Audi Q7 Installation guide

Audi
Service Training
Audi Q7 e-tron quattro (type4M)
Self Study Programme 649
For internal use only
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Audi presents the Q7e-tronquattro - its second model to feature a
high-performance plug-in hybrid drive. The electric current pro-
vided by the lithium-ion battery allows the large SUV to run for up
to 56 km solely on electric power – quietly, powerfully and emis-
sion free. Together with the diesel engine, this gives a total range
of 1410 km.
The AudiQ7e-tronquattro is the world's first plug-in hybrid with a
6-cylinder diesel engine and full-time quattro all-wheel drive. In
some countries, it is also available with a 2.0l TFSI engine.
According to the ECE standard for plug-in hybrid vehicles, the
AudiQ7e-tronquattro with 3.0l V6 TDI can cover 100km on only
1.7l of diesel, which works out at CO2emissions of 46 g/km. The
standard thermal management system with integrated heat pump
was developed specially for the Q7 e-tron quattro.
The Q7 e-tron quattro sets a new benchmark with the display and
operating concept of the standard Audi virtual cockpit and the
newly developed MMI system.
The standard MMI Navigation plus system, with Audiconnect
internet module, is integrated in tthe hybrid management system
on the Audi Q7 e-tron quattro.
The new electromechanical power steering system is highly e-
cient and responsive. The likewise newly developed five-link wheel
suspensions on the front and rear axles are more than 60 kg lighter
than the axles on the preceding model and are a major factor
contributing towards high driving dynamics.
Comfort is further enhanced by the optional adaptive air suspen-
sion. The driver can control the suspension via the standard Audi
drive select dynamic handling system, which oers up to seven
modes and integrates further technical components such as
steering, active accelerator pedal and automatic gearbox.
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Introduction
Vehicle distinguishing features ____________________________________________________________________________________________________________________________ 4
Dimensions __________________________________________________________________________________________________________________________________________________ 6
Passive safety
Overview _____________________________________________________________________________________________________________________________________________________ 8
Components _________________________________________________________________________________________________________________________________________________ 8
System overview ___________________________________________________________________________________________________________________________________________10
Airbag control unit J234 ___________________________________________________________________________________________________________________________________12
Internal combustion engines
3.0l V6 TDI engine Gen.2 evo (EA897) ___________________________________________________________________________________________________________________14
Third-generation 2.0l R4 TFSI engine (EA888) _________________________________________________________________________________________________________16
Technical features __________________________________________________________________________________________________________________________________________18
Power transmission
Overview ____________________________________________________________________________________________________________________________________________________24
Selector mechanism _______________________________________________________________________________________________________________________________________26
Emergency release, parking lock _________________________________________________________________________________________________________________________27
Plug-in hybrid drive ________________________________________________________________________________________________________________________________________ 28
Hybrid module (separation clutch actuator, sensors) __________________________________________________________________________________________________30
8-speed automatic gearbox 0D7 (cutaway view, ATF and MTF systems, ATF supply) _______________________________________________________________36
Gearbox schematic, gear set, shift elements ____________________________________________________________________________________________________________44
Shift matrix, operating modes, mechatronic module __________________________________________________________________________________________________46
ATF cooling _________________________________________________________________________________________________________________________________________________58
Function diagram, information and data exchange ____________________________________________________________________________________________________ 60
Functions influencing gearbox control (Audidriveselect, e-tronmodes) ____________________________________________________________________________61
Combinations of selector positions and e-tron modes within the Audi drive select modes ________________________________________________________63
Service _______________________________________________________________________________________________________________________________________________________64
Chassis
Overall concept _____________________________________________________________________________________________________________________________________________66
Brake system _______________________________________________________________________________________________________________________________________________68
Electro-mechanical brake servo __________________________________________________________________________________________________________________________69
Brake system pressure accumulator VX70 _______________________________________________________________________________________________________________71
Wheels and tyres ___________________________________________________________________________________________________________________________________________73
Air conditioning and cooling
Thermal management and heat pump __________________________________________________________________________________________________________________74
Coolant circuits _____________________________________________________________________________________________________________________________________________ 82
Operating states of the heat pump ______________________________________________________________________________________________________________________ 90
Air conditioning the vehicle interior ______________________________________________________________________________________________________________________ 93
System overview ___________________________________________________________________________________________________________________________________________94
Infotainment
Overview ____________________________________________________________________________________________________________________________________________________96
Service
Inspection and maintenance ______________________________________________________________________________________________________________________________ 97
Appendix
Self study programmes ____________________________________________________________________________________________________________________________________99
Reference
NoteThe 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 about maintenance and repair work, always refer to the current technical literature.
