services (depending on market) _ 56 Audi connect (depending on market) _ 56 Control unit for emergency call module and communication unit J949 _ 57 Displays and controls Exterior sound _ 60 Electric drive button E656 _ 60 Display elements for driving in hybrid mode _ 61 Service Inspection and maintenance _ 64 Special tools and workshop equipment _ 66 Annex Test your knowledge 68 Self Study Programmes 70 The Self Study Programme teaches a basic understanding of the design and mode of operation of new models, new automotive components or new technologies It is not a Repair Manual! Figures are given for explanatory purposes only and refer to the data valid at the time of preparation of the SSP This content is not updated For further information on maintenance and repair work, always refer to the current technical literature Information Reference < Back Forwards > Ξ Contents Introduction Vehicle distinguishing features MMI system with e-tron displays e-tron logo on the dash panel (front passenger side) Switch for EV mode e-tron logo on the wings e-tron logo on the selector le e-tron logo on the design cover in the engine bay e-tron specific single-frame radiator grille in chrome/matte black e-tron specific front bumper with aluminium-look clips on the air intake covers ever < Back Dash panel insert with power meter and e-tron displays Forwards > Ξ Contents e-tron logo on the boot lid e-tron specific rear bumper with diffusor and aluminiumlook clips and concealed exhaust tail pipes e-tron light alloy wheel (17" for Ambiente, 18" for Ambition) 627_002 e-tron logo on the door sills S line sills < Back Forwards > Ξ Contents In brief 1424 Dimensions 955 1542 1516 1785 1966 675 957 987 627_020 871 2630 811 4312 627_021 13441 764 Ξ Contents 1000 Forwards > 14222 13921 14532 < Back 627_022 Interior dimensions Other specifications Concept Plug-in hybrid (PHEV) Battery type Lithium-ion system 957 Total capacity in kWh 8.8 Through-loading width in mm 1000 130 Load sill height in mm 675 Top speed in electric-only mode in kph Boot capacity in l 280/12204) Top speed in kph 222 Acceleration 0 – 60 kph in electriconly mode in s 4.9 Acceleration 0 – 100 kph in s 7.6 Range (electric drive only) in km up to 50 Front cabin width in mm 13921)/14532) Rear cabin width in mm 13441)/14222) Front headroom in mm 9873) Rear headroom in mm Exterior dimensions and weights Length in mm 4312 Total range in km up to 940 Width in mm 1785 Drag coefficient cw 0.32 Width in mm 19666) Frontal area in m2 2.13 Height in mm 1424 Capacity of fuel tank in l 40 Front track width in mm 1542 Rear track width in mm 1516 Wheelbase in mm 2630 Kerb weight in kg 1540 Gross vehicle weight in kg 2050 5) Shoulder room width Elbow room width 3) Maximum headroom 4) With rear backrest folded down 5) Excluding mirror 6) Including mirror 1) 2) All dimensions are given in millimetres and refer to the unladen weight of the vehicle < Back Forwards > Ξ Contents Safety instructions Electrical safety rules The following five safety rules must always be observed and followed whenever performing work on the high-voltage system This work may only be performed by qualified persons The following steps must be taken by the high-voltage technician These steps are not relevant to high-voltage vehicles ! ! This also applies to the qualified person responsible for the automotive high voltage systems: the high-voltage technician These safety rules must be applied in the given order before commencing work on electrical systems De-energise the vehicle Secure system against re-starting Check that no voltage is present Earth and short-circuit vehicle Cover or block off adjacent live parts Information Even AC voltages of 25 volts and DC voltages of 60 volts are hazardous to humans It is, therefore, important to follow the safety instructions given in the Service Literature and in the Guided Fault Finding routine, as well as the warnings displayed on the vehicle Information Work on the high-voltage system may only be performed by a qualified high-voltage technician < Back Forwards > Ξ Contents Warning signs To minimise the risk associated with the high-voltage system for users, service and repair shop personnel, as well as for technical and medical emergency responders, there are several warning and information labels attached to the Audi Q5 hybrid quattro Basically, two types of warning label are used: • Yellow warning label with