Self-Study Program 990123 Audi Q5 hybrid quattro Audi of America, LLC Service Training Printed in U.S.A. Printed 6/2012 Course Number 990123 ©2012 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 affi liated 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 modifi ed 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. Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Hybrid Vehicles at Audi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Hybrid Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Types of Full Hybrid Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Other Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Introduction to the Q5 hybrid quattro . . . . . . . . . . . . . . . .8 Identifying Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Design Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.0L TFSI Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Specifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 2.0L TFSI Engine Modifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine Control Module J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Eight-Speed Automatic Transmission with Hybrid Module . . . . . . . . . . . . . . 18 Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Electromechanical Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 High Voltage System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Warning Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hybrid Battery Unit AX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Components of Hybrid Battery Unit AX1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 High Voltage System Maintenance Connector TW . . . . . . . . . . . . . . . . . . . . . 24 Battery Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Electric Drive Power and Control Electronics JX1 . . . . . . . . . . . . . . . . . . . . . . 28 Electro-Drive Drive Motor V141 (e-machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 High Voltage Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Safety Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Pilot Line Connector 1 TV44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 12 Volt Onboard Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Network Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 i Table of Contents System Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Drive Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Display and Operating Elements for Driving in Hybrid Mode . . . . . . . . . . . . 47 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 MMI Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Other Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Frequently Asked Questions (FAQs) . . . . . . . . . . . . . . . . .58 Self-Study Programs for the Audi Q5 hybrid quattro . .60 Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . .61 ! Note Alternating current (AC) voltage as low as 25 volts, and direct current (DC) voltage as low as 60 volts are hazardous to humans. It is therefore important to pay strict attention to the safety instructions in current technical literature, Guided Fault Finding, and warnings displayed on the vehicle. All work on the high voltage system must be performed by a qualifi ed high voltage technician. Only qualifi ed high voltage technicians are allowed to disconnect the maintenance connector to de-energize the vehicle. To ensure the proper and safe use of high voltage special tools, guidelines in current technical literature must also be strictly followed. The Self-Study Program provides introductory information regarding the design Reference Note and function of new models, automotive components, or technologies. ! The Self-Study Program is not a Repair Manual! All values given are intended as a guideline only. For maintenance and repair work, always refer to current technical literature. ii Introduction Hybrid Vehicles at Audi AUDI AG can look back at over 20 years of The A4 Avant duo electric motor could also experience with hybrid technology. The fi rst recover energy during deceleration. In electric generation of the Audi duo, a hybrid concept car mode, the duo attained a top speed of 50 mph based on the Audi 100 Avant, made its European (80 km/h) and a maximum speed of 105 mph (170 debut in 1989. A fi ve-cylinder gasoline engine km/h) with TDI power. drove the front wheels and a part-time electric Further development in hybrid technology motor developing 12 hp (9 kW) drove the rear was showcased in the Audi R18 e-tron quattro wheels. Rechargeable nickel-cadmium batteries prototype race cars at the 2012 24 Hours of Le provided the energy source. Mans. Audi dominated the competition, taking Another duo variant based on the Audi 100 Avant fi rst and second place, becoming the fi rst quattro followed two years later. manufacturer to win the legendary race with hybrid technology. The winning cars featured In 1997, AUDI AG became the fi rst European a TDI turbo diesel engine powering the rear manufacturer to build a limited edition hybrid wheels, and an electric motor powering the production vehicle. It was based on the Audi A4 front axle for greater acceleration coming out of Avant. corners. Drive for this A4 was provided by a 1.9 liter TDI In addition to hybrids, Audi is also developing engine developing 90 hp (66 kW), and a water- a new family of electrically powered vehicles cooled electric motor developing 29 hp (21 kW). (e-tron) capable of driving long distances. This front-wheel drive vehicle used an electric motor powered by a lead-gel battery that could The Audi A1 e-tron, designed for congested city be recharged by plugging into an electrical driving conditions, always operates electrically. outlet. No additional gasoline or TDI engine is used to extend driving range. 489_020 489_021 489_022 The Q5 hybrid quattro is the fi rst Audi hybrid model with twin drive systems. Its 2.0L TFSI engine develops 211 hp (155 kW), operating in tandem with a water-cooled electric motor developing 54 hp (40 kW). The electric motor is powered by a compact lithium-ion battery. 