Audi A6 Allroad, A6 Allroad 2000 User Manual
241
Service.
The Audi allroad quattro
with additional shift stage
Design and Function
For internal use only
Self-study programme 241
Audi allroad quattro - the best of both worlds
After a 20 year history of four-wheel drive,
Audi presents the allroad quattro. For the first
time, a production model with off-road
capability.
The Audi allroad quattro is the synthesis of
the classic estate and the traditional off-road
vehicle. It combines the outstanding driving
dynamics of the Audi A6 with the off-road
capability of a four-wheel drive.
The Audi allroad quattro is the embodiment
of a new vehicle category, the so-called
“allroader”.
Featuring the proven quattro drive,
the improved running gear with
”4-level air suspension”, the optional
”low range” additional shift stage
and the changes to the bodywork and
the interior, the Audi allroad quattro
combines two previously separate
vehicle categories thereby offering
”the best of both worlds” .
241_041
241_042
2
allroad quattro
Design features/vehicle design ............................................. 4
Engine .....................................................................................11
Gearbox ..................................................................................20
Technical data and dimensions ........................................... 22
Running gear ........................................................................ 24
Bodywork and electronics ................................................... 30
Poor surface measures ......................................................... 32
Power flow in the drive train ............................................... 34
quattro drive .......................................................................... 35
Clutch actuation ................................................................... 36
Additional shift stage
System overview ................................................................... 38
Operation ............................................................................... 39
Additional shift stage design construction ........................ 40
Power flow ............................................................................. 42
Electrohydraulic control ...................................................... 44
Diagram of hydraulic system .............................................. 45
Hydraulic regulator ............................................................... 46
Shift positions/shift process ............................................... 48
Error functions ...................................................................... 54
Electronic control ................................................................. 55
Travel sensor system ............................................................ 56
Sensors .................................................................................. 62
CAN information exchange ................................................. 65
Interfaces ............................................................................... 66
ESP in the Audi allroad quattro............................................ 67
Function diagram .................................................................. 72
Contents
Page
Service
Self-diagnosis of the additional shift stage ....................... 74
Special tools .......................................................................... 75
The self-study programme will provide you with information on the
design and functions of the different assemblies/systems.
The self-study programme is not intended as a workshop manual.
For maintenance and repairs please refer to the current technical
literature.
Mechanical components: Workshop Manual Audi A6 1998 >
6 speed manual gearbox 01E, four wheel drive TM 3
Self-diagnosis: Workshop Manual Audi A6 1998 >
6-speed manual gearbox 01E, four wheel drive self diagnosis.
Order No.:
This figure can be ordered as a size A0 poster through
Bertelsmann Distribution for a net price of DM
Direct ordering through Bertelsmann only applies to Germany.
Dealers in export markets are requested to contact their importer.
507.5319.01.00
New
Note
15.00 DM/7.50 EUR
Important:
Note
.
3
allroad quattro
The design features
The roof has the same rib structure as the
underride protection It forms an independent
design element together with the paint work,
which has been kept in the silk matt
contrasting colour.
The chunky bumpers, also highlighted in a
contrasting colour, and the prominent plastic
wheel arches emphasise the off-road qualities
of the allroad quattro and offer protection in
minor collisions.
In the special aluminium finish option the
roof rail, the trim strip on the tailgate and the
door cladding strips in aluminium are silk
matt and the side window surrounds are
highly-polished aluminium (production: all in
contrasting colour).
The integral stainless steel underride
protection, in the front and rear bumpers,
matches the aluminium finish and offers
protection against ground contact. It is also
reinforced on the inside with a plastic
honeycomb structure. In terms of
appearance, the underride protection is a
design element which emphasises the offroad capabilities of the Audi allroad quattro.
Front space frame
Exterior mirrors
241_043
Door surround stripUnderride protection
4
Extra large exterior mirrors on both sides
ensure good all-round vision, particularly off
road.
The aluminium wheels and tyres have also
been newly developed, exclusively for the
allroad quattro. Together with the other
design features, they complement the strong,
robust image of the allroad quattro.
Further information can be found under
Wheels/ tires, from page 28 on.
Side window surround
A unique interior design has been created for
the allroad quattro.
Attention should be drawn to the seats, which
have been newly developed for off-road use.
They combine great lateral stability with
excellent seating comfort and offer the driver
good support for sporty cornering or in
heavy, off-road terrain.
The underride protection must be
removed in order to access the rear
towing lug. It is therefore fitted with
quick-release screws.
Roof rail
241_044
Underride protection
Tailgate trim strip
5
allroad quattro
The vehicle design
What makes the allroad quattro an allrounder:
• quattro drive
• 4-level air suspension
• Optional activation of additional shift stage
”low range“
quattro drive
Audi has proved the
superiority of the permanent
four-wheel drive over two
decades and in all types of
terrain.