warning symbol for electrical voltage • Warning label marked "Danger" against a red background The following yellow warning labels are used to identify high voltage conducting components or high-voltage components installed in the immediate vicinity or, for example, hazardous components concealed by covers Warning against hazardous electrical voltage according to DIN 4844-2 (BGV A8) Warning against a hazardous area according to DIN 4844-2 (BGV A8) Warning against touching live parts 627_004 627_005 Warning against hazardous electrical voltage according to DIN 4844-2 (BGV A8) Mandatory signs: Observe instructions for use according to DIN 4844-2 (BGV A8) The warning labels marked "Danger" identify high-voltage components or high voltage conducting components 627_006 627_007 Warning against hazardous electrical voltage according to DIN 4844-2 (BGV A8) Warning against touching live parts Mandatory signs: Observe instructions for use according to DIN 4844-2 (BGV A8) Special high voltage battery identification label This adhesive label is affixed to the top of the high-voltage battery, both in English and in the import country's national language < Back Forwards > Ξ Contents Drive unit Specifications Torque-power curve EA211 series 1.4l TFSI engine with engine code CUKB Power in kW Torque in Nm Internal combustion engine Internal combustion engine Electric motor Electric motor System (15 sec.) System (15 sec.) 627_093 Engine speed [rpm] 10 < Back Forwards > Ξ Contents Networking The control unit for emergency call module and communication unit J949 is integrated into the convenience CAN bus It exchanges data with various control units via the convenience CAN bus The following is a schematic diagram of the control units which communicate with the control unit for emergency call module and communication unit J949 The information exchanged is also shown J949 is a data interface only The relevant functions, such as charging the batteries or setting the desired temperature at drive-away, are performed by the control units themselves Control unit for emergency call module and communication unit J949 Control unit in dash panel insert J285 Battery regulation control unit J840 ← Time ← Current mileage (km) ← Trip data including distance, power consumption and time (onboard computers 1 and 2) ← Electrical range ← Current state of charge ← Status of charging plug ← Charging time ← Desired departure time ← Air conditioning status → Desired departure time → Instant pre-conditioning system start / stop or charging Control unit for information electronics J794 Climatronic control unit J2551) ← Current location ← Air conditioning status → Pre-conditioning Onboard power supply control unit J519 Door control units J386, J387, J388, J389 ← Current locking status ← Current lighting status ← Door status (open, closed) Key: → Data received from control unit for emergency call module and communication unit J949 ← Data sent to control unit for emergency call module and communication unit J949 1) The Climatronic control unit J255 receives the information via the battery regulation control unit J840 58 < Back Forwards > Ξ Contents Pin assignments Shielding Signal GPS1) Control unit for emergency call module and communication unit J949 PIN PIN 14 Terminal 30a Convenience CAN high PIN 26 Convenience CAN low PIN 627_091 Terminal 31 The GPS aerial is only connected to the control unit for emergency call module and communication unit J949 if no navigation unit is fitted in the vehicle (in conjunction with MMI radio) 1) Diagnostics The control unit for emergency call module and communication unit J949 has the diagnostic address word 75 J949 is integrated into the immobiliser system Response of control unit J949 to open circuit at terminal 30 The control unit for emergency call module and communication unit J949 can be de-energised by removing the terminal 30 fuse It then shuts down Ther function control units continue to execute all instructions received from the control unit and relayed to the charge management system up to this point Function control units execute functions which the customer has activated by smartphone for example If the customer sends a command to the vehicle after the fuse has been removed, this command is accepted if control unit J949 comes back online within 10 minutes of entering this command If the vehicle cannot be accessed within this 10-minute time limit, the