eSelf Study Program 600285

The 2016 Audi A3 Sportback e-tron

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Audi of America, LLC
Service Training
Created in the U.S.A.
Created 8/2015
Course Number 600285
©2015 Audi of America, LLC
All rights reserved. Information contained in this manual is based on
the latest information available at the time of printing and is subject to
the copyright and other intellectual property rights of Audi of America,
LLC., its affiliated companies and its licensors. All rights are reserved to
make changes at any time without notice. No part of this document
may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording
or otherwise, nor may these materials be modified or reposted to other
sites without the prior expressed written permission of the publisher.
All requests for permission to copy and redistribute information should
be referred to Audi of America, LLC.
Always check Technical Bulletins and the latest electronic service repair
literature for information that may supersede any information included
in this booklet.

Revision 1:8/2015
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Contents
Introduction __________________________________________________________ 1
Vehicle distinguishing features ___________________________________________________________________________________ 2

Electrical Safety_______________________________________________________ 6
High Voltage System ______________________________________________________________________________________________ 6
Dealership Roles ___________________________________________________________________________________________________ 6
Emergency Situations _____________________________________________________________________________________________ 6
Do not make a second victim _____________________________________________________________________________________ 6
Warning signs _____________________________________________________________________________________________________ 7
High voltage lines _________________________________________________________________________________________________ 9
High Voltage System Maintenance Connector __________________________________________________________________ 10

Drive unit_____________________________________________________________11
Specifications ____________________________________________________________________________________________________
Internal combustion engine ____________________________________________________________________________________
Brief technical description ______________________________________________________________________________________
Cylinder block ____________________________________________________________________________________________________
Intercooler _______________________________________________________________________________________________________
Turbocharger ____________________________________________________________________________________________________
Fuel system ______________________________________________________________________________________________________

11
13
14
14
15
16
17

Power transmission___________________________________________________18
Overview _________________________________________________________________________________________________________ 18
Electro-mechanical brake servo ________________________________________________________________________________ 19

Suspension___________________________________________________________20
Overview _________________________________________________________________________________________________________ 20

High voltage battery__________________________________________________22
Overview of hybrid components ________________________________________________________________________________
Hybrid Battery Unit ______________________________________________________________________________________________
Charging _________________________________________________________________________________________________________
Hybrid manager _________________________________________________________________________________________________

22
24
25
30

Climate control_______________________________________________________32
Cooling systems, climate control and thermal management _________________________________________________
Electrical A/C compressor _______________________________________________________________________________________
High Voltage Heater (PTC) ______________________________________________________________________________________
Stationary HVAC _________________________________________________________________________________________________

32
34
34
35

Infotainment_________________________________________________________36
Overview of versions ____________________________________________________________________________________________
Audi connect _____________________________________________________________________________________________________
Audi connect e-tron services ____________________________________________________________________________________
Display elements for driving in hybrid mode ___________________________________________________________________

36
38
38
39

Service________________________________________________________________42
Service interval overview for North American region __________________________________________________________ 42

Frequently Asked Questions (FAQs)__________________________________43
Self-study programs__________________________________________________45
Knowledge assessment______________________________________________47

This eSelf Study Program teaches a basic knowledge of the design and functions of new models,
new automotive components or technologies.
It is not a Repair Manual! All values given are intended as a guideline only.
For maintenance and repair work, always refer to the current technical literature.

Note

Reference

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Introduction
The Audi A3 Sportback e-tron is a plug-in hybrid engineered
to provide a fully integrated e-mobility solution.
There is no need for drivers to change their driving habits
because the Audi A3 Sportback e-tron is designed to allow
simple use of e-mobility.

The Audi A3 Sportback e-tron brings together the best of
both worlds - an electric motor for emission-free driving
and an economical internal combustion engine for long
range.
It combines both driving enjoyment and environmental
awareness.

It has an all-electric driving range of 16 to 19 mi (25 to 30
km) and is driven by a 102 hp (75 kW) electric motor with a
top speed of 80 mph (130 km/h). At high speeds and under
heavy acceleration, the internal combustion engine is
automatically activated to provide additional power.

627_042

1

Vehicle distinguishing features

MMI system with e-tron displays

e-tron logo on the instrument panel (front passenger side)
(European version shown)

Switch for EV mode

e-tron logo on the front fenders

e-tron logo on the selector
lever

e-tron logo on the design cover in the engine compartment

e-tron specific single-frame radiator grille in chrome/
matte black

e-tron specific front bumper with two aluminum-look
surrounds on the air intake covers

2

Instrument cluster with power meter and e-tron displays

e-tron logo on the rear deck lid

e-tron specific rear bumper with diffusor, aluminum-look
surrounds and concealed exhaust pipes

Various e-tron light alloy wheels available. See the Product
Information Book for complete details.