Contents
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Vehicle distinguishing features
e-tron specific single-frame
radiator grille in chrome/
matte black
e-tron specific decorative grille in front bumper
e-tron logo on the design cover
in the engine bay
e-tron logo on the car key
e-tron logo on the door sills
with lighting
e-tron logo on the wing
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Introduction
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In vehicle interior
At rear end of vehicle
Dash panel insert of Audi virtual cockpit
with power meter and e-tron displays
MMI system with e-tron displays
e-tron specific rear bumper with
diusor without visible exhaust
tail pipes
e-tron logo on the boot lid
Switch for EV mode
e-tron alloy wheels
Charger socket 1 for high-voltage battery
charging UX4 behind a flap
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1679
1968
1071
1)
1016
1082
2994
5051
975
788/6932)
1741
1690
2212
1219
Dimensions
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649_053 649_054
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1086
1179
15124) 14854) 15713) 15613)
20205)
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1) Maximum headroom
2) Air suspension at loading height
3) Elbow room width
4) Shoulder room width
5) With rear seat folded down
6) Including driver (75kg)
7) with 3.0l V6 TDI engine
All dimensions are given in millimetres and refer to the unladen weight of the vehicle.
Exterior dimensions and weights
Length in mm 5051
Width (not including exterior
mirrors) in mm
1968
Width (including exterior mirrors)
in mm
2212
Height in mm 1741
Front track width in mm 1679
Rear track width in mm 1690
Wheelbase in mm 2994
Kerb weight in kg 25206), 7)
Gross vehicle weight in kg 31857)
Drag coecient cw0.34
Inner dimensions and other specifications
Front headroom in mm 10711)
Front shoulder width in mm 15714)
Rear headroom in mm 10161)
Rear shoulder width in mm 15614)
Through-loading width in mm 1216
Load sill height in mm 788/6932)
Boot capacity in l 650/18355)
Capacity of fuel tank in l 75
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Components
Depending on country version and trim level, the passive occupant
and pedestrian protection system in the Audi Q7 e-tron quattro
may comprise the following components and systems:
• Airbag control unit
• Adaptive driver airbag
• Adaptive front passenger airbag
(front passenger airbag, two-stage country version)
• Front side airbags
• Rear side airbags (equipment option)
• Head airbags
• Front airbag crash sensors
• Crash sensors for side impact detection in the doors
• Crash sensors for side impact detection in the C posts
• Crash sensor for side and longitudinal impact detection
• Centre pedestrian protection crash sensor
(acceleration sensor, country version)
• Left and right pedestrian protection crash sensors
(pressure sensors, country version)
In-car airbags
Front pass. airbag Front side airbagDriver airbag
Front side airbag
• Front inertia-reel seat belts with pyrotechnic belt tensioners
• Front inertia-reel seat belts with electrical belt tensioners
• Front inertia-reel seat belts with active belt force limiters
• Inertia-reel seat belts for 2nd seat row with pyrotechnic belt
tensioners, driver and front pass. sides (country version)
• Front lap belt tensioner (country version)
• Seat belt warning for all seats (country version)
• Seat occupancy sensor in front pass. seat
• Front pass. airbag disabling switch (country version)
• Front pass. airbag OFF and ON warning lamp
• Driver and front pass. seat position sensors
• Pedestrian protection trigger (country version)
• Battery isolator, 12-volt electrical system
• Battery isolator of high-voltage system
Overview
On the following pages you will find a summary of the occupant
protection system in the Audi Q7 e-tron quattro.