command input by the customer is ignored Examples of function control units are: • Climatronic control unit J255 • Battery regulation control unit J840 The customer can still retrieve existing data stored in the backend The door and light status signals indicate that the vehicle cannot be accessed After terminal 30 is disconnected, control unit J949 does not come back online until it receives a valid GPS signal Given that a GPS signal normally cannot be received inside a repair shop, the control unit for emergency call module and communication unit J949 does not come back online until the vehicle has been driven out of the repair shop again Information The control unit for emergency call module and communication unit J949 must be deactivated when the high-voltage system is disconnected 59 < Back Forwards > Ξ Contents Displays and controls Exterior sound Depending on speed, the vehicle generates less noise when driving under electric power than when it is powered by the internal combustion engine For safety reasons, exterior sound is mandatory for electric vehicles in some countries The following components are fitted in the vehicle for this purpose: • Engine noise generation control unit J943 • Engine noise generation actuator R257 627_046 Engine noise generation control unit J943 The engine noise generation control unit J943 is installed under the right-hand seat and is integrated into the powertrain CAN bus 627_047 Engine noise generation actuator R257 The engine noise generation actuator R257 is fitted behind the bumper on the front right Engine noise generation actuator R257 The engine noise generation actuator R257 generates a noise similar to that of a vehicle with a running internal combustion engine For this purpose, the engine noise generation actuator R257 is activated by the engine noise generation control unit J943 depending on the speed at which the vehicle is travelling The engine noise generation control unit J943 evaluates the following information: internal combustion engine active / inactive, speed, RPM and load torque When the vehicle is operating under electric power, the external loudspeaker generates a constant noise which is reduced at approx. 30 kph The engine noise generation actuator R257 does not generate any noise when the vehicle is at a standstill and travelling at speeds in excess of approx 50 kph Electric drive button E656 The green LED in the electric drive button E656 comes on when EV mode is activated 627_051 60 < Back Forwards > Ξ Contents Display elements for driving in hybrid mode The Audi A3 Sportback e-tron uses the following components to indicate that it is running in hybrid mode: • • • • Power meter instead of rev counter Special display in the instrument cluster Animated display on MMI screen High-voltage battery charge indicator instead of coolant temperature display Displays in power meter The power meter displays various vehicle operating states and the power output or charging capacity of the hybrid system during the trip Sender 635 km 600 km 35 km 2027 D1 97.0 km +22.5°C 627_048 12 11 10 Key: Vehicle ready "Hybrid Ready", "Terminal 15 on" and "Enable terminal 50 on" depending on the enabling conditions Electric driving (engine starting is possible) or hybrid driving Threshold for EV mode Economical driving (partial throttle range) Full throttle range Internal combustion engine 100 % 10 11 12 Electric drive motor provides assistance in addition to maximum engine torque (boost) Fuel gauge Charge level of high voltage battery Terminal 15 off or terminal 15 on and terminal 50 off Hydraulic braking in addition to electrical braking Energy recovery by recuperation (under braking and acceleration) 61 < Back Forwards > Ξ Contents Displays in the dash panel insert The occupants can see the energy flow within the high voltage system The messages displayed in the dash panel insert and/or MMI display can be used for this purpose Status of the hybrid system Charging cycle display EV mode is activated Information on range of high-voltage battery charge and charging duration Sender e-tron mode: EV activated 50 km 02:14 h D7 +21.5°C 0/0 627_061 627_062 Information on the hybrid system Range display A system malfunction has occurred and the driver is prompted to take the vehicle in for servicing The range of the electric motor and the internal combustion engine are displayed Range with electric motor Total range Range