489_023 1 Hybrid Technology The word “hybrid” comes from the Latin word “hibrida”, which means the offspring of a mixed union. In vehicles, a hybrid is a system which combines two different technologies. Automotive hybrid powertrain technology can be either: • Bivalent drive • Hybrid drive Bivalent Drive Hybrid Drive Vehicles with bivalent drive technology have A combination of two different drive units, an internal combustion engine which can burn hybrid drive technology is an internal different types of fuel to provide drive power. combustion engine working with an electric motor (e-machine). These vehicles can run on fossil and renewable fuels (diesel and biodiesel) or liquid and gaseous Hybrid drive can generate electrical energy fuels (gasoline, natural gas, and liquid propane from kinetic energy (for instance, brake energy gas), and are gaining market share. recuperation), serve as a motor for driving the vehicle, and act as a starter for the internal combustion engine. There are three types of hybrid drives: • Full hybrid drive • Mild hybrid drive • Micro hybrid drive Internal combustion engine Crankshaft Electric motor (e-machine) 489_075 2 Full Hybrid Drive This is the system used in the Audi Q5 hybrid Additional features include an e-machine start- quattro and will be used on other Audi models. stop function that automatically shuts down and restarts the internal combustion engine during For this drive, a powerful e-machine capable idling situations, such as when the vehicle is of electric-only, low speed driving is combined stopped at a traffi c light, in stop and go city with an on-demand internal combustion engine, driving, or when it is coasting. This improves fuel which is used for longer distances and higher economy and reduces emissions. drive speeds. Clutch Automatic High voltage battery transmission 12 volt battery DC/DC converter Charge/discharge mode Total drive power Brake energy recuperation 489_015 Mild Hybrid Drive Micro Hybrid Drive While mild hybrid drive is identical to full hybrid In this drive design, which is not capable of drive with regard to technology and components electric-only driving, the electrical components used, this system is not capable of electric-only (e-starter/generator) are used only to implement operation. Via the start-stop function, a smaller the start-stop function. e-machine is activated in select situations, such This system does have some capacity for brake as when the car is coasting, braking, or stopped. energy recuperation to charge the high voltage This system also uses brake energy recuperation battery. Characteristics of the 12 volt battery are to charge the high voltage battery. adapted for frequent engine starting. This system is used in the Audi A1 (not offered in the North American market at this time). 12 volt battery Charge/discharge mode Brake energy E-starter/ recuperation Internal generator Total drive power comenbguinsteion 489_013 3 Types of Full Hybrid Drives Full hybrid drives are subdivided into four subgroups: • Parallel hybrid drive • Power-branched hybrid drive • Serial hybrid drive • Power-branched serial hybrid drive Parallel Hybrid Drive Power-Branched Hybrid Drive The parallel confi guration is noted for its The power-branched confi guration has an simplicity. This solution is used for “hybridizing” e-machine and an internal combustion engine existing model lines. mounted on the front axle. Drive is provided by both the internal combustion engine and The internal combustion engine, e-machine, e-machine, and is transmitted through a and transmission are mounted on a shaft. planetary gear set to the vehicle transmission. The individual power output of both drives is transferred directly to the wheels. Unlike the parallel hybrid confi guration, the individual power output of both drives is not This design uses many carry-over parts from transmitted entirely to the wheels. The generated the original vehicle. In quattro models, the power is partly used to drive the vehicle, while drive power is distributed to all four wheels in a the remainder is stored as electrical energy in parallel hybrid confi guration. the high voltage battery. High voltage Clutch battery e-machine High voltage battery Transmission Transmission 489_016 489_018 Internal e-machine Internal Planetary combustion combustion gear set engine engine 4 Serial Hybrid Drive Power-Branched Serial Hybrid Drive With this confi guration, the vehicle is driven by This confi guration is a cross between the the e-machine only, with the internal combustion previously described hybrid drive types, and is engine having no mechanical connection to designed for all-wheel drive vehicles. the drive axle. The internal combustion engine The vehicle is equipped with an internal drives an electrical generator which supplies the combustion engine and two e-machines. The e-machine with electrical power or charges the internal combustion engine and e-machine 1 are high voltage battery during vehicle operation. mounted on the front axle, while e-machine 2 is mounted on the rear axle and is activated only as required. The internal combustion engine and e-machine 1 can drive the vehicle’s transmission through a planetary gear set. A high voltage battery is mounted between the two vehicle axles. e-machine e-machine 1 High voltage Transmission battery e-machine 2 Generator High voltage battery Internal 489_017 Internal Planetary 479_019 combustion combustion gear set engine engine 5 Other Terminology Plug-In Hybrid Brake Energy Recuperation This term describes a hybrid drive vehicle that The word “recuperation” comes from the Latin can have its high voltage battery externally “recuperare,” meaning to recover or restore. In charged via a charging station or a household hybrid vehicles, it means the recovery of kinetic power outlet. energy during deceleration. Kinetic energy is recovered when a vehicle is braking or coasting, A cross between a pure hybrid and an electric and is then stored in the vehicle battery. car, plug-in hybrid vehicles combine the advantages of both internal combustion engine- Recuperation is a key component of the vehicle’s equipped vehicles and battery powered vehicles. electrical energy management system. Energy Flows Between the High Voltage Components Electric Motor Operation: High Voltage Battery is Recuperation: High Voltage Battery is Recharged Discharged During vehicle deceleration, the vehicle is braked When driving under electric power, power is electrically by the e-machine, which recharges drawn from the high voltage battery, which also the high voltage battery. A portion of the energy supplies power for the 12 volt vehicle electrical is recovered as soon as the driver takes his foot system. off the accelerator, with the amount recovered increasing during vehicle braking. The 12 volt vehicle electrical system is supplied with power from the e-machine. JX1 with J841 JX1 with J841 V141 3 x 145V 12V V141 3 x 145V 12V 12 volt vehicle 12 volt vehicle electrical system electrical system 266V 266V AX1 with J840 AX1 with J840 J623 J623 489_088 489_089 Key: High voltage wires Hybrid CAN AX1 Hybrid Battery Unit JX1 Electric Drive Power and Control Electronics V141 Electro-Drive Drive Motor J623 Engine Control Module J840 Battery Regulation Control Module J841 Electrical Drive Control Module 6