Audi RS 3 LMS SEQ

USER MANUAL
2018

Downloaded from www.Manualslib.com manuals search engine

 INDEX

1 TECHNICAL INFORMATION ........................................................................................... 4

AUDI RS 3 LMS SEQ display ................................................................................... 4
Dimensions and weight .............................................................................................. 5
Bodywork ...................................................................................................................... 5
Engine ........................................................................................................................... 6
Fuel tank ....................................................................................................................... 7
Power transmission..................................................................................................... 7
Chassis ......................................................................................................................... 8
Electronic units ............................................................................................................ 9
2 DRIVER CONTROLS ........................................................................................................ 9
Main panel .................................................................................................................. 10
Steering wheel module ............................................................................................. 10
Speed limiter (Pit limiter/Full Course Yellow/120 limiter) .................................... 12
Display alarms and shift lights................................................................................. 12
Gearbox functioning.................................................................................................. 13
Standing start procedure .......................................................................................... 14
Rear brake pressure proportioning valve .............................................................. 14
.......................................................................................................................... 14
............................................................................. 15
3 ELECTRONICS ................................................................................................................ 17
AIM MXG .................................................................................................................... 17
MXG connection schemes ....................................................................................... 18
Data acquisition ......................................................................................................... 19
Fusebox ...................................................................................................................... 20
Fuel level display ....................................................................................................... 23
Auxiliary connectors .................................................................................................. 25
Fire extinguisher ........................................................................................................ 28
4 SETTING ADJUSTMENTS ............................................................................................. 29
Standard set-up ......................................................................................................... 29
Steering rack centring............................................................................................... 30
Front camber and toe adjustments ......................................................................... 30
Rear camber and toe adjustments ......................................................................... 31
Suspension ................................................................................................................ 31

Downloaded from www.Manualslib.com manuals search engine

 Anti-roll bars ............................................................................................................... 34
Kinematics .................................................................................................................. 35
Brakes ......................................................................................................................... 37
Aerodynamics ............................................................................................................ 38
Driving position .......................................................................................................... 39
5 WORKSHOP MAINTENANCE ....................................................................................... 42
First roll-out ................................................................................................................ 42
Check-list .................................................................................................................... 42
Body-shell and engine identification....................................................................... 43
Fluids ........................................................................................................................... 44
Engine ......................................................................................................................... 44
Air filter ........................................................................................................................ 44
SADEV ST82-17 gearbox ........................................................................................ 45
Differential .................................................................................................................. 46
Fuel tank ..................................................................................................................... 47
Airjacks ....................................................................................................................... 50
6 PARTS MILEAGE............................................................................................................. 52

Downloaded from www.Manualslib.com manuals search engine

 1 TECHNICAL INFORMATION

AUDI RS 3 LMS SEQ display

Engine
\ Type Four-cylinder in line 2.0 TFSI
\ Layout Transversally mounted in front axle
\ Capacity 1984 cc
\ Bore / stroke 82.5 mm / 92.8 mm
\ Output 257 kW (350 hp) / 6250 rpm
\ Torque 420 Nm / 2500 to 5500 rpm
\ ECU Continental SIMOS
\ Exhaust Racing catalyst

Power transmission
\ Transmission Front-wheel drive
\ Gearbox Six-speed sequential
\ Differential Mechanical with external preload adjustment
\ Clutch 2 plate cerametallic race clutch
\ Shift control Paddle-shift on steering wheel

Chassis
\ Front suspension McPherson, adjustable in height, toe and camber
\ Anti-roll bar Front and rear adjustable in 6 positions
\ Rear suspension Multi-link adjustable in height, toe and camber
\ Front brakes 6-piston callipers, ⌀ 378x34 mm ventilated discs
\ Rear brakes ⌀ 272x10 mm solid discs
\ Brake pedal With brake balance regulation
\ Hand brake Hydraulic with mechanical locking
\ Steering system Electrical power steering rack
\ Rims Audi Sport 10x18 inch
\ ABS Optional