with internal combustion engine Sender 720 km Drive: system malfunction! Please take vehicle in for servicing 670 km 50 km 2004 –10 °C D1 km 77.0 +21.5°C 627_063 Reference For further information about messages displayed in the in the dash panel insert and MMI, refer to Self Study Programme 489 "Audi Q5 hybrid quattro" or the Owner's Manual 62 627_049 < Back Forwards > Ξ Contents Displays on the MMI screen Energy flow display Audi drive select Handbook The energy flow is indicated to the driver on the screen comfort auto dynamic individual Car systems Set individual 12:00 627_050 e-tron statistics Car The driver can call up the e-tron statistics on the display "Emission-free:" • distance covered with zero emissions (electric + sailing + recuperation) e-tron statistics Trip distance from onboard computer 1 100.0 km Emission free: 75 % Fuel grade: 25 % "Fuel type:" • distance covered with the internal combustion engine Statistics can be displayed for actual trip and total distance covered The current display is dependent on the onboard computer Handbook Car systems 12:00 627_064 Charging and e-tron mode Car The driver can view the settings Handbook Charging & e-tron mode Next departure time: Th 15.05. 07:00 Timer selection e-tron mode Car systems 12:00 627_065 63 < Back Forwards > Ξ Contents Service Inspection and maintenance The following service intervals are displayed: • Oil change service • Mileage-based service events • Time-based service events Example of a service interval display in the MMI Car Handbook Service intervals Fixed service event Mileage-based service event Next oil change: in 15,000 km / 365 days Next inspection: in 30,000 km / 730 days Time-based service event CAR systems 12:00 627_017 The Audi A3 Sportback e-tron is generally subject to fixed inspection and maintenance intervals The value in the mileage-based servicing events field is now 30,000 km for new vehicles and is decremented in increments of 100 km The value in the time-based servicing events field is now 730 days (2 years) for new vehicles and is updated on a daily basis (upwards of a total mileage of approx 500 km) The value in the next oil change due field reads 15,000 km / 365 days and is updated on a daily basis Service work Interval Oil change 15,000 km / year Inspection 30,000 km / years Pollen filter change interval 60,000 km / years Air filter change interval 90,000 km Brake fluid change interval Change after 3, 5, years Spark plug change interval 60,000 km / years Fuel filter change interval – Timing gear 210,000 km2) Gear oil change interval1) 60,000 km 1) 2) S tronic Timing belt replacement Information The specifications in the current service literature generally apply When changing the oil, it is important to observe the applicable oil standard 64 < Back Forwards > Ξ Contents Overview of maintenance intervals for vehicles in the USA The Audi A3 Sportback e-tron is generally subject to fixed inspection and maintenance intervals in the US market The value for the next inspection is 15,000 miles / 730 days for new vehicles The next inspection after this is done together with the oil change at 20,000 miles / 730 days 25,000 miles / years 35,000 miles / years Oil change service 15,000 miles / years Inspection with oil change Inspection with oil change 5000 miles / year Oil change service Oil change service The value indicated for the next oil change is 5,000 miles / 365 days for new vehicles The next oil change after this is set at 10,000 miles / 365 days 45,000 miles / years 627_018 Overview of maintenance intervals for vehicles in China 10,000 km / 365 days later 20,000 km / 365 days later 30,000 km / 365 days later Inspection with oil change Inspection with oil change 5,000 km / year Inspection with oil change Oil change service The value indicated for the next oil change is 5,000 kilometres / 365 days for new vehicles The value for the next inspection is 10,000 kilometres / 365 days for new vehicles In China a separate oil change is done during the first service appointment only After this, no further oil changes are performed separately Thereafter, an oil change is always performed in conjunction with each inspection The display now shows the next service visit set to every 10,000 km / 365 days Inspection with oil change The Audi A3 Sportback e-tron is generally subject to fixed inspection and maintenance intervals in the Chinese market 40,000 km / 365 days