Audi A6 Avant 2005 Service Training

Service Training

The New Audi A6 Avant ´05

Self-Study Programme 344

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

The New Audi A6 Avant ‘05

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 a lready 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.

Into the lead: With Design & Performance

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Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Table o f contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Running gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Infotainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Convenience electronics . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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.

NoteReference

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Introduction

Overview

Dimensions of the Audi A6 Avant ´05.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Tai lg at 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.

Body

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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:
–no corrosion,
–no sealing problems,
–internal wiring,
–no grommets are needed to seal through-holes

in the body,
–larger cargo area
possibility for electric tailgate drive.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Occupant protection

Safety system

The g oal 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.

Reference

For further information on the safety
system, please refer to Self-Study
Programme 323 - Audi A6 ´05.

Front passenger front airbag

–Airbag igniter 1, front passenger side N131
–Airbag igniter 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.

Rupture disc

Prim ing charge 2

Igniter 2 Igniter 1

Metal filter Partition Metal filter

Outlets

Rupture disc

Prim ing charge 1

6

Housing

Metal filter Metal filterPropell ant ch arg e 2

Compensating material

Outlets

Propell ant ch arg e 1

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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.

Part ition Igniter I

Compensating material

Outlet

Rupture discMetal filter

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Metal filterOutlet Propellant charge 1

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Airbag igniter 2, front passenger side N132

The a irbag 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.

Igniter 2

Housing

Primi ng charg e 2

Propell ant ch arg e 2 Outlet Compensating material

Metal filter

Rupture disc

Outlet

Metal filter

Partition

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Engine

The 2.7l V6 TDI with common rail

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.

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with respect to the correctness of information in this document. Copyright by AUDI AG.

The engine number is located on the cylinder block
at the front right adjacent to the vibration absorber.

Torq u e /p ow e r c ur v e

Max. torque in Nm

Max. power output in kW

Engine speed in RPM

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Specifications

Engine code BPP

Typ e of eng ine V6 diesel engine

Displacement 2698 cm

Powe r outp ut 132 kW (180 bhp)

To rq ue 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

Exhaust emission control Oxidising catalytic converter, maintenance free diesel particulate filter

Exhaust emission standard EU 4

3

with max. 1600 bar operating pressure and 8-port piezo injectors

(optional), lambda probe and cooled exhaust gas recirculation

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Engine

Modifications to the 2.7l engine

–The stroke was reduced from 91.4 mm to

83.1 mm by modifying the crankshaft, con-rod

and piston

–Cast exhaust manifold and steel compensator

without air-gap insulation

–Deletion of the shield plates above the manifolds

–Piezo injectors with eight-port nozzles instead of

seven-port nozzles

–An inlet restrictor has been integrated into the

fuel rail for each injector

Crankshaft drive

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 cm
obtained by changing the stroke.

3

was

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

In-rail restrictor

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.

to injector

Fuel line

Inlet restrictor

Rail

Piezo injector

To re d uc e p ar ti c 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.

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Note

When replacing the injector, pay attention
to the genuine parts number!

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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.

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