Handling Control

Systems
Design and Function

Audi of America, Inc.

3800 Hamlin Road
Auburn Hills, MI 48326
Printed in U.S.A.
Self-Study Program
July 2001 Course Number 961103
Audi of America, Inc
Service Training
Printed in U.S.A.
Printed 07/2001
Course Number 961103

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Technical Bulletins and the Audi Worldwide
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that may supersede any information included
in this booklet.
 HANDLING CONTROL SYSTEMS

ABS is the abbreviation

for anti-lock braking system.
The task of ABS is to provide the driver better
braking and steering control during situations
in which traction is reduced or lost.
Continuing developments in passenger car
ABS and traction assist systems have resulted
in powerful and reliable systems that are
capable of furnishing optimum braking,
traction and steering response during critical
conditions.

Important/Note! New!

i
HANDLING CONTROL SYSTEMS

ii
 HANDLING CONTROL SYSTEMS

Table of Contents
Anti-lock Braking Systems (ABS)
Introduction ............................................................................................................................................. 1
System Abbreviations .............................................................................................................................. 3
Introduction to Audi ABS Systems ............................................................................................................. 4
System Application Chart ................................................................................................................... 4
Basic Operation of ABS ........................................................................................................................... 5
Common ABS System Components ........................................................................................................... 6
Wheel Speed Sensors (G44, G45, G46 and G47) .............................................................................. 8
ABS Control Module (J104) .............................................................................................................. 10
Hydraulic Unit ................................................................................................................................. 13
Brake System Warning Lights ........................................................................................................... 15

Traction Assist Systems

Description and Operation ..................................................................................................................... 17
Electronic Brake Pressure Distribution (EBD) ....................................................................................... 17
Electronic Differential Lock (EDL) ....................................................................................................... 18
Anti-slip Regulation (ASR) ................................................................................................................ 19
Electronic Stability Program (ESP) ..................................................................................................... 20

AUDI ABS Systems

Bosch 2S ABS ....................................................................................................................................... 21
Bosch 5.0 ABS ...................................................................................................................................... 23
Bosch 5.3 ABS ...................................................................................................................................... 25
Bosch 5.7 ABS ...................................................................................................................................... 28
Teves MK 20 IE ABS .............................................................................................................................. 32
Teves MK 60 ABS .................................................................................................................................. 34
ABS Service .......................................................................................................................................... 36

4-Level Air Suspension

Introduction ........................................................................................................................................... 37
Air Suspension Levels ............................................................................................................................ 38
Air Suspension Control Display .............................................................................................................. 39
Manual Suspension Control ................................................................................................................... 40
Conditions for Manual Operating Mode ............................................................................................ 40
Service (Jack) Mode ........................................................................................................................ 41
Hoist Mode ..................................................................................................................................... 41
Automatic Suspension Control ................................................................................................................ 42
Cornering ....................................................................................................................................... 43
Air Suspension Components ................................................................................................................... 44
Warning Lamp (K134) ..................................................................................................................... 44
Control Module (J197) ..................................................................................................................... 44
Leveling Senders (G76, G77, G78 and G289) .................................................................................. 45
Air Springs ..................................................................................................................................... 46
Air Compressor ............................................................................................................................... 47
Temperature Sensor (G290) ............................................................................................................. 48
Solenoid Valves ............................................................................................................................... 48
Pressure Sensor (G291) ................................................................................................................... 48
Pressure Accumulator ...................................................................................................................... 49
Test Your Knowledge
Teletest .................................................................................................................................................. 51
Answer Worksheet ................................................................................................................................ 55

iii
HANDLING CONTROL SYSTEMS

NOTES:

iv
 ANTI-LOCK BRAKING SYSTEMS

ANTI-LOCK BRAKING
SYSTEMS (ABS)
Introduction
One of the most significant safety advances in These critical braking conditions, when
automotive engineering in recent decades are encountered without ABS, may lead to wheel
Anti-Lock Braking Systems (ABS). Vehicles lock, which can cause wheel slip. Wheel slip
equipped with todays modern anti-lock brake often results in loss of steering control and
and traction assist systems, provide drivers increased stopping distances. ABS can help
with better braking and steering control in prevent wheel slip, and help drivers to
situations were traction is reduced or lost. Audi maintain steering control and vehicle stability.
introduced ABS in 1984 on the Audi 200.
Anti-lock brake systems can provide fast and
effective vehicle braking under critical braking
conditions such as: Some early Audi ABS systems
Wet or slippery road surfaces offered an ABS on/off switch.

Obstacle avoidance maneuvers

Panic or emergency stops

SSP207/42

1
ANTI-LOCK BRAKING SYSTEMS

Introduction - continued
Audi research and testing have shown that
maximum braking force is transmitted to each ABS and its related traction assist sys-
wheel when a wheel slip range of approx- tems rely on the proper operation of
imately 8% to 35% is obtained, depending on the mechanical and hydraulic por-
the road surface and the type of tires being tions of the conventional brake
used. Wheel slip can occur during vehicle system. Any malfunction of the con-
acceleration and deceleration. ventional brake system will cause
ABS to not operate correctly. When
diagnosing an ABS or related system
ABS will NOT shorten braking concern, always start with an inspec-
distances under all circumstances. tion of the conventional brake system.
When driving on gravel or newly
fallen snow on top of icy surfaces, This inspection should include:
braking distances may be Brake fluid level and fluid
increased. condition
Tire pressure, tire size, and
tire condition
Brake pad and rotor condition
Suspension condition
Brake lines and hose
Proper handbrake adjustment

Transmitted
Operating range of braking force
the ABS on dry concrete
surface

Rolling wheel Locked wheel

0% 8% 35% Wheel 100%

slip

2
 ANTI-LOCK BRAKING SYSTEMS

System Abbreviations
Since Audi uses so many handling control
systems that sound alike, abbreviations can be
confusing. The following summarizes the most
commonly used systems:

ABS EDL
(Anti-lock Braking System) (Electronic Differential Lock)
This system prevents the wheels from This system makes it possible to drive on
locking during critical braking maneuvers, road surfaces where each wheel has a
allowing the driver improved brake effect, different degree of traction by braking the
track stability and steering control. wheel that is spinning. This action sends the
power/torque to the wheel with the most
ASR traction.
(Anti-Slip Regulation)
This system inhibits drive wheel spin on ESP
FWD vehicles while accelerating by (Electronic Stabilization Program)
intervening with the engine management This system helps to control the vehicle in
system and applying brake pressure to the critical maneuvers, such as negotiating
drive wheels. curves, by preventing the wheels from
losing traction. This is done by intervening
with the engine management system and
EBD applying brake pressure to the wheels.
(Electronic Brake Pressure Distribution)
This system prevents over-braking of the
rear wheels due to load/weight shift. EBD
takes the place of the previously used
mechanical brake pressure regulator (load
sensing valve).