later 627_019 65 < Back Forwards > Ξ Contents Special tools and workshop equipment Special tools Locking cap T40262 Adaptor for workhop crane T10542 627_067 627_068 Workshop equipment Hybrid warning labels Lightning flash VAS 6649 627_069 Warning label for high-voltage batteries Switch VAS 6650A 627_070 High voltage testing module VAS 6558A VAS 6786 627_081 High-voltage test adaptor VAS 6558/9-6 627_071 627_072 High-voltage test adaptor for charging socket VAS 6558/10-1 (Europe) 627_075 66 USB adaptor for e-tron charging system 627_076 < Back High-voltage test adaptor VAS 6558/9-5 Forwards > Ξ Contents High-voltage test adaptor VAS 6558/9 627_073 High-voltage test adaptor VAS 6558/15 627_074 High-voltage diagnostics box VAS 5581 627_078 627_077 Assembly platform support for engine bracket VAS 6131/16-4 Test adaptor VAS 6606/10 627_079 627_080 Other workshop equipment is as follows: • AC flushing adaptor, high pressure VAS 6338/40 • AC flushing adaptor, low pressure VAS 6338/41 67 < Back Forwards > Annex Test your knowledge The exhaust tail pipes on the Audi A3 Sportback e-tron are? □ □ □ □ a) Visible on the left-hand side b) Visible on the right-hand side c) Visible on the left- and right-hand sides d) Non-visible What is the pressure inside the fuel tank? □ □ □ □ a) 0.3 bar b) 0.4 bar c) 0.5 bar d) 0.6 bar What is the capacity of the fuel tank in the Audi A3 Sportback e-tron? □ □ □ □ a) 40 litres b) 50 litres c) 55 litres d) 60 litres At what engine speed does the hybrid module with electric drive motor V141 deliver its maximum output? □ □ □ □ a) 1200 – 1300 rpm b) 2200 – 2300 rpm c) 3200 – 3300 rpm d) 4200 – 4200 rpm With which brake servo is the Audi A3 Sportback e-tron fitted? □ □ □ □ a) Vacuum brake servo b) Hydraulic brake servo c) Electro-mechanical brake servo d) Electro-hydraulic brake servo What is the maximum system power output? □ □ □ □ 68 a) 75 kW b) 110 kW c) 150 kW d) 204 kW Ξ Contents < Back Forwards > Ξ Contents How many cells does the hybrid battery unit AX1 have? □ □ □ □ a) 90 cells b) 92 cells c) 94 cells d) 96 cells What is the rated voltage of the high-voltage system in the Audi A3 Sportback e-tron? □ □ □ □ a) 266 volts b) 288 volts c) 352 volts d) 374 volts What does the high-voltage heater (PTC) Z115 heat? □ □ □ □ a) Coolant b) Air c) Refrigerant d) Oil 10 Which gears are selected in sub-gearbox 1? □ □ □ □ a) 1, 3, and reverse b) 1, 3, c) 2, 4, a) 2, 4, and reverse 11 What is button E766 for? □ □ □ □ a) The charging profile b) Instant charging c) The LED module for charging socket d) Fuel filler flap release 12 In which position must the selector lever be during the charging cycle? a) P b) N c) R d) D Test solutions: d; a; a; b; c; c; d; c; a; 10 b; 11 b; 12 a □ □ □ □ 69 < Back Forwards > Ξ Contents Self Study Programmes For further information, please refer to the following Self Study Programmes SSP 489 Audi Q5 hybrid quattro SSP 615 Audi A6 hybrid and Audi A8 hybrid Order number: A11.5S00.83.20 Order number: A13.5S00.99.20 70 SSP 616 Audi 1.2l and 1.4l TFSI engines of the EA211 series SSP 618 Audi Modular Information/ Entertainment System Order number: A12.5S01.00.20 Order number: A13.5S01.01.20 < Back SSP 609 Audi A3’13 Forwards > Ξ Contents SSP 610 Audi A3 ’13 Onboard Power Supply and Networking Order number: A12.5S00.93.20 Order number: A12.5S00.94.20 SSP 611 Audi A3 ’13 Vehicle Electronics and Driver Assist Systems SSP 612 Audi A3 ’13 suspension Order number: A12.5S00.96.20 Order number: A12.5S00.95.20 SSP 625 Audi A3 saloon Order number: A13.5S01.09.20 71 All rights reserved Technical specifications are subject to change Copyright AUDI AG I/VK-35 service.training@audi.de AUDI AG D-85045 Ingolstadt Technical status 06/14 Printed in Germany A14.5S01.12.20 627 Audi Vorsprung durch Technik ... the engine torque to sub-gearbox 2, in which the uneven gears (2, and 6) and reverse gear are engaged The reverse gear pinion meshes with the 2nd gear pinion The reverse gear is engaged by power... sleeve To increase the brake pressure, the booster sleeve is moved towards the tandem master brake cylinder (to the left in the diagram) After a defined amount of the idle travel (play), the... system of the Audi A3 Sportback e- tron is based on the suspension system of the conventional-engined Audi A3 Sportback 2 suspension system versions are available for the Audi A3 Sportback e- tron
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