Body
\ Roll-cage Welded steel FIA homologated
\ Weight 1.180 kg
\ Front width (max) 1.950 mm
\ Rear width (max) 1.950 mm
\ Length 4.589 mm
\ Wheel base 2.665 mm

Equipment and safety

\ Acquisition system AIM - MXG 60 channels
\ Car check control Auto-diagnosis OBDII / DiagRA – LE
\ Speed limiter (VSC) 5 variable speeds
\ Launch control Available
\ Airjack system 3 airjacks (⌀ 50 mm)
\ Fire extinguisher OMP
\ Rescue hatch Roof hatch to allow lifting driver helmet
\ Seat Audi Sport PS-3
\ Door panel Side-impact protection panel
\ Fuel tank FIA FT3 Fuel Tank

Downloaded from www.Manualslib.com manuals search engine

 Dimensions and weight

Dimensions Measurements Remarks

Overall length 4589 mm
Overall bodywork front width 1950 mm
Overall bodywork rear width 1950 mm
Wheel base 2665 mm
Over hang front splitter 874 mm
Over hang front bumper 844 mm
Over hang rear 954 mm
Over hang rear wing* 96 mm From the wing to the bumper
Minimum ground clearance - 80 mm according to TCR regulations

Weight Measurements
Total weight in race conditions without fuel 1180 kg **
Car balance 59% front / 41% rear
Distribution weight/power 3,37 kg/hp
Notes:
* Measured from the rear bumper to the end of rear wing profile.
** The scrutineering dimensions and minimum weight are the ones on the Audi RS 3 LMS SEQ Technical
Form.

Bodywork

Part number Description Material

01 Bonnet Steel
02 Left / right front door Steel
03 Left / right rear door Steel
04 Roof Steel
05 Boot lid Steel
10 Roof hatch Carbon
11 Bonnet opening Carbon (painted)
12 Front splitter Carbon
13 Fender air exit Carbon (painted)
14 Front bumper Fiberglass
15 Rear bumper Fiberglass
16 Left / right side trim Carbon + Kevlar
17 Left / right rear door extension Carbon (painted)
18 Left / right rear fender extension Carbon (painted)
19 Left / right front fender Carbon (painted)
20 Diffuser Carbon (painted)

Downloaded from www.Manualslib.com manuals search engine

 21 Windscreen Glass
22 Left / right front door window Glass
23 Left / right rear door window Glass
24 Left / right rear triangle window Glass
25 Rear window Glass

Engine

Engine features Description

Downloaded from www.Manualslib.com manuals search engine

 Type 2,0 TFSI / Turbocharged and direct fuel injection
Engine identification CJX
Cylinder capacity 1984 cc
Corrected cylinder capacity 1984x1,7 = 3372,8 cc
Maximum power 257 kW (350 hp) at 6250 rpm
Maximum torque 420 Nm / from 2500 to 5500 rpm
Maximum rpm 6800 rpm
Specific power 175 hp/l
Electronic control unit CONTINENTAL SIMOS 18.1
Fuel RON MIN 98 / RON MAX 102
Fuel consumption 0,37 to 0,42 l/km
Exhaust Racing catalyst FIA Homologated
Distribution Chain (sealed)
Oil system Wet sump
Water pump Mechanical water pump + one auxiliary electrical pump
Water thermostat Electromechanical
Fan range Operating range 92°C to 87°C

Engine power and torque curve:

Fuel tank

Fuel tank features Description

Fuel tank type FIA FT3 homologated fuel tank
Capacity 100 l ±2%
Minimum fuel level before engine fault Less than 1 litre
Ventilation valve FIA homologated roll-over, ventilation and 200 mbar pressure
regulator valve
Refuelling Safety FIA plug

Power transmission

Power transmission features Description

Transmission Front-wheel drive

Downloaded from www.Manualslib.com manuals search engine

 Gearbox Six-speed sequential
Differential Mechanical with external preload adjustment
Clutch 2 plate cerametallic race clutch
Shift control Paddle-shift on steering wheel
Gearbox electronic control unit GCU placed on EM-Box
Gearbox actuator Electromagnetic actuator
Cooling system Gearbox oil radiator
Downshift over-rev protection Electronically activated

