gearbox AUDI A4 2001 B5 / 1.G Technical Features Design And Function

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Important:
Note
New

Contents
It is not intended as a workshop manual.
The self-study programme will provide you with information on
design and functions.
For maintenance and repair operations it is essential that you
refer to the current technical literature.
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine and gearbox
Running gear
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Mechanical unit mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Brake assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
CAN BUS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Steering column switch module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Function circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Control unit for vehicle electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Function circuit diagram for "lowline" version . . . . . . . . . . . . . . . . . . . . . 50
Function circuit diagram for "highline" version . . . . . . . . . . . . . . . . . . . . 52
Convenience system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Radio - chorus II, concert II and symphony II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Navigation IV and Navigation Plus-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Multi-communication bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Electric logbook "Audi Logbook" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Heater/AC
Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7-piston compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Glove compartment cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Solar roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fresh air blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Actuators/sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Functional diagram for fully automatic air conditioner . . . . . . . . . . . . . . 84
Additional heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 2.0 l R4 and 3.0 l V6 engines (see SSP 255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Innovations - 2.5 l V6 TDI engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Innovations - automatic gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electrical system

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Introduction
Infinitely variable perfection
For the first time in this vehicle class, Audi
offers the infinitely variable "multitronic"
automatic gearbox for all front-wheel drive
versions.
The architecture of motion
Performance and smooth running
The engine programme of the new Audi A4
includes two petrol engines of a completely
new design, with aluminium housings.
The 2.0 litre 4-cylinder in-line engine with
96 kW (130 PS) and the 3.0 litre V6 with
162 kW (220 PS) fulfil the EU 4 emissions
standard.
A high degree of running smoothness is
achieved via balancer shafts.
The new light alloy running gear
With the four-link front axle, each wheel is
controlled by four aluminium transverse links.
The pivot bearings are also made from the
same light alloy.
The trapezium link rear axle for the quattro
drive system is also used in the front-wheel
drive models of the Audi A4.

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Engine and gearbox
with five-valve cylinder head, produces162 kW
(220 PS) at 6300 rpm from 2976 cm
3

.
The maximum torque of 300 Nm is developed
at 3200 rpm.
Engine
The 4-cylinder, 2.0 l engine
provides high propulsive force due to the
maximum torque of 195 Nm at 3300 rpm.
The 3,0 l V6 engine
Detailed information on these engines
can be found in SSP 255.
Power output [kW] Torque [Nm]
Power output [kW]Torque [Nm]

SSP254_060
SSP254_061
Engine speed in rpm
Engine speed in rpm
SSP254_038
SSP254_030

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Engine and gearbox
In order to initiate pre-injection for cold and
warm engines, the solenoid valve dynamics
have been significantly increased.
The associated increased heat generation in
the solenoid valve, is compensated by
improved fuel flow and optimal filling of the
high pressure section is achieved.
Noise levels have been significantly improved
by the pre-injection for cold and warm opera-
tion and the use of dual-spring nozzle hold-
ers.
Injection pump VP 44 S3.5
Previously, pre-injection via the solenoid
valve was only realised during the engine
warm-up phase. The high pressure section of the injection
pump has been redesigned with regard to
pressure levels and quicker solenoid valve
actuation.
The injection pressure at part throttle has
been increased by the following measures:
– increased cam stroke from 3.5 to 4.0 mm
– more stable support structure for high
pressure section on pump body
– conversion from 3 pistons with a diameter
of 6.0 mm, to 2 pistons with a diameter of
7.0 mm.
By reducing the number of high-pressure pis-
tons from 3 to 2, it was possible to reduce
high-pressure leakage via the sealing sur-
faces.
Forced flush
return
Distributor bushing
Distributor shaft
Supply piston
Thermal shoulder
Forced flush feed
Solenoid valve
SSP255_040

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The charge air cooler design comprises two
sections, in which part of the charge air is fed
via a through duct, connected to a space-sav-
ing pipe, to the section of the other charge air
cooler which is fitted with cooling fins.
The rest of the charge air is fed directly
through the cooling fins, via a separate pipe,
to the second charge air cooler and into the
through duct.
Charge air cooler
Engine and gearbox
The existing series connection of the two
charge air coolers for the 110 kW engine is
inadequate for the 132 kW engine with its
high air throughput.
A new charge air cooler design was devel-
oped, in order to ensure optimal charge air
flow.
SSP255_043
Through duct
Cooling duct section