Passive safety
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Note
The diagrams in the chapter "Passive occupant safety" are schematic diagrams designed to aid understanding.
649_010
Front side airbag Head airbag,
driver and front pass. side
Rear side airbag
Rear side airbag
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649_009
System overview
The system overview shows the components for all markets. Keep in
mind that this constellation is not possible in a production model.
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Additional equipment
Equipment specifications may vary due to the dierent require-
ments and statutory provisions which apply to vehicle manufactur-
ers in the various markets.
Key to figure on page 10:
E24 Driver side seat belt switch
E25 Front pass. side seat belt switch
E224 Airbag disabling switch, front pass. side
F390 Driver side seat belt switch, 2nd seat row
F391 Centre seat belt switch, 2nd seat row
F392 Front pass. side seat belt switch, 2nd seat row
G128 Seat occupied sensor, front pass. side
G179 Side airbag crash sensor, driver side
G180 Side airbag crash sensor, front pass. side
G256 Side airbag crash sensor, rear driver side
G257 Side airbag crash sensor, rear pass. side
G283 Front airbag crash sensor, driver side
G284 Front airbag crash sensor, pass. side
G551 Driver side seat belt force limiter
G552 Front pass. side seat belt force limiter
G553 Driver side seat position sensor
G554 Front pass. side seat position sensor
G598 Pedestrian impact mitigation trigger 1
G599 Pedestrian impact mitigation trigger 2
G693 Centre crash sensor for pedestrian impact mitigation
G851 Driver side crash sensor for pedestrian protection 2
G852 Front pass. side crash sensor for pedestrian protection 2
G858 Centre crash sensor for X/Y axis
J234 Airbag control unit
J285 Instrument panel control unit
J533 Data bus diagnostic interface J533 (gateway)
J706 Seat occupancy recognition control unit
J854 Front left belt pretensioner control unit
J855 Front right belt pretensioner control unit
K19 Seat belt warning system warning lamp
K75 Airbag warning lamp
K145 Front pass. airbag OFF warning lamp (ON and OFF status of
front pass. airbag is indicated)
N95 Driver side airbag igniter
N131 Front pass. side airbag igniter 1
N132 Airbag igniter 2, front pass. side
N153 Driver seat belt pretensioner igniter 1
N154 Front passenger seat belt pretensioner igniter 1
N196 Rear seat belt pretensioner igniter on driver side
N197 Rear seat belt pretensioner igniter on front pass. side
N199 Side airbag igniter, driver side
N200 Side airbag igniter on front pass. side
N201 Rear side airbag igniter on driver side
N202 Rear side airbag igniter on front pass. side
N251 Driver side curtain airbag igniter
N252 Front pass. side curtain airbag igniter
N253 Battery isolation igniter
N297 Seat belt tensioner igniter 2, driver side
(lap belt pretensioner)
N298 Seat belt tensioner igniter 2, front pass. side
(lap belt pretensioner)
N490 Igniter for exhaust valve for driver airbag
N491 Igniter for exhaust valve for front pass. airbag
N563 High-voltage battery isolator igniter
T16 16-pin connector, diagnosis connection
Wire colours:
Diagnostics CAN
Infotainment CAN
Input signal
Output signal
FlexRay
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Airbag control unit J234
Crash signal
The airbagcontrol unit J234 registers a crash based on the infor-
mation supplied by internal and external crash sensors. The
airbagcontrol unit classifies a crash as "minor" or "severe" depend-
ing on crash severity. A minor crash is further subdivided into
multiple crash levels depending on severity.
A severe crash is registered if restraint systems, e.g. seat belt
tensioners and airbags, are deployed. The airbagcontrol unit sends
a signal indicating the crash severity and crash level to the data
bus. Other bus subscribers receive this crash signal and can then
take the appropriate action, e.g. shut o fuel supply.
Airbag control unit J234
High-voltage battery isolator igniter N563
High-voltage battery switch box SX6
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Response of hybrid battery to crash signal
If the airbag control unit has detected a relevant crash, the hybrid
battery is deactivated for safety reasons. In the event of a crash,
the airbag control unit sends to a crash signal to the data bus. The
gateway (data bus diagnostic interface J533) relays the signal to
the battery regulation control unit J840.