Gear ratios
Gear Total RPM GEAR SHIFT CUT DIFF
GEAR Z1 Z2
relation relation 3000 6500 6800 RPM
1 12 28 0,429 0,113 42 90 94
2 13 23 0,565 0,149 55 119 124 1644
3 22 31 0,710 0,187 69 149 156 1384
4 21 24 0,875 0,230 85 184 192 1285
5 26 25 1,040 0,274 101 219 229 1079
6 29 24 1,208 0,318 117 254 266 947
Final drive 15 57 0,263

7000

6000

5000

4000

3000

2000

1000

0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300

Chassis

Suspension features Description Remarks

Front damper Bilstein 2 way adjustable / Aluminium body Clicks: 10 bump / 10 rebound
Springs front and rear 170/60/70-80-90-100-110-120 Eibach ERS-H
Front antiroll-bar 22x2 / 22x3 Adjustable in 6 positions
Rear bumper Bilstein 2 way adjustable / Aluminium body Clicks: 10 bump / 10 rebound
Rear antiroll-bar 22x3 / 22x4 Adjustable in 6 positions
Front and rear tenders 60/60/2

Brake features Description Remarks

Front calliper AP Racing Monobloc 6 pistons Special VW Group
Front disc Ventilated ⌀ 378x34 mm
Front pump AP Racing 19,1 mm
Front pads Pagid RST 3 Thickness: 25 mm

Downloaded from www.Manualslib.com manuals search engine

 Rear calliper AP Racing 2 pistons
Rear disc Solid ⌀ 272x10 mm
Rear pump AP Racing 22,2 mm
Rear pads Pagid RS 4-4
Rear press reducer AP Racing 7 position lever
Brake balance Tilton balance bar

Hand brake features Description Remarks

Hand brake Hydraulic with mechanical locking Acting on rear axle
Brake pump AP Racing 15 mm

Wheel features Description

Rim dimension 10”x18” ET36
Rim centre lock 5 studs x 112 mm
Maximum tyre dimension recommended 27/65 R18
Tyre temp difference inside/outside 20°C
Minimum cold pressure recommended 1.2 bar

Electronic units

Electronic modules Remarks Software Place

ECU VW AG Motorsport Engine bay
GCU Skynam Motorsport Engine bay (EM-Box)
Gearbox actuator XAP Motorsport Engine bay
Low fuel pump control VW AG Series Roll-cage
Fuel level display SEAT Sport Motorsport Cockpit
Electronic steering rack VW AG Motorsport Front subframe
ABS/ESP unit VW AG Not active Cockpit
Gateway VW AG Series adapted Cockpit
Blackbox VW AG Motorsport Cockpit
MXG display/logger AIM Motorsport Cockpit
Fusebox SEAT Sport Motorsport Cockpit
Steering wheel module SEAT Sport Motorsport Cockpit

Modules based in series

ABS/ESP

Gateway
Low fuel

Steering
Engine

pump
ECU

rack

Specific software/mapping: Yes No Yes No Yes

Specific codifications: Yes No Yes Yes Yes
Interchangeable between cars: Yes Yes Yes Yes Yes
Spare part ready for plug and play: Yes Yes Yes Yes Yes
Modification allowed: No No No No No
Notes:
 Use always spare parts from Audi Sport. Although the mentioned parts derive from series cars, the
software and codifications are different and modified by Audi Sport.
 All series modules used on the car are based in the MQB platform. Through the diagnostic tools
available on the VW AG dealers, it is possible to diagnostic any malfunction.

2 DRIVER CONTROLS

In this section, it is explained how the driver can handle the different commands and functions of the car
within his range while driving.