The allroad quattro is the
result of twenty-years of
quattro history.
As an all-new vehicle design,
the “allroader” demonstrates
this in a most impressive way.
The current quattro drive
generation offers optimum
driving dynamics and safety
on all roads. However, the
quattro drive also offers a
high degree of traction and
comfort off-road and on snow
and ice.
Details of the quattro drive
can be found from page 35
on.
Air spring/front axle
242_007
241_050
6
4-level air suspension
To design a vehicle which is ideal for on and off-road use,
would appear to be impossible.
Usually, the strengths of the off-road vehicle are definite
weaknesses with regard to road use.
Variable ground clearance is the solution for allroad use, in
the form of 4-level air suspension.
Additional shift stage
”low range“
Air spring/rear axle
242_006
241_051
With the help of the optional
additional “low range” shift
stage for the manual
gearbox, the overall gear
ratio is reduced by a factor
of 1.54. This increases the
traction of the allroad quattro
and also reduces the speed
by a factor of 1.54.
Additional shift stage
241_040
7
allroad quattro
4-level air suspension
A high ground clearance, essential for uneven
terrain, gives the vehicle a correspondingly
high centre of gravity.
However, this is just as disadvantageous
when cornering as it is for driving stability at
higher speeds.
Additionally, this is increases air resistance,
which significantly affects fuel consumption.
On the other hand, the reduced spring travel
and the harder set-up version of a "roadrunning gear", result in inadequate off-road
driving comfort.
The 4-level air suspension is a sophisticated
electronically controlled air suspension
system on both axles.
The system permits variation of the ground
clearance by 66 mm and offers four defined
ground clearance levels between 142 and
208 mm.
Depending on driving conditions and
requirements, greater ground clearance or a
lower vehicle centre of gravity can be
selected.
The 4-level air suspension keeps the pre-set
vehicle level constant, irrespective of load
and weight distribution.
Operating unit
241_062
8
The driver can vary the ground clearance (the
vehicle level) in four stages, by means of the
operating unit in the centre console.
The four levels can be set manually or
automatically within defined speed ranges.
It is also possible to switch between manual
and automatic mode and switch off the
system using the operating unit.
Ground clearance
208 mm
LED displays in the operating unit indicate the
operating status and the control process to
the driver.
The operation, design and function of
the 4-level air suspension is explained
in full in SSP 243.
High level 2
+ 31 mm above
normal level
Ground clearance
192 mm
Ground clearance
167 mm
Ground clearance
142 mm
The ground clearance at the low level is 49 mm higher than that
of the Audi A6.
High level 1
+25 mm above
normal level
Normal level
± 0 mm
Low level
-25 mm below
normal level
242_063
9
allroad quattro
Additional shift stage
The additional shift stage offers the following
advantages:
• Additional advantage in heavy terrain on
extreme uphill slopes via increased
traction.
• Increased engine breaking effect on steep
downhill slopes.
• Lower vehicle speeds in difficult terrain or
manoeuvring with high trailer load (up to
2300 kg).
• The additional shift stage makes driving
easier under difficult conditions (uphill
slopes / high loads) and protects the
clutch.
• Maximum operating comfort due to
electrohydraulic control.
• Electronic monitoring of shifting process
provides maximum protection against
incorrect shift procedure.
The design and function of the
additional shift stage is described in
full from page 38 on.
Vehicle speeds in 1st gear at 1000 rpm (6-speed manual gearbox)
A6 allroad
quattro
2.5-l-V6-TDI
2.7-l-V6-Biturbo
10
8.0 km/h 7.6 km/h 4.9 km/h
8.2 km/h 7.6 km/h 4.9 km/h
242_054
allroad quattro with additional
shift stage engaged
Engine
For every allroad quattro eventuality, …
... two high-performance and high-torque
engines are available.
The 2.7-l-V6-Biturbo
... is identical to the performance version
installed in the Audi S4 and A6.
Performance and torque have been adapted
for use in the allroad quattro.
Fuel grade: RON 95
In order to provide adequate fuel metering in
low-range operation, the engine control
provides a separate accelerator pedal map.
Power output diagram:
The maximum power output of 184 kW is
achieved at 5800 rpm.
The maximum torque of 350 Nm is available
between 1800 and 4500 rpm.
Technical data:
Fuel grade: RON 95 (RON 91 with
reduced performance)
Exhaust gas
standard: EU III
Flexible service
interval: up to 30,000 km,
max. 2 years
241_046
The design and function is described in
SSP 198.
