Audi A2 Technology.pdf

Service.

AUDI A2 Technology

Design and Function

Self-study program 240

For internal use only

Exciting technology in a

new lightweight design

The Audi A2 is paving the way for advanced

mobility in the 21st century

and

at the same time is the ﬁrst volume-produced

car to have an aluminium body.

With its future-oriented lightweight design, it

represents a new dimension in dynamism

and economy.

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A car for the modern world,

innovative, compact, roomy, lightweight, safe and environmentally compatible.

Contents

Page

In a nutshell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Running gear

Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Components and ﬁtting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

ESP control system 30

ESP control system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Diagnosis warning lights and buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Electrical system

Vehicle’s electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

CAN BUS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Comfort system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Central control unit for comfort system J393 . . . . . . . . . . . . . . . . . . . . . . 45

Door control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Anti-theft alarm with interior monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Functional diagram of comfort system . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Heater/AC

Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Additional heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Service/maintenance

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Repair concept of the Audi A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Special tools / workshop equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

New

Attention!

Note

The self-study programme will provide you with information on

design and functions.

It is not intended as a workshop manual!

For maintenance and repairs please refer to the current technical

literature.

In a nutshell

Body

Anyone who thinks only steel can be stable

obviously hasn’t yet heard about aluminium.

, the

A2’s aluminium body is more than 40 %

lighter than the conventional steel design. Its

unladen weight is just 895 kg, around 150 kg

lighter than other vehicles its size.

Drive system

The high-torque 1.4l 55 kW TDI three-cylinder

power unit with pump-nozzle injection uses

just 4.2 litres of diesel per 100 kilometres,

accelerates from 0 to 100 km/h in 12.1

seconds and has a top speed of 173 km/h.

The 1.4 litre four-cylinder petrol engine, also

with a power output of 55 kW, allows the Audi

A2 achieve similar performance levels and

produces a satisfactory average fuel

consumption of 6.1 l; the engine is classiﬁed

as low emissions to EU4 standard.

With its 1.2 l three-cylinder TDI engine, Audi

will be the ﬁrst manufacturer in the world to

offer a four-door 3-litre car; the launch is

scheduled for a later date.

Thanks to the Audi Space Frame (ASF)

Safety

The Audi’s outstanding drag coefﬁcient of

0.28 is the best in its class.

The Audi Space Frame, made from high-

strength aluminium proﬁle sections,

surrounds the occupants like a safety cage,

thus providing them with a high level of

passive safety.

Driver, passenger and side airbags are

standard. The SIDEGUARD system is optional.

Running gear

In the Audi A2, Audi has combined the latest

electronic components, such as the standard

ABS, EBPD and ESP, with the tried and tested

technology of McPherson strut front

suspension and a torsion beam rear axle.

Thanks to the new electrohydraulic power

steering system, optimum steering effort

support is provided.

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Maintenance

Longlife service has been achieved for the

above-mentioned engines right from market

launch.

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