Minor crash
In the event of a minor crash with a suciently high crash level,
the battery regulation control unit J840 isolates the hybrid battery.
A hybrid battery isolated by a minor crash can be reactivated by
switching terminal 15.
Severe crash
In the event of a severe crash, the signal to isolate the hybrid
battery is transmitted by two dierent pathways. This provides
redundant (multiple) backup for signal transmission.
• Pathway 1: As with a minor crash of sucient intensity, the
battery regulation control unit J840 isolates the hybrid battery.
• Pathway 2: The airbagcontrol unit J234 is wired discretely to
the high-voltage battery isolator igniter N563. The igniter is
installed in the switch box of the high-voltage battery SX6. The
igniter and the switch box form a unit. Contrary to what the
name might suggest, the high-voltage battery isolator igniter
N563 does not have any pyrotechnics. In the event of a severe
crash, the airbag control unit activates the igniter and isolates
the hybrid battery.
An electric current of between approx. 1.75 A and 2A is used
for signal transmission.
Reference
For more information about the hybrid battery, refer to Self Study Programme650"AudiQ7e-tronquattro(type4M) high-
voltage system and vehicle electrics".
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Response to crash signal: online roadside assistance or Audi emergency call
Depending on crash severity, online roadside assistance or an Audi
emergency call is activated.
Online roadside assistance
Online roadside assistance is activated after the following events:
• The airbag control unit has detected a minor crash.
• A collision with a pedestrian is detected and the pedestrian
impact mitigation system has deployed.
The signal to activate onlineroadside assistance is transmitted via
the data bus systems. In this case, the airbag control unit signals
the ascertained crash level to the gateway (data bus diagnostic
interface J533) which activates onlineroadside assistance.
Reference
For more information about onlineroadside assistance and the Audi emergency call, refer to Self Study Programme647
"AudiA4 (type8W) Infotainment and Audiconnect".
Audi emergency call
An Audi emergency call is activated if the airbag control unit has
detected a severe crash.
The signal to activate Audi emergency call is transmitted in two
dierent ways. This provides redundant (multiple) backup for
signal transmission.
• Pathway 1: The airbag control unit sends the crash signal
(severe crash) to the gateway (data bus diagnostic interface
J533) which activates the Audi emergency call.
• Pathway 2: The airbag control unit J234 is also wired discretely
to the gateway (data bus diagnostic interface J533). In the
event of a severe crash, a pulse-width-modulated signal is
transmitted across this line. The gateway evaluates the signal
and activates the Audi emergency call.
Pulse width modulation (PWM)
In the pulse width modulation (PWM) process, a technical variable,
e.g.electrical voltage, alternates between 2 values. This means
that, in principle, the voltage is switched on and o in quick suc-
cession.
The on and o times (pulse width) can be changed while maintain-
ing a constant period duration (T). This means that the pulse width
is modulated. The PWM signal must be demodulated (made
readable) so that it can be utilised.
PWM signal 1
PWM signal 2 PWM signal 3
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649_015 649_016
ON signal
ON signalON signal
OFF signal
OFF signalOFF signal
Period duration(T)
Period duration(T)Period duration(T)
Pulse width
Pulse widthPulse width
Time (t)
Time (t)Time (t)
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3.0l V6 TDI engine Gen.2 evo (EA897)
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Features and characteristics
• Starter generator
• Active accelerator pedal module
• Double belt tensioner for the poly V-belt
• Electrically driven AC compressor
• Engine is braked in start-stop mode by the starter generator
after the ignition is turned o
• Active engine and gearbox mounting system
• Exhaust flap in left tail pipe
• Reduction of compression ratio from 16.8 to 16.0 by modifi-
cation of the piston recess geometry
• 2-stage exhaust gas recirculation system with EGR precooler
• Ceramic glow plugs
• Particulate sensor
• NOxoxidising catalyst with SCR coated diesel particulate
filter
Reference
For more information about the 3.0l V6 TDI engine and the SCR system, refer to Self Study Programmes479
"Audi 3.0l V6 TDI engine (second generation)", 622 "Second-generation Audi clean diesel" and 632 "Audi Q7 (type 4M)".