3
ANTI-LOCK BRAKING SYSTEMS

Introduction to Audi ABS Systems

All late model Audi vehicles use one of the
following versions of anti-lock braking systems:
Bosch 2S, FWD models are 4-channel,
Quattro models are 3-channel
Bosch 5.0, 4-channel
Bosch 5.3, 3-channel
Bosch 5.3 with ESP, 4-channel
Bosch 5.7 with ESP, 4-channel
Teves MK 20 IE, 4-channel
Teves MK 60, 4-channel

System Application Chart

Vehicle Model Year
1996 1997 1998 1999 2000 2001 2002

Cabriolet Bosch 2S Bosch 2S Bosch 2S

A4 Bosch 5.01 Bosch 5.0 Bosch 5.32 Bosch 5.32 Bosch 5.32 Bosch 5.32,7 Bosch 5.7

S4 Bosch 5.33 Bosch 5.33 Bosch 5.7

A6 Bosch 2S Bosch 5.0 Bosch 5.32,4 Bosch 5.32 Bosch 5.32 Bosch 5.32,6 Bosch 5.7

S6 Bosch 5.0 Bosch 5.0

A8 Bosch 5.0 Bosch 5.0 Bosch 5.0 Bosch 5.05 Bosch 5.33 Bosch 5.7

S8 Bosch 5.33 Bosch 5.7

TT Teves Teves Teves

MK 20 IE2,6 MK 20 IE2,6,8 MK 602

Allroad Bosch 5.33 Bosch 5.7

Quattro
1. EDL optional
2. FWD vehicles equipped with EBD, EDL and ASR. AWD vehicles equipped with EBD and EDL
3. Equipped with EBD and EDL
4. A6 Wagon equipped with Bosch 5.0
5. Bosch 5.3 ABS with EDL optional
6. ESP optional
7. Bosch 5.7 with ESP optional
8. Running production change to Teves MK 60

4
 ANTI-LOCK BRAKING SYSTEMS

Basic Operation of ABS

With a vehicle equipped with conventional During braking, the ABS control module
brakes, the driver must pump the brakes to determines if one or more wheels have begun
help prevent skidding. When the vehicle is to lock up by comparing the rate at which the
equipped with ABS, the driver keeps a firm wheels are rotating. As soon as the difference
foot on the brake, allowing the system to in rotational speed indicates wheel lock-up,
automatically pump the brakes, much faster ABS will modulate hydraulic pressure to the
than the driver possibly can. Because the affected wheels brake caliper.
wheels dont lock, drivers have the increased
When ABS is activated, the driver may hear
ability to steer around hazards if they are
the sound of the system working, and feel
unable to stop.
some pulsation or increased resistance in the
When a driver operating an ABS equipped brake pedal. This sound and feel are actually
vehicle steps firmly on the brake pedal, ABS the ABS hydraulic unit relieving and applying
automatically modulates the brake pressure at pressure within the brake calipers.
all four wheels to prevent wheel lock-up and
ABS remains activated until normal braking
maximize braking efficiency.
(braking without ABS intervention) can be
ABS modulates brake pressure using a resumed without the risk of wheel lock-up.
hydraulic unit and return pump, which are
both controlled by the ABS control module
It is important that the driver keep
(J104).
firm pressure on the brake pedal
when ABS is activated for the
system to be effective.

Without ABS With ABS

5
ANTI-LOCK BRAKING SYSTEMS

Common ABS System

Components
All of the anti-lock braking systems include the Operation of the anti-lock braking system
following components: relies on the integrity of the conventional
hydraulic brake system. The master cylinder
Wheel Speed Sensors (G44, G45, G46
must be able to generate several hundred
and G47)
pounds per square inch of pressure, and the
ABS Control Module (J104) remainder of the brake system must be able to
maintain that pressure without leaking. It is
Hydraulic Unit (DIN number varies
therefore important that the conventional brake
depending on design) system be in good working order for the ABS
Brake System Warning Lights system to function properly.
(K47 and K118)

Sensors ABS/EDL control module Actuators

J104

ABS hydraulic
pump V39

Front left + right

speed sensor
G45/G47 Hydraulic unit with
solenoid valves
N99-102/ N133-136
Rear left + right N166-168
speed sensor
G44/G46
ABS warning lamp K47

Brake light
switch F Braking system
warning lamp K118

Additional signals, Additional signals

e.g., time signal
Diagnostic connection

6
 ANTI-LOCK BRAKING SYSTEMS

Common ABS System

Components - continued
Different variants of anti-lock braking systems The 4-channel control anti-lock braking system
are used depending upon the braking-force- permits individual control of wheel-brake
distribution concept of the vehicle. Two pressures. This is accomplished by using a
variations of ABS are used to control brake solenoid-operated hydraulic-control valve for
pressures in Audi vehicles: each of the vehicles wheel-brake circuits.
4-Channel System Bosch 2S (FWD The 3-channel control system regulates the
models), Bosch 5.0, 5.3 with ESP, and 5.7, brake pressures to each front wheel indepen-
Teves MK 20 IE and MK 60 dently and to the rear wheels simultaneously.
With this control system, one solenoid-
3-Channel System Bosch 2S (Quattro operated hydraulic-control valve is used for
models) and Bosch 5.3 each front wheel-brake circuit, along with a
single hydraulic control valve that regulates
the brake pressure to both rear wheels.

ABS Control Variations

4-Channel 3-Channel
4 Sensors 4 Sensors
Front - Rear Diagonal Front - Rear

Control Channel Sensor

7
ANTI-LOCK BRAKING SYSTEMS

Wheel Speed Sensors

(G44, G45, G46 and G47)
All anti-lock braking systems use wheel speed
sensors to determine each wheels rotating
speed. Wheel speed sensors provide
alternating current (AC) signals to the ABS
control module. Wheel speed sensors are
composed of a permanent magnet and a coil.
Wheel speed sensors use a sensor ring or
toothed rotor, commonly known as a trigger
wheel. The trigger wheel can be mounted to
the brake rotor, wheel bearing assembly, or it
can be part of the constant velocity (CV) joint.
The wheel speed sensor is mounted in the
spindle. As the trigger wheel turns, the tip of
the wheel speed sensor faces alternately a
tooth on the trigger rotor and then a gap. This
causes the magnetic field in the wheel speed
sensor to change repeatedly, inducing an AC
voltage signal. This signal changes
proportionally with the speed of the wheel.

Wheel Speed Sensor Designs

Trigger wheel

Pole plate

Magnetic core

Housing

Wire core

Tip
Permanent
Trigger wheel magnet
Coil
Pole plate

8
 ANTI-LOCK BRAKING SYSTEMS

Wheel Speed Sensors Front Wheels

(G44, G45, G46 and G47) - continued Wheel spindle
Trigger wheel
The gap between the wheel speed sensor and
the trigger wheel is only about 1 millimeter.
This precise tolerance must be maintained to
ensure reliable AC voltage signals.
Drive axle
The ABS control module compares the voltage
of the wheel speed sensors to each other. If the
voltage between the wheel speed sensors
varies too much during normal driving
conditions, a fault (DTC) will be set for the
sensor that is out of the normal operating
Wheel speed sensor
range. Normal operating voltage should not
vary between the sensors by more than
0.15 volts when wheel speeds are equal. Rear Wheels
Speed sensor trigger

Wheel speed
sensor

AC Voltage Signal
Scanning frequency
To control unit
Test Instruments Auto Mode
DSO Wheel
2 V/Div .= 10 ms/Div.
Freeze Frame speed
sensor
Channel A

Channel B

Trigger mode

T 0 Measuring
mode

Time/Div. Position Multimeter

Trigger wheel
Go to Print Help

Adjustment of scanning frequency Shifting of curve

9
ANTI-LOCK BRAKING SYSTEMS

ABS Control Module (J104)

The ABS control module receives, amplifies
and filters wheel speed sensor signals to Address Word 03 is used to
determine wheel speeds, brake slip, and rates access the ABS Control Module.
of vehicle acceleration and deceleration. The
control module then determines the amount of
hydraulic brake pressure that should be
applied to each wheel and sends output
commands to the flow-restricting solenoid-
operated valves within the hydraulic unit to
control braking force.
The ABS control module can effectively change
hydraulic brake pressures for a wide variety of
road surface conditions, such as dry, wet, icy
or loose surfaces. The control module can also
compensate for a mix in these road conditions,
such as when one wheel is on ice, and the
other wheels are on wet or dry road surfaces.