Downloaded from www.Manualslib.com manuals search engine

 Main panel

Ignition switch

Lights switch

Main switch

Blinker switch

Brake balance

Function Remarks
Ignition switch It activates the power to all devices. The main switch has to be active.
Main switch It activates the power supply.
It activates the low beam. High beam and flash activation buttons are placed on
Lights switch
the steering wheel module.
It activates the left and right turn lights. A green alarm on the display appears
Blinker switch
showing that the turn light is blinking.
Turning the balance wheel you can balance the brake pressure from front to
rear or vice versa.
Brake balance Do not press the brake pedal while moving the balance wheel.
Through the driver display you can check the front and rear brake pressure and
the brake balance.
Notes:
 To start the car, always proceed in this order: main switch, wait until display has booted (Audi Sport
logo disappears), then ignition switch.
 The correct procedure to stop the car is the following:
1. Stop the engine using only the yellow switch (ignition switch/KL-15).
2. Wait at least 60 seconds.
3. Switch off the car using the red switch (main switch/KL-30).
 If this procedure is followed correctly the OBD faults memory is saved and these faults can be
checked with the diagnostics tools at any time thereafter. These faults are saved until the memory
is deleted manually using the diagnostics program.
The diagnostic tool DiagRA-LE is recommended for customers to be able to check the cars.

Steering wheel module

The electronic steering wheel module permits activating different functions without removing hands from the
steering wheel.
Some of the buttons have double functionality.

10

Downloaded from www.Manualslib.com manuals search engine

 Button Function Remarks

Driver voice activation

Radio
Maintain pushed to talk

Full Course 4 variable* speeds (40/50/60/80)

Yellow Short push to activate/deactivate
Double short push to activate
120 limiter
Single short push to deactivate

Cockpit fan Short push to activate/deactivate

Change display
Short push to change display page / rolling change
page

Allows entering to and exiting from N without pressing the

Safety brake clutch pedal. IMPORTANT: the use of this button is under
signal button user responsibility, a bad use of it may cause fatal
damages on the gearbox

Diff map No use on cars with sequential gearbox

change Only use on DSG cars.

Active if gearbox is in Neutral or the clutch is pressed

Starter
Active if rpm < 500
4 variable* speeds (40/50/60/80)
Pit limiter Active if rpm > 500 and speed > 5 km/h
Short push to activate/deactivate

Activates water pump

Drink
Note: pump not supplied with the car

Rain lights Short push to activate/deactivate

Wiper Short push to roll low speed/high speed/deactivate

Windscreen
Long push to activate water splash + wiper activation
water

Short push to flash

High beam
Long push to activate/deactivate

Tip up / Tip
A led informs when tip up or down
down
Usual status: led off
CAN info
If there is a CAN Bus problem: led on

11

Downloaded from www.Manualslib.com manuals search engine

 Notes:
 The FCY speed can be selected between the following speeds: 40, 50, 60 and 80. The speed can
only be selected with the car stopped following this process: +30 switch ON, +15 switch OFF, keep
FCY button pushed and select the speed using the gear shift paddles. The selected speed can be
seen on the AIM MXG display.
 The Pit limiter speed can be selected between the following speeds: 40, 50, 60 and 80. The speed
can only be selected with the car stopped following this process: +30 switch ON, +15 switch OFF,
keep Pit limiter/Starter button pushed and select the speed using the gear shift paddles. The
selected speed can be seen on the AIM MXG display.
 Although it is possible to uncouple completely the steering wheel from the column with the engine
running, it is not advisable (causes fault messages on the OBD).

Speed limiter (Pit limiter/Full Course Yellow/120 limiter)

The speed limiter system allows limiting the car speed at a preselected value. There are five possibilities:
40, 50, 60, 80 and 120 km/h. This system is recommended for the pit lane area or Full Course Yellow (FCY)
situations.
Process:
1. Select the desired speeds for each steering wheel button before starting the car and leaving the
pits. Only the FCY and Pit limiter speeds are variable, the 120 limiter cannot be changed. The
selected speeds are shown on the display.
2. Activate the desired speed limiter with the corresponding button. From this moment on throttle pedal
may be fully pressed and the speed will be limited.
3. If the car speed is over the target, the engine torque may be cut. If the speed is below the target,
torque will be applied till the speed is reached.
4. Make a short push on the selected speed limiter button on the steering wheel to deactivate the
function.