Internal combustion engines
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Specifications
Features Specications
Engine code CVZA
Type 6-cylinder V-engine with 90° V angle
Displacement in cm32967
Stroke in mm 91.4
Bore in mm 83.0
Number of valves per cylinder 4
Firing order 1-4-3-6-2-5
Compression ratio 16.0:1
Power output in kW at rpm 190 at 3250–4500
Torque in Nm at rpm 600 at 1250-3000
Fuel type Diesel to EN 590
Engine management Bosch EDC 17 with start-stop and recuperation
Maximum injection pressure in bar 2000
Fuel injectors 8-port piezo injectors
Exhaust gas treatment NOxoxidising catalyst, SCR coated diesel particulate filter, particulate sensor,
oxygen sensor
Emission standard EU6 (W)
Torque/power curve of 3.0l V6 TDI engine CVZA
Power output of internal combustion engine in kW
Torque of internal combustion engine in Nm
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649_118
Engine speed [rpm]
The engine code is, as seen in the direction of travel, located at the
front left below the cylinder head on the protruding edge of the
engine block.
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Third-generation 2.0l R4 TFSI engine (EA888)
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Features and characteristics
• Elimination of the belt drive (electrical AC compressor, no
conventional generator)
• Polymer-coated main bearings, conrod bearings and stop discs
in the crank mechanism. These are needed to meet the demand
for improved emergency running properties, due to frequent
cold-starting and starting from electric mode (engine speed is
higher than during a normal engine start).
• Simos 18.4 engine management system with engine control
unit interface to the FlexRay bus system
Reference
For more information about the Gen. 3 2.0l TFSI engine, please refer to Self Study Programmes 606 "Audi 1.8 and 2.0l TFSI
engines of EA888 series (third generation)" and 645 "Audi 2.0l TFSI engines of EA888 series".
• Audi valvelift system (avs) on the exhaust side
• Reconfiguration of the crankcase ventilation flow over the
balancer shafts in the area of the engine block
• Currently available in Japan, Singapore, Korea and China only.
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Specifications
Features Specications
Engine code CVJA
Type 4-cylinder inline engine
Displacement in cm31984
Stroke in mm 92.8
Bore in mm 82.5
Number of valves per cylinder 4
Firing order 1-3-4-2
Compression ratio 9.6:1
Power output in kW at rpm 185 at 5000-6000
Torque in Nm at rpm 370 at 1600-4500
Fuel type Premium unleaded 95 RON
Engine management SIMOS 18.4
Maximum injection pressure in bar Adaptive lambda control, adaptive knock control
Fuel injectors Sequential (dual) direct injection (FSI) and multipoint injection (MPI) with adap-
tive idle charge compensation
Exhaust gas treatment Close-coupled ceramic catalyst, oxygen sensors before and after
catalytic converter
Emission standard EU6 (W)
Torque/power curve of 2.0l TFSI engine CVJA
Power output in kW
Torque in Nm
649_003
Engine speed [rpm]
649_119
Engine code on the engine block
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Active accelerator pedal
The AudiQ7e-tronquattro usually starts in electric-only mode.
The driver's power requirement are indicated to the system via the
active accelerator pedal. To activate the internal combustion
engine, the driver must press the active accelerator pedal beyond a
defined point of resistance. The point at which the resistance
occurs is dependent on the requirements of the hybrid manage-
ment system. The linear solenoid for the active accelerator pedal in
the accelerator pedal module produces a variable pressure point by
means of a spring-loaded lever. When the pressure point is
exceeded, the internal combustion engine is engaged. The inte-
grated active accelerator pedal control unit J1115 receives the
relevant information from the hybrid management system.
The pressure point varies depending on the charge state of the
hybrid battery. Depending on the state of charge of the hybrid
battery, the driver canconsciously avoid engagement of the inter-
nal combustion engine and run in electric-only drive mode. To
generate boost, where both engines deliver their maximum power
output, a pressure point must be overcome.