Engine code: ARE
200
180
160
140
120
100
80
500
450
400
350
300
250
200
60
40
20
Power output [kW]
0
0 1000 2000 3000 4000 5000 6000 7000
Engine speed [rpm]
241_027
150
100
50
Torque [Nm]
0
11
allroad quattro
The 2.5-l-V6-Biturbo
... as increased-performance version of the
2.5-1-V6-TDI with 110 kW (150PS), whose
function and design is described in SSP 183.
Power output diagram:
The increased maximum power output of
132 kW is achieved at 4000 rpm.
The maximum torque of 370 Nm is available
between 1500 and 2500 rpm.
Technical data:
Capacity: 2496 cm
3
Bore x stroke: 78.3 mm x 86.4 mm
Compression ratio: 18.5 : 1
Fuel injection
system:
Bosch EDC-15 M with
pre-injection and dual-
spring injector holder
Firing order: 1 - 4 - 3 - 6 - 2 - 5
Turbocharger: VNT 20 with variable
turbine geometry
Exhaust emissions
control:
Exhaust gas
recirculation system
Primary catalytic
converter,
Main catalytic
converter
Primary catalytic
Ceramic 3.66" x 2.9" :
converter:
Main catalytic
converter:
Ceramic, 5.66" x 6"
and/or 2" x 5.69"/
3.3" x 6.08" (quattro)
Emissions level: EU III
Fuel grade: Diesel 49 CZ
Flexible service
interval:
up to 35,000 km,
max. 2 years
Engine code: AKE
140
130
120
110
100
90
80
70
60
50
40
30
20
241_047
420
390
360
330
300
270
240
210
180
150
120
90
60
12
The differences between the 132 kW
version and the 110 kW version are
described below.
Power output [kW]
10
0
0 1000 2000 3000 4000 5000
Engine speed [rpm]
Comparison with V6-TDI 110 kW
241_028
30
0
Torque [Nm]
ostSc
Th essential differences of the V6-TDI/132 kW
version
• Pistons made of new, more heat-resistant
piston alloy to compensate for higher
thermal load.
• Altered shape of piston recess to optimise
combustion process.
• Compression ratio reduced to
18.5 : 1 by enlarging piston recess.
• Piston/conrod with trapezoidal head to
compensate for the higher combustion
pressure and to reduce the oscillating
mass by approx. 10% (see SSP 226,
Page 10).
Piston recess
Trapezoidal head
241_064
• Crankcase housing with
additional vent outlet on the
front engine side to reduce oil
component in engine ventilation.
• Reduction of the air mix in the
engine oil via lateral baffles in
the crankcase housing (see also
SSP 245 and 255).
Increased
bearing surface
Increased
bearing surface
Vent gas
Cyclone oil mist separator
Vent outlet
241_065
Vent outlet
13
allroad quattro
• Crankcase ventilation with cyclone oil mist
separator to reduce oil component in the
oil mist and blow-by gas (see SSP 226,
Page 17).
241_067
Principle
Due to the limited available
space the cyclone oil mist
separator consists of four
single cyclones.
These are connected in parallel
and offer the same throughput
as a single version.
Unlike oil separators with mesh
inserts (filters), the cyclone oil
mist separator cannot become
blocked.
A high functional reliability is
thus guaranteed for the service
life of the engine.
The cyclone oil mist
separator can be also
retrofitted as a complete
unit (oil filter module) into
the 110 kW version.
De-oiled blow-by
gas
14
241_066
Blow-by gas
Separated oil
Oil return to central crankcase
• Radial piston distributor fuel injection
pump VP44S3 with 3 rams for increased
injection pressure. Fuel injection
pressures of up to 1850 bar are achieved
at nominal capacity.
VP44S3 radial piston distributor fuel
injection pump
3 rams
Comparative injection pressure 110 kW with 132 kW, EU III: Maximum line pressure upstream
from the injector
2000
1800
1600
1400
1200
1000
241_068
800
600
Line pressure [bar]
400
1000 1500 2000 2500 3000 3500 4000 4500
Engine speed [rpm]
110 kW, EU III
132 kW, EU III
241_070
15
allroad quattro
• New: pre-injection controlled via solenoid valve.
In conjunction with the dual-spring injector
holder combination, it helps reduce
combustion noise, particularly when the engine
is cold.
Needle lift with pre-injection at 2500 rpm and 40 mg injection quantity
0,3
0,25
0,2
0,15
0,1
0,05
0
Needle lift [mm]
-20-10 0 10203040
Crank angle [degrees]
• Six-hole instead of five-hole injectors for
better mixture formation and emissions
reduction.
241_069
Spring 1
Spring 2
241_071
Stop sleeve
Injector needle
Needle guide
Intermediate washer
16
Lift 2
0.215 mm
Lift 1
0.035 mm
17
• Turbocharger made of more heatresistant material, optimised turbine
and compressor wheel and improved
kinematics of the guide vane
adjustment.
