Audi A6 Avant '05 344 Assembly instructions

344
All rights reserved.
Technical specifications
subject to change without
notice.
Copyright
AUDI AG
I/VK-35
Service.trai[email protected]
Fax [phone]
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

4
Overview
Dimensions of the Audi A6 Avant ´05.
Introduction
344_062

5
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

6
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

7
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

8
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

9
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

10
–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

11
The closing of the injector produces a pulse which
propagates from the injector to the fuel rail and is
reflected back to the injector. In this connection, the
injector pintle and injector pintle seat are subjected
to a high mechanical load (bounce). A restrictor is
installed upstream of each injector to dampen the
pulses in the fuel rail. This restrictor dampens the
incoming and outgoing pulses and so prevents the
injector pintle from colliding with the injector pintle
seat.
The restrictor is mechanically press-fitted into the
fuel rail.
In-rail restrictor
to injector
Rail
Fuel line
Inlet restrictor
344_061
Note
When replacing the injector, pay attention
to the genuine parts number!
Piezo injector
To r ed uc e p a r tic ul ate emissions still further and to
optimise combustion, 8-port injectors are used in
place of 7-port injectors. This enables the fuel to be
more finely atomised and provides a smoother
combustion process.

12
Running gear
A steel-spring suspension is used in the basic version of Audi A6 Avant `05. In comparison with the running
gear in the A6 saloon, the set-ups for the springs, dampers and anti-roll bars have been revised. In the Avant,
too, there are suspension systems for front-wheel-drive and quattro versions. The dynamic suspension
system is available in the basic version. A sport suspension, which lowers the overall car's ride height by
15 mm compared to the dynamic suspension system, is available as an optional extra. Heavy-duty running
gear, which raises the car's ride height by 15 mm compared to the dynamic suspension system, is also
optional.

13
344_029

14
Running gear
Adaptive air suspension (aas)
A modified aas system is optional in the Audi A6 Avant `05. By comparison with the aas in the A8, there is no
distinction to be made between the aas standard suspension and the aas sports suspension. The following
fundamental differences exist between the aas in the A6 and the aas in the A8:
the control was adapted for the A6, with modified ride
heights compared to the A8
modified mechanical design of the dampers and
modified damping control
the solenoid valve block and compressor are installed
mounted on a common bracket
aas is also available in combination with MMI Basic
body acceleration senders are integrated in the wheel arch

15
separate spring/damper arrangement
modified pressure accumulator design,
mounted to luggage compartment floor
344_030