Warning lights Toothed

Wheel speed sensor rotor

G45 K47 K118 G44

Control
module

J104

V64 Hydraulic
unit F Brake
switch
N55

G47 G46

Brake circuit Output signals

Anti-lock Braking System
ABS ITT/Mark 20 IE
Brake circuit Input signals

10
 ANTI-LOCK BRAKING SYSTEMS

ABS Control Module (J104) - continued

For safety, the ABS control module uses reference speed. From this baseline data, the
redundant microprocessors to analyze, logic section can then determine wheel
calculate and compare input data and output deceleration/acceleration and wheel slip
commands. One processor serves as a control values. With this comparative information, it
channel, and the other processor serves as a can then generate output signals to the
test channel. If ever the input data and output hydraulic modulator as necessary.
commands dont agree, ABS becomes
The safety circuit provides a fail-safe
disabled and the braking system functions as a
mechanism a kind of checks and balances
conventional brake system without ABS.
system to double-check the logic sections
The signal-process section of the ABS control analysis of signal input. The logic sections
module filters the A/C voltage signals from measured reference speed and calculated
the wheel speed sensors and amplifies them. output values to the hydraulic modulator are
The analog sinusoidal A/C voltage is then reviewed by the safety circuit to see if they
converted to a square-wave output signal. match. If the safety circuit detects a flaw in
The logic section further refines the wheel the decisions made versus the input
speed sensor signal, compensating for such information received, a Diagnostic Trouble
variables as tire size and varying wheel Code (DTC) is set in the ABS control module
speeds during cornering. The logic section memory and ABS operation is disabled.
uses this information to determine a vehicle

ABS Control Module

Sensors Actuators

LOGIC
SECTION

TEST SAFETY
CIRCUIT

Wheel COOLING
SIGNAL STAGE
speed PROCESS
sensors TO Solenoid
SECTION PREVENT valves
BRAKE
OVER-
SAFETY HEATING
CONTROL
CIRCUIT

Power supply relay

Return flow pump
Battery
FAULT relay
MEMORY
ABS warning light

11
ANTI-LOCK BRAKING SYSTEMS

ABS Control Module (J104) - continued

The ABS control module stores braking system In the event of high brake system
related DTCs in the order in which they occur, temperatures (caused by repeated
until they are intentionally erased. The ABS severe EDL operation), the safety
control modules memory is nonvolatile, which circuits within the ABS control
means, any stored DTCs will NOT be erased module may deactivate EDL control.
when battery power is disconnected. Any EDL will become operational again
stored brake DTCs can be retrieved from the once the ABS control module
control module, even if the module has been recognizes a brake temperature
disconnected for an extended period of time.
within a specified range. This is
done to eliminate the risk of
overheating the brakes.

ABS/EDL control module

J104

12
 ANTI-LOCK BRAKING SYSTEMS

Hydraulic Unit
The hydraulic unit modulates brake pressure to If at this point the wheel remains locked, or is
the brakes by using solenoid-activated valves decelerating too quickly, the ABS control mod-
and an electric hydraulic pump. The ABS ule sends another command to the hydraulic
control module operates the solenoid valves unit to open the normally closed dump/outlet
and hydraulic pump during an ABS braking solenoid valve for that brake circuit. This ac-
event. tion releases any pressure from the wheels
The ABS hydraulic unit is located in the engine brake circuit.
compartment, near the master cylinder and
consists of:
Valve block
Hydraulic pump
The valve block contains the solenoid valves
that allow or restrict the flow of brake fluid
through the wheels brake circuit as required
when braking.
If the driver applies the brakes hard enough to
cause a wheel to lock-up, the ABS control
module sends an output command to the
hydraulic unit to activate the solenoid that
controls the isolation/inlet valve for the locking
wheels hydraulic circuit. The isolation/inlet
valve cuts off fluid flow to prevent any more
hydraulic pressure from reaching the wheels As the hydraulic brake pressure is released
brake caliper. from the wheels brake circuit, the hydraulic
pump transmits the released brake fluid
through an accumulator. The accumulator
absorbs any pressure surges that occur as the
brake fluid is discharged. From the accumula-
tor, the brake fluid is pumped back into the
master cylinder. This action ensures that the
master cylinder always contains a sufficient
amount of brake fluid, so that the driver must
only hold the brake pedal down during an
extended ABS braking event.
ABS cycles between holding, releasing and
applying pressure individually at each brake
caliper until ABS intervention is no longer
needed and normal braking can occur without
the risk of wheel lock-up.

13
ANTI-LOCK BRAKING SYSTEMS

Hydraulic Unit - continued

Different traction situations require more or
less cycling of the valves. On dry pavement the
valves may only cycle one or two times to
prevent wheel lock-up. However, on ice the
valves may cycle up to ten times per second to
prevent the wheels from locking-up.
On 3-channel control ABS, rear wheel braking
pressure is determined by using the select-low
principle. When braking, the ABS control
module uses the rear wheel with the greatest
amount of slip to determine the amount of
brake pressure required at both rear wheels.
If a rear wheel begins to slip, the amount of
brake pressure supplied to the slipping wheel
is automatically applied to both rear wheels.
The hydraulic unit is not serviceable and can
only be replaced as an assembly. The reason
for this is that the valve block must be able to
withhold pressures of up to 5075 psi (350 bar)
and it contains precision-made springs, seals,
seats and solenoid valves, that during
assembly, require exact fit and careful
adjustment using special test equipment.

Bosch 5.3 Hydraulic Unit Teves MK 20 IE Hydraulic Unit

14
 ANTI-LOCK BRAKING SYSTEMS

Brake System Warning Lights

Brake system warning lights illuminate to alert
the driver to various brake system conditions
and are usually located on the instrument
cluster.
K47
Each time the vehicle is started, the ABS
control module performs a diagnostic self-
check of the ABS system. During this self-check
the ABS warning light (K47) in the dash panel
insert (J285) will illuminate for a short period
of time (up to six seconds). After the self-check
has been completed, the ABS warning light
will go out.
If a malfunction is detected within the anti-lock
braking system during the diagnostic self-
check, the ABS warning light will illuminate
and remain ON and ABS will be turned OFF,
until the cause of the malfunction is repaired. K118
However, the conventional braking system will
remain fully operational.
The brake warning light (K118) will illuminate
if the brake fluid level becomes low or if the
parking brake is engaged.