Eciency assist
If eciency assist is installed, the driver is prompted to ease o
the accelerator by a signal tone, in addition to the visual display in
the instrument cluster. If the driver continues to depress the
accelerator pedal, the kick-down mode is activated as usual.
649_025
Accelerator pedal moduleGX2 with:
• Active accelerator pedal control unit J1115
• Accelerator pedal position sensor G79
• Accelerator pedal position sensor 2 G185
Linear solenoid for
active accelerator
pedal
Spring-loaded
lever
Return spring
Internal combustion engine engagement signal
A pressure point can be felt when the active accelerator pedal is
pressed. If this pressure point is "exceeded", the internal combus-
tion engine is engaged to provide the driver with the required
engine power.
Signal tone before starting of the internal combustion engine
Shortly before the engagement of the internal combustion engine
due to the charge state of the hybrid battery and the driver's
current driving style, a counter-force is briefly produced by the
active accelerator pedal.
In addition, a corresponding text message is displayed in the
instrument cluster. This indicates the driver that he needs to ease
o the accelerator, in order to continue driving in electric-only
drive mode.
649_029 649_030
TimeTime
Force Force
Pressure point
Signal tone as
driver information
Kick-down
Please release
accelerator pedal
Technical features
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Start scenario of the diesel and petrol engines
If the engine start button is pressed at the same time as the brake
pedal, the drive system is activated. e-tron READY mode is dis-
played in the Audi virtual cockpit. The vehicle uses the e-machine
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Starting of the internal combustion engine via the starter generatorC29 (12-volt starting)
3.0l V6 TDI models are equipped with a starter generatorC29,
which is used for starting the internal combustion engine under
defined conditions.
649_093
Guide pulley
Crankshaft Belt pulley for poly V-beltStarter generator
C29
Tensioning roller for
belt tensioner 1
Pendulum
Tensioning roller for
belt tensioner 2
Viscous torsion damper
Engine control unit
J623
Separation clutch actuator
V606
NOxsender control unit
J583
NOxsender control unit 2
J881
Particulate sensor
G784
Blocking diode for electrical
system disconnection
J1165
Active accelerator pedal control
unit
J1115
Sub-bus
for drive if the hybrid battery has sucient charge. If the hybrid
battery is not suciently charged, the internal combustion engine
is started.
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Starting with starter generator C29 is also referred to as 12-volt
starting. During 12-volt starting, the separation clutch K0 in the
gearbox is opened. The lower belt section is fully tensioned at start
and pushes the lower roll down. This pressure is transferred via the
pendulum bar to the upper roll, which tensions the poly V-belt.
If a 12-volt supply is available for the starter generator C29, the
internal combustion engine is started via the belt under the follow-
ing conditions:
• Belt start
If the capacity of the e-machine is utilised in electric drive mode
to such an extent that smooth slip-starting cannot be achieved
via the e-machine, the internal combustion engine is started by
the starter generator C29.
• Change of mind
In hydrid drive mode, the e-machine and the internal combus-
tion engine deliver power to the gearbox. If the internal com-
bustion engine is shut o after the driver eases o the accelera-
tor, the engine can be restarted after the driver presses the
accelerator again by activating the ignition and the injection
system in the engine control unit as long as the engine has the
required starting speed. If the engine speed is too low for
restarting, the engine is brought up to starting speed and
started by the starter generator C29.
If the internal combustion engine has been started and is running
in sync with the gearbox input shaft, the separation clutch K0 in
the gearbox is closed.
Controlled shut-o
If the internal combustion engine is shut o in start-stop mode,
the starter generatorC29 brakes the engine to a stop, in order to
prevent judder at shut-o.
The starter generator is supplied with voltage by the 12-volt
electrical system while the internal combustion engine is running.
It is running in generator mode but is delivering electrical current.
In this operating state the poly V-belt is highly tensioned because
the generator is in braking mode. Therefore the lower roll is
pushed up by the pendulum bar and feeds the poly V-belt.
649_115
649_116
Generator mode
Engine start
Reference
For more information about the third-generation 2.0l TFSI engine, refer to Self Study Programme650
"AudiQ7e-tronquattro(type4M) high-voltage system and vehicle electrics".
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