weight AUDI A8 2003 D3 / 2.G Technical Features Manual

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Introduction
The new Audi A8 is designed to replace its
predecessor of the same name which achieved
a total production figure of 105,092 since its
introduction in June 1994. This was the first
standard saloon with aluminium body and
epitomised a new philosophy in the luxury
vehicle sector.
The weight-saving Audi Space Frame ASF
represented a major breakthrough in terms of
enhanced vehicle dynamics, whilst at the same
time solving the problem of increasing weight.
Introduction
This body concept was further perfected in
the Audi A2 and the design of the Audi A8 ´03
reflects the experience gained from both
projects.
The aim when developing the Audi A8 ´03 was
not merely to surpass its predecessor in
terms of technical features and details.
Convenience/infotainment control
via multimedia interface (MMI)
3.7 or 4.2 l V8 engine
with intake manifold
changeover function
Adaptive cruise control (ACC)
with radar sensor
in front bumper
Headlight with adaptive
light functionActive head restraints
for front seats

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9712944
5051
1136
714 125
Brief outline
Body
SSP282_026
Kerb weight 1,780 kgGross weight 2,380 kg
Turning circle 12 mLuggage compartment volume approx. 500 l
Tank capacity approx. 90 litresDrag coefficient 0.27 Cd
1629
1894
1444
2028
1615
976

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Body
The Audi A8 ´03 sets new standards in its
class by combining lightweight construction
with outstanding stability. This is achieved
through the use of innovative Audi Space
Frame technology for the body design of the
Audi A8.
The technical progress reflected by the
unique body concept stems from the
consistent implementation of experience
gained from the aluminium Audi A8 and A2
models.
SSP282_027
Based on the findings obtained from these
vehicles, it was possible to further reduce the
number of body components and
significantly increase the level of automation
in the production process as compared to the
Audi A8 predecessor model.
The static torsional rigidity of the new Audi A8
body is 60 % higher than that of the previous
Audi A8 body.
A crucial contribution is made to the
increased rigidity level by the advanced
Audi Space Frame structure.Characteristic features of the new structure:
– Large castings with numerous integrated
functions and a high degree of joint
strength
– IHF* sections – optimum cross sections at
all locations, for example at side of roof
frame
– Sheet metal panels with high levels of local
rigidity thanks to the use of special
technologies designed to achieve differing
functional cross sections and structures
*IHF = Internal high-pressure forming

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Body
Front doors
The doors are made up of a combination of
aluminium panels, aluminium sections and
aluminium castings.
Optimised rib geometry and wall thickness in
the hinge and lock mounting castings formed
the basis for ideal implementation of the
lightweight construction concept.
Rear doors
Large, high-strength side impact members
are integrated into the door to provide even
load distribution in the event of side impact.
SSP282_039
Door shell and door frame are connected at
the door pre-assembly stage by means of
fitted bolts to ensure the accurate
assignment of both components. Window
lifter frame, window lifter motor/gear
mechanism, door control unit and speaker
are pre-assembled on a base plate and bolted
to the door subframe.

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Active head restraints
The front seats of the Audi A8 ´03 are provided
with active head restraints.
With this system, the head restraints move
forwards in the event of a rear-end collision to
shorten the distance between head and
restraint.
SSP282_082
The danger of cervical vertebrae injury is
greatly diminished by reducing the relative
acceleration between shoulder and head.
In head-on collision situations, the mechanics
of centrifugal weight are neutralised.
Belt tensioners
Five belt tensioners are fitted as standard.
There is no centre belt tensioner if the rear
seats are electrically adjustable.

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Two different versions are available:
– 420 Nm for the V8 5V 4.2 l or
3.7 l engine and
– 600 Nm for the V8 TDI 4.0 l or
6.0 l W12 engine To satisfy high comfort requirements, the
Audi A8 ´03 features a new 6-speed automatic
gearbox capable of handling a high engine
torque of max. 600 Nm.
Gearbox
Design and operation of the 09E gearbox
are described in SSP 283 (Part 1) and
SSP 284 (Part 2).
SSP282_043
Technical data
Designation: 09E
Factory
designation: AL 600-6Q
ZF
designation: 6HP-26 A61
Type: 6-speed planetary
gearbox, featuring electro-
hydraulic control
with hydrodynamic
torque converter and
slip-controlled lock-
up clutch
Control: Via mechatronic system
(integration of hydraulic
control unit and
electronic control
to form one unit)Max. torque
transmission: 420 Nm for
V8 5V 4.2 l /3.7 l engine
600 Nm for
V8 TDI 4.0 l /W12
6.0 l engine
Front/rear axle
torque distribution: 50/50
Gear oil capacity
(total): 10.4 litres ATF
Gear oil capacity
(replacement): 10 litres ATF
Total weight: approx. 138 kg
(420 Nm version)
approx. 142 kg
(600 Nm version)

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All axle components are new on account of
the geometric and kinematic modifications as
compared to the predecessor model, the air
suspension and the weight reductions
achieved.
Front axle
The familiar four-link front axle was retained
for the Audi A8 '03.
A significant new feature is the air
suspension in combination with
electronically controlled dampers (refer to
Section on air suspension).
Front axle highlights
– Subframe
– Auxiliary frame
– Anti-roll bar
– Wheel bearing housing
– Wheel bearing with wheel speed sensing
– Mounting bracket for damper unit
Front axle design and operation are
described in SSP 285.
SSP282_050
Running Gear

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All axle components are new on account of
the geometric and kinematic modifications as
compared to the predecessor model, the air
suspension and the weight reductions
achieved.
Rear axle highlights
– Use of air suspension in conjunction with
electronically controlled damping
– Aluminium subframe to help
reduce weight
– Connection of anti-roll bar to trapezium
link
– Use of shorter track rod to reduce change
in toe on compression and extension of
suspension
– Use of ball studs to connect wheel bearing
housing and track rod, thus reducing
secondary spring rate
– Use of slotted bonded rubber bushes in
upper transverse link and connection
between trapezium link and subframe
Rear axle design and operation are
described in SSP 285.
Rear axle
The rear axle is a more advanced version of
the familiar Audi A8 trapezium-link axle.
Running Gear
SSP282_051

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Vehicle electrical system
A major factor in terms of vehicle reliability is
one which is never even seen: the electrical
system.
Use is made for the Audi A8 ´03 of a customer-
specific one-piece modular wiring harness.
"One-piece" means that power is supplied for
all essential electrical functions from a single
continuous wiring harness. The only isolating
points are at the doors, roof module and
engine.
"Customer-specific" means that each wiring
harness is designed to serve exactly the
equipment ordered by the customer. The
wiring harness is subdivided into individual
logic modules, each of which is responsible
for a clearly defined range of functions.
SSP282_038
Design and operation of the optical fibre
are described in SSP 286 – New data bus
systems. A plastic optical fibre is fitted for the
transmission of optical communication and
infotainment signals.
Its advantages as compared to a copper
conductor are its insusceptibility to
electromagnetic interference, a high
transmission capacity and less weight.
To achieve greater headroom, the wiring
harness to the roof module has been
extended to include the flexible flat cable
(FFC). This represents a new method of
solving the wiring problem in extremely
confined spaces (max. 2 mm between
headliner and body outer skin).