• Primary catalytic converter
immediately downstream from the
turbocharger
Turbocharger with variable turbine
geometry
Comparison with charge pressure curve V6-TDI
110 kW with 132 kW
2,4
2,2
2,0
1,8
1,6
1,4
1,2
Absolute charge pressure [bar]
1000 2000 3000 4000 5000
Engine speed [rpm]
110 kW, EU III
132 kW, EU III
Primary catalytic converter
Main catalytic converter
241_073
Compensator
241_072
Airgap insulated front pipe
Airgap insulated manifold
allroad quattro
• Fuel cooling via fuel-coolant heat
exchanger and coolant-air heat exchanger
integrated into the engine cooling system
(see also SSP 226, Page 22).
• To guarantee adequate engine cooling on
any terrain, the V6-TDI in the allroad
quattro is fitted with an uprated coolant
heat exchanger.
Fuel feed
Fuel return
• Larger oil-coolant heat exchangers
compensate the increased thermal
loading of the engine oil caused by
the increase in performance.
The fuel cooler is initially intended only
for the allroad quattro, but will also be
used in other vehicles in the future.
to the coolant pump
Fuel-coolant heat exchanger
Coolant-air heat exchanger
(low temperature)
241_020
18
from the cooler
Coolant pump for fuel
cooling V166
Notes
19
allroad quattro
Gearbox
6-speed manual gearbox 01E
The following gearboxes are available for
both engine versions:
• 6-speed manual gearbox 01E
• 6-speed manual gearbox 01E with
additional low range shift stage (optional).
In conjunction with the manual gearbox 01E,
both engine versions have the self-adjusting
"SAC" clutch. The design and function is
described in SSP 198, Page 66.
The 01E manual gearbox is generally fitted
with an oil cooling system (see SSP 198,
Page 71).
20
241_007
5-speed 01V automatic gearbox
The 01V 5-speed automatic gearbox with tiptronic is also available (cannot be supplied with
additional shift stage) for the V6-Biturbo and the V6-TDI.
In both engine versions, the maximum speed is achieved in 5th gear.
Additional ATF cooler
The 01V is fitted with an
additional ATF cooling
system (see also SSP 213).
241_025
Engine cooler/
ATF cooler
241_029
Additional ATF
cooler
Return
Feed
Thermostat
21
allroad quattro
Technical data and dimensions
allroad quattro
2.7-l-V6-Biturbo
6-speed manual
gearbox
Maximum speed in km/h 236 (234) 207 (205)
Acceleration 0 - 100 km/h in s: 7.4 (7.7) 9.5 (9.6)
Urban fuel consumption in l/100 km
Non-urban fuel consumption in l/100 km
Overall fuel consumption in l/100 km
Cooling system capacity (incl. heater) in l: approx. 6
Engine oil capacity (incl. filter) in l: approx. 6
Tank capacity in l: 70
Steering ratio: 16.2
Turning circle in m: 11.68
Unladen weight in kg (without driver): 1795 (1825) 1790 (1825)
Admissible total weight in kg: 2425 (2455) 2420 (2455)
Admissible front axle load in kg: 1260 (1285) 1270 (1285)
1
): 18.0 (19.2) 12.3 (13.4)
1
): 9.8 (9.7) 7.0 (7.5)
1
): 12.8 (13.2) 8.9 (9.6)
allroad quattro
2.5-l-V6-TDI
6-speed manual
gearbox
Admissible rear axle load in kg: 1300
Admissible unbraked trailer load in kg: 750
Admissible trailer load, braked on
8% uphill gradient, in kg
Admissible trailer load, braked on
12% uphill gradient in kg
Admissible roof load in kg: 100
Admissible support load in kg: 95
Luggage compartment capacities
according to VDA (German automobile
industry association) luggage volume
standards in l (with back seats folded down
and loaded to roof height):
1) according to 93/116/EC
2) use of trailer anti-roll bar increases the admissible trailer load to 2300 kg
(up to max. 80 km/h)
2
):
2
):
2300
2100
455 - 1590
22
The values in brackets relate to
automatic gearbox.
24
1501-1567
1056
23
208****
1597**
1565
1978
1950(+30)
1074**
1069
976**
970
142*
1586**
1536
1843
1810(+33)
ET25 ET25
192***
2760**
2758
4810
4797(+13)
Dimensions: red = allroad quattro, black = A6 Avant
Values in brackets correspond to the differences in comparison with the A6 Avant.
694***
241_049
A
A
Overhang angle
Front:
B
Ramp breakover
angle
C
Overhang angle
rear:
D
Ground clearance: approx. 208 mm ****
approx. 20 degrees
****
approx. 19 degrees
****
approx. 23 degrees
****
B
D
241_026
C
* Low level
** Normal level
*** High level 1
**** High level 2
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