During the ABS diagnostic self-

check, the brake pedal switch
circuit is not tested. The warning
light may still illuminate and then
go out normally during the self-
check, even if a brake light DTC is
stored in the ABS control modules
memory.

15
ANTI-LOCK BRAKING SYSTEMS

NOTES:

16
 TRACTION ASSIST SYSTEMS

TRACTION ASSIST SYSTEMS

Description and Operation

Electronic Brake Pressure Distribution

(EBD)
Some Audi anti-lock braking systems When applying the brakes with the vehicle
incorporate a feature called Electronic Brake turning, EBD adjusts the brake pressure to the
Pressure Distribution (EBD). rear wheels. When driving on curves, if the
difference in wheel speeds between the front
EBD replaces the mechanical brake-pressure-
and rear, or left to right wheels becomes too
proportioning valve found on some braking
high, EBD reduces the hydraulic brake
systems by using software in the ABS control
pressure to the rear brakes by cycling the ABS
module. The software assesses the amount of
inlet valve. This action limits the amount of
traction at each wheel and electronically
brake pressure applied to the rear wheels,
distributes the brake pressure to the rear
which helps ensure that the rear wheels do not
wheels accordingly. The range of EBD control
become over-braked.
ends when ABS control is applied.
EBD supplements the standard ABS functions on:
Bosch 5.3 ABS
Bosch 5.7 ABS Braking in a corner (average retardation)
Braking pressure plotted against time
Teves MK 20 IE ABS
100
Teves MK 60 ABS (bar)

EBD uses the wheel speed sensors for wheel

speed input. Detecting wheel speed
differences between the individual wheels
Braking Pressure

allows EBD to determine whether the vehicle is

traveling straight ahead or turning. EBD can
also determine any differences in tire wear
and friction of the road surface.
When driving in a straight line, EBD allows
maximum braking pressure to reach the rear
wheels. This helps ensure that the shortest
stopping distances are obtained.
Braking pressure, front axle, time(s) 2.0
Braking pressure, rear axle, with EBD
Braking pressure, rear axle, with
mechanical braking pressure reducer

17
TRACTION ASSIST SYSTEMS

Electronic Differential Lock (EDL)

Electronic Differential Lock (EDL), is a low- If excessive drive wheel spin is detected, the
speed traction assist system that acts self-priming pump in the hydraulic unit extracts
automatically without the drivers intervention. brake fluid from the master cylinder reservoir,
EDL uses many of the ABS components to then pumps the fluid through a solenoid valve
adjust drive wheel speed for improved and into the brake caliper of the wheel with
traction, steering control and stability. EDL the highest rotation rate. As a result, the drive
operates during acceleration up to speeds of: torque is transmitted through the differential to
the drive wheel with the most traction.
25 mph (40 km/h) front-wheel drive
(FWD) vehicles
50 mph (80 km/h) all-wheel drive
(Quattro) vehicles If EDL is under extreme use, the
EDL supplements the standard ABS functions on: system will be temporarily disabled
to prevent the brakes from
Bosch 5.0 ABS overheating.
Bosch 5.3 ABS
Bosch 5.7 ABS
Teves MK 20 IE ABS
Teves MK 60 ABS
To prevent the drive wheels from spinning
during low speed acceleration, EDL monitors
the drive wheels using the wheel speed
sensors.

18
 TRACTION ASSIST SYSTEMS

Anti-slip Regulation (ASR)

Wheel spin can also be controlled using a ASR can be switched ON or OFF by pressing the
traction assist system known as Anti-slip ASR button (E256). However, when the ignition is
Regulation (ASR). ASR uses the vehicles anti- cycled, ASR will automatically be switched ON.
lock braking system and engine management
system to inhibit drive wheel spin during initial ASR should normally be left ON. ASR should
or moving acceleration. only be switched OFF in certain circumstances
where wheel spin can offer advantages, such as:
ASR is only available on FWD vehicles and can
be incorporated into the following systems: When driving using the compact spare tire

Bosch 5.3 ABS When rocking the vehicle back and forth

Bosch 5.7 ABS When starting off on an uphill gradient

where the amount of traction is severely
Teves MK 20 IE ABS reduced on one side of the vehicle
Teves MK 60 ABS When ASR is switched OFF, the ASR indicator
ASR works by adapting drive wheel speeds and light (K155) remains illuminated.
engine torque to a level that corresponds with the
available traction on the road surface. ASR takes
advantage of the EDL function to slow down a To ensure that ASR works properly,
spinning wheel, then sends a message through the all four wheels must be fitted with
can-bus to the powertrain control module (PCM). identical tires. Any differences in
The PCM then tries to keep excessive wheel spin the rolling radius of the tires can
under control by: cause ASR to reduce engine power.
Adjusting throttle valve position
Retarding ignition timing
Suppressing individual injector pulses

ASR Indicator Light (K155) ASR Control Switch(E256)

19
TRACTION ASSIST SYSTEMS

Electronic Stability Program (ESP)

The Electronic Stability Program (ESP)
recognizes when the vehicle is in danger of Without ESP
skidding and automatically compensates if the
vehicle breaks traction. ESP is a traction assist
system that operates across the vehicles entire
speed range.
ESP uses many of the ABS components, along
with several additional components, to adjust
drive wheel speeds in critical maneuvers such
as curves in the road, or when an obstacle in
the road must be suddenly avoided.
ESP supplements the standard ABS functions on:
Bosch 5.3 ABS
Bosch 5.7 ABS
Teves MK 20 IE ABS
Teves MK 60 ABS
As the vehicle begins to move and accelerate,
the wheels are prevented from losing traction
by intervening with the engine management
system to reduce engine torque and by
applying brake pressure to the required
wheels in order to allow the vehicle to pivot With ESP
around an object or curve. For more
information, refer to the Electronic
Stabilization Program (ESP), Self-Study
Program, Course Number 961903.

Since ESP works in conjunction with

ABS, ESP will be disabled if there is
any problem with the ABS system.

20
 AUDI ABS SYSTEMS

AUDI ABS SYSTEMS

Bosch 2S ABS
The Bosch 2S anti-lock braking system found
on FWD models is a 4-channel design, using Bosch 2S ABS does not have
3-position solenoid operated valves for each self-diagnositic capabilities and
wheel brake circuit. This anti-lock braking requires the use of ABS 2 Tester
system regulates brake pressure to each wheel VAG 1710.
independently.
The Bosch 2S anti-lock braking system found
on Quattro models is a 3-channel design.
This system uses three solenoid valves, one
individual valve for each front wheel, along
with one other solenoid valve to control the
brake pressure at both rear wheels combined.

21
AUDI ABS SYSTEMS

Bosch 2S ABS - continued

All solenoid valves are of a directional control
design with three hydraulic ports and three
operating positions. This design allows the
ABS control module to regulate the brake
pressures between the master cylinder, wheel-
brake caliper and return circuit during the
pressure build up, pressure hold and pressure
reduction modes. The hydraulic unit is located
near the brake master cylinder in the engine
compartment, and the ABS control module, in
most models, is located in the passenger
compartment under the rear seat.