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P
R+NDS

Innovations - automatic
gearbox
5-speed 01V automatic gearbox
The Audi A4 quattro MJ01 with 5-speed auto-
matic gearbox features a new shift lever gate,
together with a new shifting concept.
The existing selector lever positions, 4,3,2 are
discontinued and are replaced by the "S"
position.
Gearshift positions 4,3,2 have been discontin-
ued as they are hardly ever used in practice.
The DSP (dynamic shift programme) and "tip-
tronic" function have basically rendered them
superfluous.
With the selector lever is in the "S" position, a
sports shift programme provides the relevant
driving dynamics. In position "S", the DSP
also provides for adaptation of the driving set
values to the driving conditions.
The introduction of the "S" programme ena-
bles a significant extension of the useful shift
range between economy and sports.
The "S" programme comprises the following
special features:
– If, during driving with constant accelerator
pedal position, the selector lever is set to
the "S" position, the system always shifts
down, within defined limits.
– In order to achieve a direct driving reaction
in response to accelerator pedal actuation,
the converter clutch is closed during driv-
ing operation, where possible.
– If, in conjunction with the overall gearbox
ratio, 5th gear is designed as overdrive
gear (overdrive, 4+E), only 1st -4th gears
are shifted.
We recommend the multi-function steering
wheel (available as optional extra) with steer-
ing wheel "tiptronic" ("thumb shifting").
Gearbox output speed [rpm]
Throttle valve angle [%]

SSP254_103 SSP254_117
D - normal driving programme
S - sports driving programmeExample: Dynamics code 40
Shift map 1

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Special feature:
The countdown from approx. 10 seconds to
return to normal automatic operation is inter-
rupted, in the event that cornering is detected
or the vehicle is in overrun operation.
When normal driving conditions are detected
again, the countdown recommences from
approx. 10 seconds. An innovation for all automatic gearboxes is
the "Tip in D " function. This means that the
steering wheel "tiptronic" function is now
also available in selector lever position "D".
The transition to the "tiptronic" function is
effected by actuating one of the two tip
switches on the multi-function steering wheel
(selector lever in position "D"). The system
then switches to the "tiptronic" function for
approx. 10 seconds. All gears can be shifted
within the range of permissible engine
speeds.
The system returns to normal automatic oper-
ation approx. 10 seconds after the last tip
request.
Engine and gearbox
"multitronic" and 5-speed automatic gearbox
SSP254_088

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The additional cross member enables support
over a longer lever arm, which positively influ-
ences vibration and load cycle characteristics.
The aluminium cross member is bolted to the
body as well as to the rear subframe mount-
ings and, in addition to its supporting func-
tion for the gearbox mounting, serves as a
body-stiffening tunnel bridge.
Mechanical unit mountings
Running gear
The three-point mechanical unit mount-
ing is used for all engine/gearbox
combinations except those including
the 01V 5-speed automatic gearbox. A newly designed three-point mechanical unit
mounting is used in the new Audi A4.
The hydraulically damped engine mountings
(electrically-controlled version for diesel
engines) are fastened directly to the longitu-
dinal members via die-cast aluminium brack-
ets.
The gearbox mounting is effected by means
of a conventional rubber bearing on a body-
mounted aluminium carrier, which is pro-
duced according to the hollow sand casting
technique.
Torque
member
Engine mounting 1
Engine
mounting 2Gearbox
mounting 3
Cross member

SSP254_107

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Front airbag crash sen-
sor, driver’s side G283

Vehicle electrical system
Electrical system
Control unit for
coolant fan,
Stage 1+2 J293Control unit
for ESP J104 Control unit for
telematics J499
Control unit for
mobile phone control
electronics J412
Front airbag crash
sensor, passen-
ger’s side G284
Control unit
for Motronic J220
Control unit for auto-
matic gearbox J217
Control unit for headlamp
range control J431Chip card
reader R99
Steering column
switch module J527
Battery
Control unit with
display in dash panel
insert J285

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CAN data bus
The Audi A4 is equipped with a widely
extended CAN data bus system.
Due to the ever increasing number of control
units installed in the vehicle and the associ-
ated requirement for data exchange, the
importance of the CAN data bus system
increases significantly.For communication between the
installed control units and the diagnos-
tic tester, two diagnosis wires (K and L)
are available.
The newly developed adapter VAS 6017 ena-
bles communication with all control units.
Drive BUS 500 kBaud
Convenience BUS 100 kBaud
Display BUS 100 kBaud
Diagnosis connection
K wire
Diagnosis connection
L wire (2nd K wire)
J402 Control unit for operating electronics,
navigation, TV tuner
J446 Control unit for parking aid
J453 Control unit for multi-function
steering wheel
J499 Control unit for telematics
J502 Control unit for tyre pressure monitor
J507 Control unit for speech entry
J519 Control unit for vehicle electrical
system
J526 Control unit for telephone -
permanent installation
J527 Control unit for steering column
electronics
R Radio
R94 Interface for navigation
R99 Chip card reader G85 Steering angle sender
E87 Operating and display unit for
air conditioner
J104 Control unit for ESP
J136 Control unit for seat adjustment with
memory, optional
J162 Auxiliary heater, optional
J217 Control unit for automatic gearbox
J220 Control unit for motronic
J234 Airbag control unit
J285 Control unit with display unit in
dash panel insert
J345 Control unit for trailer recognition
J386 Door control unit, driver’s side
J387 Door control unit, passenger side
J388 Rear left door control unit, optional
J389 Rear right door control unit, optional
J393 Central control unit for convenience
system
J401 Navigation system control unit
SSP254_112