627_002

e-tron logo on the door sills

S line sills

3

56.06 in (1424 mm)

Dimensions

37.5 in (955 mm)

60.7 in (1542 mm)

59.6 in (1516 mm)
77.4 in (1966 mm)

70.2 in (1785 mm)

34.2 in (871 mm)

103.5 in (2630 mm)

m)
57 m
in (9

26.5 in (675 mm)

37.6

38.8

in (9

87 m

m) 3

627_020

31.9 in (811 mm)

169.7 in (4312 mm)
627_021

4

39.3 in (1000 mm)

52.9 in (1344 mm)1

55.9 in (1422 mm)2

54.8 in (1392 mm)1

57.2 in (1453 mm)2

30.07 in
(764 mm)

627_022

Interior dimensions

Other specifications
Concept

Plug-in hybrid (PHEV)

Battery type

Lithium-ion system

Total capacity in kWh

8.8

38.8 in (987 mm)3)

Top speed in electric-only mode

80 mph (130km/h)

Rear headroom

37.6 in (957 mm)

Top speed

138 mph (222km/h)

Through-loading width

39.3 in (1000 mm)

4.9 seconds

Load sill height

26.5 in (675 mm)

Acceleration
0 - 37 mph (0 - 60 km/h)
in electric-only mode in s

Trunk capacity

13.6 cu ft (385 l)4)
43 cu ft (1220 l)4)

Acceleration
0 ­– 60 mph (0 - 100 km/h) kph

7.6 seconds

Range (electric drive only)

up to 31 m (50 km)

Total range

up to 584 m (940 km)

Drag coefficient cw

0.32

Capacity of fuel tank

10.5 gal (40 l)

Front cabin width

54.8 in(1392 mm)1)
57.2 in (1453 mm)2)

Rear cabin width

52.9 in (1344 mm)1)
55.9 in (1422 mm)2)

Front headroom

Exterior dimensions and weights
Length

169.7 in (4312 mm)

Width

70.2 in (1785 mm)5)

Width

77.4 in (1966 mm)6)

Height

56.06 in (1424 mm)

Front track width

60.7 in (1542 mm)

Rear track width

59.6 in (1516 mm)

Wheelbase

103.5 in (2630 mm)

Curb weight

3395 lb (1540 kg)

Gross vehicle weight

4519 lb (2050 kg)

Shoulder room width
Elbow room width
3)
Maximum headroom
4)
With rear backrest folded down
5)
Excluding mirror
6)
Including mirror
1)
2)

All dimensions are based on the unladen weight of the vehicle.

5

Electrical Safety
High Voltage System
The high voltage electrical systems in hybrid vehicles can
be very dangerous if not handled correctly. Risk of
injury and potential death is present if the following
restrictions and procedures are not followd closely.

All high-voltage lines in the high-voltage system are
are color-coded orange for identification. Due to the
high voltages and currents involved, the electrical
lines have a significantly larger cross-section

Dealership Roles
Each role within the dealership has an obligation to know
the safety precautions necessary when dealing with high
voltage vehicles. It is extermely important that each role
knows and observes the following guidelines.
High Voltage Technician
• Trained Technician who has been certified to perform
maintenance and repairs on high voltage vehicles
• May de-energize and energize high voltage vehicles
• May diagnose high voltage issues and concerns
• May authorize other (trained and certified) technicians to
perform maintenance or repairs on non-electrical systems of
high voltage vehicles
• Affixes warning labels to any high voltage vehicle being
worked on

Hybrid Aware Technician
• Trained Technician who has been certified to perform
maintenance and repairs on high voltage vehicles
• May only work on non-electrical systems
Hybrid Aware Service Consultant
• Can determine if a vehicle will require diagnosis or repairs to
any part of the high voltage system by correctly identifying
the hybrid warning icon
• Correctly identify the high votage vehicle and document on
the repair order
Sales Consultant / F&I / Administration

• Instructs and supervises Hybrid Aware Technicians

• Must be aware of the possible hazards of high voltage

• Is responsible to alert all employees thwne there is a vehicle

vehicles and what to do in the case of an emergency
• Must know and understand the importance of safety when
working with high voltage vehicles.

that has been energized or de-energized
• Is ultimately responsible for all repairs of high voltage
vehicles

Emergency Situations
Do not make a second victim
• Do not touch anyone who is in contact with the high
voltage vehicle
• If certified, attempt to turn off the high voltage system
without risk of personal injury
• Attempt to Separate the person in contact with the high
voltage system using a non-conductive object
• If an injured employee is not responsive
• Check vital signs (pulse and breathing)
• Call 911
• Perform CPR (lung and heart massage)
• Use defibrillator if equipped and trained

6

Warning signs
To minimize the risk associated with the high voltage
system for users, service and repair shop personnel, as well
as for technical and medical emergency responders, there
are several warning and information labels attached to the
Audi A3 Sportback e-tron.

Basically, two types of warning label are used:
• Yellow warning label with warning symbol for
electrical voltage.
• Warning label marked "Danger" against a
red background.

The following yellow warning labels are used to identify
high voltage conducting components or high voltage components installed in the immediate vicinity or, for example,
hazardous components concealed by covers.

Warning against hazardous electrical voltage
according to DIN* 4844-2 (BGV A8)

Warning against a
hazardous area according
to DIN 4844-2 (BGV A8)

Warning against
touching live parts

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627_005

Warning against
hazardous electrical
voltage according to
DIN 4844-2 (BGV A8)

Mandatory signs:
Observe instructions
for use according to
DIN 4844-2 (BGV A8)

The warning labels marked "Danger" identify high voltage components or high voltage conducting components.

627_006

Warning against
hazardous electrical
voltage according to
DIN 4844-2 (BGV A8)

Warning against
touching live parts

Mandatory signs:
Observe instructions
for use according to
DIN 4844-2 (BGV A8)