Sensors ABS control module Actuators

J104

ABS hydraulic
pump V39

Hydraulic unit with

solenoid valves
Front left + right N99-102/ N133-136
speed sensor N166-168
G45/G47

Rear left + right ABS warning lamp K47

speed sensor
G44/G46

Braking system
warning lamp K118
Brake light
switch F
Additional signals

Diagnostic connection

22
 AUDI ABS SYSTEMS

Bosch 5.0 ABS

The Bosch 5.0 anti-lock braking system is a
4-channel system. This anti-lock braking system
regulates brake pressure to each wheel
independently using a 2-position solenoid valve
for each wheel brake circuit. The hydraulic unit
uses a single, small, lightweight aluminum valve
block to contain the hydraulic solenoid valves.
Each solenoid valve has only one energized
position and is operated by the ABS control
module. The hydraulic pump and ABS control
module are attached to the valve block. The
ABS hydraulic unit is located near the brake
master cylinder in the engine compartment.

23
AUDI ABS SYSTEMS

Bosch 5.0 ABS - continued

Bosch 5.0 ABS can be equipped with
Electronic Differential Lock (EDL). For more
information on EDL, refer to Description and
Operation of Traction Assist Systems (ESP),
located in this publication.

Sensors ABS/EDL control module Actuators

J104

ABS hydraulic
pump V39

Front left + right

speed sensor
G45/G47 Hydraulic unit
with solenoid valves
N99-102/ N133-136
Rear left + right N166-168
speed sensor
G44/G46

ABS warning lamp K47

Brake light
switch F Braking system
warning lamp
K118

Additional signals,
Additional signals
e.g., time signal

Diagnostic connection

24
 AUDI ABS SYSTEMS

Bosch 5.3 ABS

The Bosch 5.3 anti-lock braking system used Front-wheel drive vehicles with Bosch 5.3 ABS
for vehicles not equipped with the driving are equipped with Electronic Brake Pressure
dynamic control system called Electronic Distribution (EBD), Electronic Differential Lock
Stablization Program (ESP) is a 3-channel (EDL) and Anti-slip Regulation (ASR). Quattro
design. This hydraulic unit uses a single, one- (all-wheel drive) vehicles are equipped with
piece valve block to contain the hydraulic EBD and EDL only. For more information, refer
solenoid valves. A pair of 2-position solenoid- to Description and Operation of Traction Assist
operated valves (inlet and outlet valves) is used Systems, located in this publication.
for each front wheel, along with one pair of
solenoid operated valves to control the brake
pressure at both rear wheels combined. A low-
noise hydraulic pump is attached to the valve
block. When equipped with EDL, low-
temperature performance of the EDL system is
improved by using a pair of diaphragm outlet
chambers, connected on the suction side (inlet)
of the hydraulic valve blocks. These outlet
chambers improve the flow of brake fluid
under low temperature conditions, helping to
prevent cavitation.

Diaphragm outlet chambers

25
AUDI ABS SYSTEMS

Bosch 5.3 ABS - continued

Vehicles equipped with Bosch 5.3 with ESP use
a 4-channel design anti-lock braking system.
ESP helps to control the vehicle in critical
maneuvers such as negotiating curves in the
road. As the vehicle begins to yaw and rotate,
the wheels are prevented from losing traction
by intervening with the engine management
system and applying brake pressure to the
wheels.
To prevent pump cavitation when equipped
with ESP, the suction pressure of the Bosch 5.3
hydraulic pump is improved by the use of an
additional ESP charge pump. Use of the
charge pump is necessary due to the single-
stage design of the hydraulic pump of the
Bosch 5.3 system.

Sensors ABS control module Actuators

J104

ABS hydraulic
pump V39

Front left + right

speed sensor
G45/G47
Hydraulic unit with
solenoid valves
N99-102/ N133-136
Rear left + right N166-168
speed sensor
G44/G46
ABS warning lamp K47

Brake light
switch F Brake system warning
lamp K118

Additional signals, Additional signals

e.g., time signal
Diagnostic connection

26
 AUDI ABS SYSTEMS

Bosch 5.3 ABS - continued

With the single-stage hydraulic pump, the With Bosch 5.3 ABS, output tests
entire suction volume must flow through the may be performed to conduct a
suction line during one piston stroke (from function check of the hydraulic
TDC to BDC) into one chamber. With this type pump and solenoid valves.
of pump, suction pressure is high. When the
ambient temperature decreases, suction
pressure rises even further as the viscosity of ESP operates across the entire speed range.
the brake fluid increases. The result of high Since ESP works in conjunction with ABS, ESP
suction pressure is cavitation and the will be disabled if there is any problem with
associated drop in performance on the the ABS system. For more information, refer to
pressure side of the pump. the Electronic Stabilization Program (ESP),
Self-Study Program, Course Number 961903.
The ABS control module is directly attached to
the hydraulic unit, except for vehicles
equipped with ESP. For ESP equipped vehicles,
the control module is located in the passenger
compartment.
Single-stage ABS return pump suction volumes

Suction volumes

UT OT UT OT UT

OT = TDC UT = BDC

Suction volumes

UT OT UT OT UT

27
AUDI ABS SYSTEMS

Bosch 5.7 ABS

The Bosch 5.7 anti-lock braking system is a
4-channel system equipped with ESP. The
hydraulic unit and control module form a
single unit similar to the Bosch 5.3 anti-lock
braking system with the addition of the
following:
The single-stage hydraulic return pump
(V39) has been replaced with a two-stage
pump.
Brake servo pressure sensor (G294) has
been added to detect emergency braking
situations.
Due to higher viscosity of the brake fluid at
extremely low temperatures, the required
delivery rate for the hydraulic return pump
with ESP can not be achieved without the use
of the additional charge pump (V156). ESP
operation resulted in an increased suction
resistance within the system.

28
 AUDI ABS SYSTEMS

Bosch 5.7 ABS - continued

With a two-stage hydraulic pump, there are
two working chambers that the piston acts
upon. Suction is effected in two stages as the
brake fluid is drawn through the suction line
during each piston stroke (from TDC to BDC
and from BDC to TDC). With this pump
design, the entire suction volume is supplied to
the pump almost continuously, creating a
significantly lower suction flow rate, which
diminishes suction pressure and prevents
cavitation. This type of hydraulic pump ensures
a quick pressure build up, even at extremely
low ambient temperatures.

Two-stage ABS return pump suction volumes

Working chamber 2

Suction volumes

Working
chamber 1 UT OT UT OT

OT = TDC UT = BDC

Suction volumes

UT OT UT OT

29
AUDI ABS SYSTEMS

Bosch 5.7 ABS - continued

The Bosch 5.7 hydraulic unit is also equipped
with a new feature called the brake assist.
During an emergency braking situation, the
brake assist feature aids the driver by
automatically increasing brake pressure to a
level exceeding the wheel lock-up limit for all
wheels. This action quickly brings ABS into its
operating range, thus achieving maximum
vehicle deceleration. In order to detect
emergency braking situations, a brake servo
pressure sensor has been added to the
hydraulic unit.