Display alarms and shift lights

Car delivery shift lights and alarms configuration:

 LED 1: continuous yellow: Low oil pressure. If no red alarm follows you can continue. If alarm
disappears you can continue pushing. Check the oil level when back into the pit.
 LED 1: slow blinking green: Left turn light is active.
 LED 2: fast blinking red + POP UP: Very low oil pressure. Big risk to break the turbo or to damage
the engine. Audi Sport recommends slowing down and entering to the pit-lane or stopping in a safe
place.
 LED 3: continuous purple: Battery voltage low warning. You can continue, check the alternator
and the alternator poly-V belt.
 LED 4: continuous yellow: Fuel pressure low warning. You can continue, check the fuel level.

12

Downloaded from www.Manualslib.com manuals search engine

  LED 5: continuous yellow: water temperature high. Pay attention, drive out of slipstream and
keep an eye on the values. If no red alarm follows you can continue. If alarm disappears you can
continue pushing.
 LED 5: slow blinking green: Right turn light is active.
 LED 6: slow blinking red: water temperature too high. Drive out of slipstream and keep an eye on
the values. Some torque reductions will appear but you can continue.
 LED 6: slow blinking red + POP UP: Critical water temperature. Audi Sport recommends slowing
down and entering to the pit-lane or stopping in a safe place, to avoid damaging the engine.
 LED 7: continuous white: Gearbox oil temperature high. Drive out of slipstream and keep an eye
on the values. You can continue.
 LED 8: continuous blue: Intake air temperature high. Drive out of slipstream and keep an eye on
the values if not some torque reductions will appear. You can continue.
 LED 8: slow blinking white: Steering initialization needed (it will appear each time the car is
switched on). Turning the steering wheel left and right should disappear. If not, there is a problem
in the electrical steering rack.
 LED 1 + LED 5: slow blinking red: Pit limiter is active.
 LED 1 + LED 5: slow blinking yellow: Full Course Yellow is active.
 LED 1 + LED 5: slow blinking blue: 120 limiter is active.
 LED 4 + LED 8: fast blinking green: Hand brake is locked and engine started. Unlock it before
trying to move the car.
 LED 4 + LED 8: fast blinking green + POP UP: Hand brake is locked while you are driving. Audi
Sport recommends unlocking the hand brake and entering to the pit-lane to check if the rear brake
callipers have been damaged.

Note:
 It is possible to customize the alarms and shift lights through the RaceStudio3 software installed
on a laptop.

Gearbox functioning

R - Reverse mode:
 It is possible to put on this R mode if the car is complete stopped and clutch pedal pressed.
 In case of clutch pressure sensor malfunction, it is also possible to use the steering wheel (P) Safety
brake signal button to put on or take out the R mode. IMPORTANT: the use of this button is under
user responsibility, a bad use of it may cause fatal damages on the gearbox.
N - Neutral mode:
 In N mode, it is possible to move the car pushing externally (pit lane use).
 To enter into this mode it is mandatory to press the clutch pedal.
 To exit from this mode it is necessary to be completely stopped and pressing the clutch pedal.
 It is also possible entering to and exiting from this mode using the steering wheel (P) Safety brake
signal button. IMPORTANT: the use of this button is under user responsibility, a bad use of it may
cause fatal damages on the gearbox.
Driving mode:
 It is possible to go from N to 1st gear if the car is completely stopped and the clutch pedal is pressed.
Also possible using the steering wheel (P) Safety brake signal button. IMPORTANT: the use of this
button is under user responsibility, a bad use of it may cause fatal damages on the gearbox.
 It is possible to put on Neutral mode at any moment only if the clutch pedal is pressed.

