Self-Study Programme 394 Audi A5 suspension.pdf

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Service Training
Audi A5 - Suspension
Self-Study Programme 394
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Four suspension versions are used on the Audi
A5.The standard suspension 1BA is basic equip-
ment.A sports suspension 1BE will be optional.
Both suspension versions have the same ride
height, but different springs, shock absorbers and
anti-roll bars.A suspension system with electronic
damping control 1BL is a third option.
This feature allows the driver to select between com-
fortable and sporty suspension set-ups at the touch
of a button.quattro GmbH offers an S-Line suspen-
sion 1BV. It has an even more sporty suspension
setup than the sports suspension, and ride height is
10 mm lower than 1BA and 1BE.
394_001
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Contents
Front axle
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear suspension
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wheel alignment and adjustment
Front axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Brake system
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Wheel brakes - overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wheel brakes - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wheel brakes - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electromechanical parking brake EPB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Steering system
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
System components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pedal assembly
Foot controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Clutch position sender G476 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Wheels and tyres
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
The self-study programme teaches the design and function of new vehicle models,
new automotive parts or new technologies.
Reference
Note
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 prepara-
tion of the SSP.
For maintenance and repair work, always refer to the current technical literature.
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Front axle
Overview
The new axle geometry provides good self-centring
of the steering system when travelling in a straight
line.The suspension kinematics have been designed
with the aim of achieving the smallest possible turn-
ing circle despite the much larger wheelbase com-
pared to the current Audi A4. The design and
geometric arrangement of the wishbone bearing
components provide sporty handling characterised
by exceptional agility, outstanding steering preci-
sion and high driving stability to within the vehicle’s
dynamic limit range.
A newly developed five-link front axle is used.In
comparison with the current Audi A4, the front axle
is 152 mm further forward on the vehicle. This opti-
mises axle load distribution and reduces the front
overhang, giving the car a more dynamic look.The
steering gear is now bolted to the axle carrier.The
track rod constitutes the fifth wishbone.The axle
carrier is rigidly attached to the vehicle body. This
ensures a high level of transverse rigidity, resulting
in immediate and precise steering response.The
kingpin inclination angle and the castor angle have
been enlarged compared to the current Audi A4.
Damper bearing
Spring
Wheel bearing +
wheel hub
Mounting bracket
Damper
Upper
wishbone
Guide link
Swivel bearing
Shock absorber fork
Axle carrier
Anti-roll bar
Steering gear
Track ro d
Support link
394_002
4
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System components
Axle carrier
The axle carrier is made of aluminium and rigidly
bolted to the body at eight screw attachment points.
The front and rear cast nodes are welded to alumin-
ium tubes as cross members. The axle carrier is
additionally reinforced by a bolted cross strut.
These modifications greatly reduce tyre noise inside
the vehicle.
The engine mounts are bolted to axle carriers and
couplings by means of screw couplings on the axle
carrier.
The steering gear is mounted on the axle carrier. As
a result, steering power is transmitted more directly
to the wheels to give improved steering response.
The rigidly mounted axle carriers assist the rapid
build-up of steering power.
Direction of travel
Engine mount
Axle carrier
Steering gear
Cross strut
394_003
Note
The vehicle must not be set down on its wheels
unless the engine mounting, couplings, steer-
ing gear and cross strut are mounted properly.
5
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