Pressure sensor G294

The brake servo pressure sensor monitors the

pressure increase gradient of the brake system
Pressure [p]

(build up of brake pressure as compared to

time). If the brake pressure gradient exceeds a
predetermined limit, the brake assistant feature
is activated.

Time [t]
SSP254_092
Emergency braking

Normal braking distance

30
 AUDI ABS SYSTEMS

Bosch 5.7 ABS - continued

The function of the brake assistant feature In the second phase, if the brake pressure
takes place in two phases. being applied by the driver falls below the
predetermined value after triggering the brake
The first phase begins if the brake pressure
assistant feature (indicating emergency
increase gradient exceeds a predetermined
braking has ceased), brake system pressure is
value (indicating emergency braking). During
restored to the level of brake pedal pressure as
this first phase, the hydraulic return pump,
applied by the driver.
along with the associated solenoid valve(s)
within the hydraulic unit, become activated by Inlet and outlet valves within the
the ABS control module. This is accomplished ABS hydraulic unit are no longer
by using the ESP logic program, which simply switched on and off (using
increases the brake pressure into range of ABS a duty cycle). They are now
control. This action is performed in a similar regulated using a pulse-width
manner by the control system used for EDL. For modulated (PWM) voltage signal.
more information, refer to Description and This allows more precise control
Operation of EDL, located in this publication. on extremely slippery surfaces,
such as ice.

Brake assistant Brake pedal Brake assistant

activated unloaded switches off

Phase 1 Phase 2
Brake pressure [p]

Time [t] SSP254_084

Brake pressure determined by

an experienced driver

Regulated brake pressure

(brake assistant)

Determined brake pressure

insufcient
inexperienced driver

31
AUDI ABS SYSTEMS

Teves MK 20 IE ABS
The Teves MK 20 IE anti-lock braking system is Teves MK 20 IE ABS can also be equipped with
a 4-channel system. This ABS hydraulic unit a driving dynamic control system called
incorporates an aluminum valve block and Electronic Stabilization Program (ESP).
2-position hydraulic solenoid valves. Each ESP helps to control the vehicle in critical
solenoid valve has only one energized maneuvers such as curves in the road. As the
position. The Inlet valves are of a design that vehicle begins to yaw and rotate, the wheels
allows better brake pressure regulation and an are prevented from losing traction by
improved brake pedal feel. The hydraulic intervening with the engine management
pump and ABS control module are attached to system and applying brake pressure to the
the valve block. The ABS hydraulic unit is wheels. ESP operates across the entire speed
located near the brake master cylinder in the range. Since ESP works in conjunction with
engine compartment. ABS, ESP will be disabled if there is any
problem with ABS. For more information, refer
Teves MK 20 IE ABS on front-wheel drive
to the Electronic Stabilization Program (ESP),
vehicles is equipped with Electronic Brake
Self-Study Program, Course Number 961903.
Pressure Distribution (EBD), Electronic
Differential Lock (EDL) and Anti-slip Regulation The ABS hydraulic unit for vehicles equipped
(ASR). Quattro (all-wheel drive) vehicles are with ABS/EDL/ESP are larger than the control
equipped with EBD and EDL. For more unit used on vehicles equipped with ABS only:
information, refer to Description and
ABS only 5.1 inches (130 mm)
Operation of Traction Assist Systems, located
in this publication. ABS/EDL/ESP 5.3 inches (135 mm)

32
 Sensors Actuators

Button for ESP E256

ABS control unit with Hydraulic pump for ABS V64
EBD/EDL/ESP J104

Brake light switch F

ABS intake valve N99, N101, N133, N134

ABS exhaust valve N100, N102, N135, N136
ESP brake recognition switch F83

Driving dynamic control valve -1- N225

Driving dynamic control valve -2- N226

Driving dynamic control high pressure

Speed sensor G44, G45, G46, G47 valve -1- N227
Driving dynamic control high pressure
valve -2- N228

Steering angle sender G85

Magnetic coil for brake pressure N247

Lateral acceleration sender G200

Relay for brake light suppression J508

Brake pressure sender -1- G201

Panel insert J285

Yaw rate sender G202
ABS warning lamp K47
Warning lamp for brake system K118

Brake pressure sender -2- G214 ESP warning lamp K155

Auxiliary signals
Longitudinal acceleration sender G249 (only e.g., Engine management
4-wheel drive vehicles) Gearbox management
Navigation management
Auxiliary signals
e.g., Engine management Diagnosis plug connection
Gearbox management

33
AUDI ABS SYSTEMS
AUDI ABS SYSTEMS

Teves MK 60 ABS
Teves MK 60 ABS is a 4-channel system. Teves MK 60 ABS can also be equipped
Brake pressure is regulated to each wheel with a driving dynamic control system
independently using 2-position solenoid called Electronic Stabilization Program
valves. The ABS hydraulic unit uses a (ESP). ESP helps to control the vehicle in
lightweight aluminum valve block of a critical maneuvers such as curves in the
compact design. The hydraulic pump and road. As the vehicle begins to yaw and
ABS control module are attached to the rotate, the wheels are prevented from losing
valve block. The ABS hydraulic unit is traction by inter vening with the engine
located near the brake master cylinder in the management system and applying brake
engine compartment. pressure to the wheels. ESP operates across
the entire speed range. Since ESP works in
Front-wheel drive vehicles with Teves MK 60
conjunction with ABS, ESP will be disabled
ABS are equipped with Electronic Brake
if there is any problem with ABS. For more
Pressure Distribution (EBD), Electronic
information, refer to the Electronic
Differential Lock (EDL) and Anti-slip
Stabilization Program (ESP), Self-Study
Regulation (ASR). Quattro (all-wheel drive)
Program, Course Number 961903.
vehicles are equipped with EBD and EDL.
For more information, refer to Description
and Operation of Traction Assist Systems,
located in this publication.

34
 Sensors Actuators

Button for ESP E256

ABS control unit with Hydraulic pump for ABS V64
EBD/EDL/ESP J104

Brake light switch F

ABS intake valve N99, N101, N133, N134

ABS exhaust valve N100, N102, N135, N136
ESP brake recognition switch F83

Driving dynamic control valve -1- N225

Driving dynamic control valve -2- N226

Driving dynamic control high pressure

Speed sensor G44, G45, G46, G47 valve -1- N227
Driving dynamic control high pressure
valve -2- N228

Steering angle sender G85

Magnetic coil for brake pressure N247

Lateral acceleration sender G200

Relay for brake light suppression J508

Brake pressure sender -1- G201

Panel insert J285

Yaw rate sender G202
ABS warning lamp K47
Warning lamp for brake system K118

Brake pressure sender -2- G214 ESP warning lamp K155

Auxiliary signals
Longitudinal acceleration sender G249 (only e.g., Engine management
4-wheel drive vehicles) Gearbox management
Navigation management
Auxiliary signals
e.g., Engine management Diagnosis plug connection
Gearbox management

35
AUDI ABS SYSTEMS
AUDI ABS SYSTEMS

ABS Service
If service to an ABS component becomes When installing a replacement ABS
necessary, use the following guidelines when hydraulic unit, DO NOT remove the
handling replacement components: shipping plugs from the hydraulic ports
Depending on application, after until you are immediately ready to install
replacement of an ABS control module, the the brake lines. Failure to do so may result
module MUST be coded. Coding the ABS in brake fluid loss from within the hydraulic
control module is necessary for the braking unit. Excessive brake fluid loss may cause
and traction assist systems to operate the hydraulic unit to lose its prime, making
correctly. For a detailed description of the brake bleeding very difficult, if not
procedure, refer to AESIS. impossible.
After the hydraulic portion of the braking ALWAYS make sure any special service
system has been opened for any reason, tools and diagnostic equipment that you
the braking system MUST be bled. The may use when servicing ABS are in
brake bleeding procedure for vehicles working order.
equipped with ABS may be different than ALWAYS observe the rules for cleanliness
those for conventional brakes, and will and safety when servicing ABS.
vary between the different available ABS
systems. For a detailed description of the
brake bleeding procedures, refer to AESIS. Warning: Brake fluid is
poisonous; BE SURE that safety
Always transport replacement components
glasses are worn when bleeding
in the original container. DO NOT unpack
brakes or possible personal
the components from the containers until injury may occur.
you are ready to immediately install them.
Caution: Brake fluid must NOT
DO NOT drop or place heavy objects on come in contact with paint-work
the replacement component and/or its or possible damage may occur.
packaging.
During installation of a replacement
hydraulic unit, pay CLOSE ATTENTION to
the positioning of the brake lines. Failure to
install the brake lines in the correct location
will lead to improper operation and
possible damage of the braking system.

36
 4-LEVEL AIR SUSPENSION SYSTEM

4-LEVEL AIR SUSPENSION

Introduction
The 4-level air suspension system is designed The air suspension system is designed for fast
to control the overall vehicle height. This response, low noise and the ability to protect
system changes ground clearance by the power supply of the vehicle.
2.6 inches (66mm) in four stages. The four
stages can be controlled manually or
automatically.
The 4-level air suspension is composed of the
following components:
4-level control display
Warning light
Air springs
Solenoid valves
Pressure sensor
Leveling senders
Air compressor
Temperature sensor
Accumulator Rear Right Vehicle
Leveling Sender
Rear Right
Air Suspension Strut Control Unit

Air Suspension
Control Display
Pressure
Accumulator
Front Right
Air Suspension Strut

Rear Left Vehicle

Leveling Sender

Rear Left Air

Suspension Strut
Electric/Pneumatic
Lines
Front Right Vehicle Air Supply Unit
Leveling Sender
Front Left Vehicle
Leveling Sender Front Left Air
Suspension Strut

37
4-LEVEL AIR SUSPENSION SYSTEM

Air Suspension Levels

Height Increase Ground Clearance

Level 1 5.6 inches 142 mm

Level 2 1 inch + 25 mm 6.6 inches 167 mm

Level 3 1 inch + 25 mm 7.6 inches 192 mm

Level 4 0.6 inches + 16 mm 8.2 inches 208 mm

Ground clearance Level 1

5.6 inches
142 mm

Ground clearance
6.6 inches
167 mm
Level 2

Ground clearance
7.6 inches Level 3
192 mm

Ground clearance
8.2 inches
208 mm
Level 4

38
 4-LEVEL AIR SUSPENSION SYSTEM

Air Suspension Control Display

The air suspension control display is located In manual mode, vehicle ride height is
on the dashboard above the radio. The increased by pressing the Up Control Button.
following is a description of how to operate If Up Control Button is pressed more than
the air controlled suspension system: once, height can be increased in stages
from the lowest level to the highest level. As
The light emitting diode (LED) in the LED
the ride height is increasing, the LED Display
Display indicates the ride height. To change
shows the actual level as a steady light and
between automatic and manual modes, press
the selected level as a flashing light.
the Up or Down Control Button for two
seconds. When manual mode is selected, the After pressing the Down Control Button, the
LED above the man inscription illuminates. vehicle drops to a lower level. The current
level flashes in the LED Display and the
selected level (not yet reached) is indicated
by a steady light.

Continuous flashing of an LED

indicates the denial of a level
request, for example, when
Down LED Up
Control Display Control speed is too high.

Manual mode, level 2 requested, vehicle

currently in level 1.

Automatic mode, moving to level 1,

vehicle currently in level 2.

Automatic mode, moving to level 3,

vehicle currently in level 1.

Automatic mode, moving to level 4,

vehicle currently in level 3.

39
4-LEVEL AIR SUSPENSION SYSTEM

Manual Suspension Control

Conditions for Manual

Operating Mode
In manual mode, the suspension system allows When the engine is running, the vehicle can
the vehicles driver to determine what height be raised as long as:
the vehicle is at. However, manual control does The air suspension compressor temperature
not allow the vehicle operator to override the is below 230 F (110 C).
basic height-to-speed settings. The vehicle will
still automatically lower when a certain road Sufficient accumulator pressure is present.
speed has been reached. There should be at least a 3 bar (44 psi)
difference between the pressure
Pressing either the up or down button for
about two seconds will switch the air accumulator and the air springs.
suspension system between manual and When the engine is not running, the vehicle
automatic modes. can be raised as long as sufficient accumulator
The vehicle can be raised or lowered in pressure is present.
manual mode as long as no relevant fault
codes are stored in memory.

Height decrease procedures

Level 4 Automatic lowering

Level 3
Possible manual control
Level 2

Level 1

0 22 50 75
Height increase procedures

Level 4 Automatic lowering

Level 3
Resetting only from level 3
Level 2
Possible manual control

Level 1

0 22 50 75

40
 4-LEVEL AIR SUSPENSION SYSTEM

Service (Jack) Mode Hoist Mode

Before raising the Allroad Quattro on a hoist The air suspension control unit goes into hoist
or jack, the vehicle should be put into the mode if the height signal of a stationary
service mode. When the vehicle is put into vehicle is increased due to a lift or jack.
service mode, air is not let into or out of the
The hoist mode prevents excessive ventilation
4-level air suspension system.
of the air springs when the vehicle is raised
Service mode can be switched on or off by for service.
pressing and holding down both the up and
Lifting of the vehicle should be carried out as
down buttons for five seconds. When in
quickly as possible, so that the air
service mode, the manual row of LEDs, the
suspension control unit clearly knows it
warning lamp and both the up and down
should enter hoist mode.
buttons will illuminate.

The service mode will be

automatically switched off when a
road speed of approximately 6
mph (10 km/h) is exceeded. The
service mode will not switch on if
the hoist mode is recognized.

41
4-LEVEL AIR SUSPENSION SYSTEM

Automatic Suspension Control

In automatic mode, the 4-level air suspension
works without driver interaction. The air
suspension system raises and lowers the
vehicle according to the speed and level charts
below.

Level 4
Level 3 Height decrease procedures

Automatic lowering
Level 2
After 30 seconds
Level 1

0 22 50 75
Speed in mph
Height increase procedures when
Level 4 vehicle is commanded to Level 3
Level 3 or Level 4 after the ignition is on.

After 30 seconds
Level 2
After 120 seconds
Level 1
Raising immediately

05 22 43 75
Speed in mph

Level 4
Height increase procedures when
Level 3
vehicle is in Level 3 or Level 4
before the ignition is on
Level 2
After 30 seconds

Level 1 Raising immediately

0 19 37 43 75

42
 4-LEVEL AIR SUSPENSION SYSTEM

Cornering
If the vehicle is cornering, it will not raise or
lower until it is through the corner, even if it is
in the process of changing the vehicle height.
Instead, the height request will be stored and
carried out when the vehicle is driving in a
straight line.
If the vehicle is accelerated quickly down a
very twisty road, it is possible for the
suspension to stay in a high position,
regardless of road speed. In this case, the
Electronic Stabilization Program (ESP) will
activate, even if the driver had turned it off
manually. ESP remains activated until the
suspension system has a chance to lower the
vehicle.

No control when No control when

cornering cornering

Level 4

Level 3

Level 2

Level 1

0 22 43 50 75
Speed in mph

43
4-LEVEL AIR SUSPENSION SYSTEM

Air Suspension Components

Warning Lamp (K134) Control Module (J197)

When a fault occurs in the 4-level air The air suspension control module (J197) is the
suspension system, warning lamp (K134) brain of the 4-level suspension system. The
illuminates. control module monitors air suspension inputs
and commands the vehicle to raise or lower,
Warning lamp operation:
depending on road speed, vehicle height and
During suspension system failures or driver requests.
when the system is disabled, the warning
The air suspension control module is located in
lamp will illuminate steadily unless fuses the left rear of the vehicle, near the accumulator.
are missing or blown.
When basic system setting has not been
carried out successfully, the warning Use Address Word 34 to access
lamp will illuminate steadily. the air suspension control
module.
Extremely low or high levels will cause
the warning lamp to flash.
Output diagnostic test mode will cause
the warning lamp to flash.

Warning Lamp K134

44
 4-LEVEL AIR SUSPENSION SYSTEM

Leveling Senders
(G76, G77, G78 and G289)
Leveling senders (G76, G77, G78 and G289) The 4-level air suspension system uses the
are inductive sensors that determine the angle PWM signal and the headlight range system
of the surface they are mounted on. These uses the voltage signal.
sensors send this information to the suspension Power is supplied to the left side leveling
control module (J197). sensors (G78 and G76) by the headlight
Both the suspension and the headlight range range control module.
systems use different angle signals for Power is supplied to the right side leveling
operation. One signal output provides an sensors (G289 and G77) by the suspension
angle-proportional voltage. A second signal control module. This ensures headlight control
output provides an angle-proportional pulse- will still operate even if the suspension control
width modulated (PWM) signal. Each leveling module fails.
sender provides both types of signals.

Cut-a-way of Level Sender

Front Level Sender Rear Level Sender

45
4-LEVEL AIR SUSPENSION SYSTEM

Air Springs
The air springs, which are located at both the
front and rear of the vehicle, allow the
changes in ground clearance and are made
up of a reinforced bag that surrounds the
shock absorbers.
When the bag is pressurized, it rolls from the
bottom to the top of the shock absorber and
raises the vehicle.

Air Spring Components

Stop buffer

Tension ring

Inner protective layer

Cord layer 1

Cord layer 2

Outer protective layer

Piston

46
 4-LEVEL AIR SUSPENSION SYSTEM

Air Compressor
Compressed air is generated by a single-stage Special features of the 4-level air suspension
piston air compressor with an integrated air system are:
dryer.
Maximum operating pressure of 16 bar
The compressor is dry-running, meaning that it (232 psi)
does not use oil for its operation. This
Suction and discharge of air pressure by
eliminates any possible oil contamination in
the air springs. an air filter/noise damper located in the
spare tire housing
During normal operation, the compressor will
only operate when the engine is running. The Temperature monitoring by a temperature
following are air compressor operation sensor located at the cylinder head
exceptions: Pressure monitoring using a pressure
Final control diagnosis sensor located in the solenoid valve unit
Basic system settings Voltage supply protection by only running
the compressor when a sufficient amount of
The ignition is on and the system detects an
electrical power is being produced from the
extremely low ride height
engines electrical system

Compressor

Discharge valve

Air dryer

Motor

Vibration isolating mount

47
4-LEVEL AIR SUSPENSION SYSTEM

Temperature Sensor (G290) Pressure Sensor (G291)

The temperature sensor (G290) is attached to The pressure sensor (G291) is integrated into
the cylinder head of the air compressor to the valve unit, and is used to monitor both the
determine the compressor temperature. accumulator pressure and the pressure to each
air shock.
The temperature sensor sends a signal to the
control unit (J197). The control unit determines The pressure sender provides a voltage signal
if the signal is within normal operating range. to the suspension control unit that is
proportional to the accumulator and shock
If the signal is not within normal operating
pressures.
range, the air suspension compressor is shut
off until an operating temperature within If the compressor shuts down due
specifications is reached. to overheating, it may take up to
15 minutes before the compressor
Solenoid Valves temperature becomes low enough
for the pump to operate.
The 4-level air suspension system uses six Depending on ambient
solenoid-operated valves. temperatures, the air suspension
The discharge valve (N111) is integrated into compressor takes approximately
the dryer housing. The function of discharge 1 hour to cool fully.
valve is to both limit and retain pressure in the
air suspension system.
The four air shock valves (transverse check
valves, N148, N149, N150 and N151) and
the accumulator valve (N311) are combined
into the solenoid valve unit which is located in
front of the spare tire housing.
All solenoid valves are of a directional design
and are closed when without current.

From compressor

Solenoid Valve Unit

48
 4-LEVEL AIR SUSPENSION SYSTEM

Pressure Accumulator
The pressure accumulator for the air While driving at road speeds below 22 mph
suspension system stores compressed air for (36 km/h), the air supply is primarily taken
later use. If there is sufficient pressure in the from the pressure accumulator (as long as
pressure accumulator, the vehicle can be sufficient pressure is present).
raised without compressor assistance.
While driving at road speeds above 22 mph
Sufficient pressure means that the pressure (36 km/h), the air supply is primarily taken
accumulator must have at least 3 bar (44 psi) from the compressor.
more pressure than the air springs have.
The pressure accumulator is made of
Maximum accumulator pressure is
aluminum and has a capacity of
16 bar (232 psi). Follow the
approximately 1.7 gallons (6.5 liters).
procedure found in AESIS to
The pressure accumulator is filled by the properly bleed the pressure
compressor under two conditions: accumulator.
When driving at a speed of approximately
22 mph (36 km/h) or above. This is done
so that compressor noise is not noticeable.
When the accumulator does not have
enough pressure to raise the vehicle to the
requested level.

49
4-LEVEL AIR SUSPENSION SYSTEM

NOTES:

50
 Knowledge Assessment
Knowledge Assessment
An on-line Knowledge Assessment (exam) is available for this SSP.
The Knowledge Assessment may or may not be required for Certification.
You can find this Knowledge Assessment at:
www.accessaudi.com

From the accessaudi.com homepage:

Click on the ACADEMY Tab

Click on the Academy Site Link
Click on the CRC Certification Link

For assistance, please call:

Audi Academy
Learning Management Center Headquarters
1-877-AUDI-LMC (283-4562)
(8:00 a.m. to 8:00 p.m. EST)

iii