13

Downloaded from www.Manualslib.com manuals search engine

  It is not necessary to use the clutch while shifting on the track, only to start from standing position.
 Once the vehicle is moving use the steering wheel paddles to upshift or downshift.
 Remember that the shifting is only manual, when the engine reaches the rev limiter (6800 rpm) the
power is limited but no automatic upshift will happen. To stop the car it is necessary to press the
clutch pedal to avoid engine stalling.
 Downshifting is protected preventing the engine from over-revs. If there is a downshift demand at
too high revs the gearbox will not do it. There is no memory function.
Parking mode:
 Use the Neutral gearbox mode and lock manually the hand brake using the locking hook. The
gearbox will not be locked, only the car due to the rear brake pressure generated by the hand brake
pump.
 To unlock the car just remove the hand brake hook.
 To lock the transmission completely, stop the car on 1st or R gear.

Standing start procedure

Rear brake pressure proportioning valve

14

Downloaded from www.Manualslib.com manuals search engine

 

P_BRK_FRONT
BRK_BALANCE = ∗ 100
P_BRK_FRONT + P_BRK_REAR

15

Downloaded from www.Manualslib.com manuals search engine

 16

Downloaded from www.Manualslib.com manuals search engine

 3 ELECTRONICS

AIM MXG

MXG is the AIM dash-logger designed to acquire and display in FHD data coming from your ECU, the internal
accelerometer and gyro, as well as from the GPS module, analog/digital inputs and predefined math
channels.
Downloading data can be done through a data download cable, a memory stick or using the available Wi-Fi
features.
Performance and data acquired can also be incremented adding expansion modules. Using the specific AIM
on-board camera SmartyCam it is possible to overlay on videos the data sampled by the logger.
To see the lap times it is necessary to insert the track where you are running. Track load has to be done by
the RaceStudio3 software.
RaceStudio3 software, latest MXG firmware and documentation available on AIM website:
http://www.aim-sportline.com/eng/download/index.htm
MXG user guide available on AIM website:
http://www.aim-sportline.com/download/doc/eng/mxs-mxg/MXG_user_guide_101.pdf

Shift lights and alarms:

17

Downloaded from www.Manualslib.com manuals search engine

 1. On the top of the display there are ten gear flash leds that can be freely configured. The rpm value
at which to turn it on and the colour can be defined. Gear dependent lights can be also defined.
2. On both sides of the screen there are eight alarm leds that can be freely configured. The conditions
to turn them on and off and the colour can be defined. Also messages on a red ribbon in the lower
part of the screen and completely screen pop-up messages can be defined.

Note:
 IMPORTANT: the change of the alarms or shift lights is under user responsibility. Car is delivered
with Audi Sport recommendation. Before changing them it is advisable to do a backup of the
standard configuration.

MXG connection schemes

Scheme 1: Data-logger standard connection scheme (car delivery).

Scheme 2: Data-logger connection scheme with Smarty-cam and expansion module (example).

Features Remarks
Lap-trigger The MXG system uses only GPS signal.
Circuit Through the RaceStudio3 software is possible to activate all the circuits in the world.
It is also possible to create and load a new circuit.

18

Downloaded from www.Manualslib.com manuals search engine

 Extra sensors In case of adding extra sensors, they have to be connected to an expansion module.
This expansion module has to be connected through the data hub as shown in the
scheme 2.
Notes:
 Channel expansion module and sensors are available through AIM dealers, not Audi Sport.
 If for any reason it is necessary to send data acquisition files to Audi Sport, following data file
extensions must be sent: .drk, .gpk and .xrk.

Data acquisition

AIM-MXG channel list:

Channel name Description Unit Recommended scale

P_TURBO Boost pressure bar 0 ... 3
T_ENG_AIR Intake air temperature °C 20 ... 75
T_ENG_OIL Engine oil temperature °C 80 ... 150
T_ENG_WATER Engine coolant temperature °C 70 ... 125
T_AIR External air temperature °C 12 ... 45
RPM_ENG Engine speed rpm 1000 … 7000
FLAG_BRAKE Brake lights on/off 0…2
P_BRK_FRONT Front brake pressure bar 0 … 100
P_BRK_REAR Rear brake pressure bar 0 … 100
BRK BALANCE Brake balance % 0 … 100
P_ENG_OIL Engine oil pressure bar 1,5 … 5
P_ENG_FUEL Fuel low pressure bar 0…7
FUEL_LEVEL Fuel level l 0 … 110
FUEL_CONS Fuel consumed l 0 … 110
S_FUEL Fuel remaining time min 0 … 120
N_FUEL Fuel remaining laps # 0 … 80
LAP_CONS Fuel lap consumption l /lap 0…3
POS_PEDAL Gas pedal position % 0 … 100
TIP_DOWN Tip down Sign 0…2
TIP_UP Tip up Sign 0…2
G_CH_Y Lateral acceleration G -2,5 … 2,5
G_CH_X Longitudinal acceleration G -1,6 … 1,6
W_CH Yaw rate °/s -50 … 50
V_WHL_RL RL wheel speed km/h 0 … 260
V_WHL_RR RR wheel speed km/h 0 … 260
V_WHL_FL FL wheel speed km/h 0 … 260
V_WHL_FR FR wheel speed km/h 0 … 260
V_WHL_REF ESP reference speed km/h 0 … 260
V_STW_LIMIT Pit limiter speed km/h 20 … 100
V_STW_FCY Full Course Yellow speed km/h 20 … 100
A_STE Steering angle ° -200 … 200
FLAG_STW_OUT1 Steering wheel button state # 0…8
FLAG_STW_OUT2 Steering wheel button state # 0…8
FLAG_STW_OUT3 Steering wheel button state # 0…8
FLAG_FBX_RELAY1 Fusebox relay 1 state # 0…8
FLAG_FBX_RELAY2 Fusebox relay 2 state # 0…8
FLAG_FBX_5 Fuse state 5 # 0…8
FLAG_FBX_4 Fuse state 4 # 0…8
FLAG_FBX_3 Fuse state 3 # 0…8
FLAG_FBX_2 Fuse state 2 # 0…8
FLAG_FBX_1 Fuse state 1 # 0…8
I_FBX_MAIN Main current A 10 … 40
I_FBX_TURNLIGHT Turn light current A 0 … 10
EXTERNAL
Battery Voltage V 8 … 15
VOLTAGE

19

Downloaded from www.Manualslib.com manuals search engine

 P_GCU_CLUTCH Clutch pressure bar 0 … 100
N_GCU_GEAR Gear # -1 … 7
T_GCU_OIL Gearbox oil temperature °C 80 … 150
U_GCU_GEAR Gearbox potentiometer mV 0 … 5000
POS_XAP_POT Actuator position # 0 … 32767
POS_ACTUATOR Actuator position filtered # 0 … 32767
U_XAP_BAT Actuator power supply V 8 … 15
I_XAP_OUT Actuator output current A 0 … 120

GPS channels Description Unit

GPS_Speed Speed km/h
GPS_Nsat N° of satellites #
GPS_LatACC Lateral acceleration G
GPS_LonACC Longitudinal acceleration G
Altitude m
Luminosity Display brightness %
Odometer km

The values shown in the following table are the standard approximate values at 20°C air temperature for
main car control channels.

Channel Idle speed* Values at T_air 20°C Maximum value**

P_TURBO 0 bar 2.7 bar 2.99 bar
P_ENG_FUEL 4.1 bar 4.3 bar 6 bar
P_ENG_OIL 2 bar 3.6 bar 5 bar
T_ENG_AIR 40°C 42°C >75°C
T_ENG_OIL 80°C 122°C >145°C
T_ENG_WATER 90°C 92°C >115°C
T_GCU_OIL 40°C 110°C >145°C
Notes:
* These values can change depending on car’s engine temperature. Those are approximate values
when T_ENG_WATER is 90°C after having warmed the car from cold always at idle speed.
** The maximum value underlined in red shows the value before performance restrictions or protection
modes are applied.

Fusebox
Fuse box LED label

20

Downloaded from www.Manualslib.com manuals search engine

 The fusebox is an electronic box that controls the power supply to practically all
devices. Internally, the thermal fuses reset automatically, so changing a fuse will
never be necessary. In case of malfunction it has to be sent to Audi Sport.
It is also possible to check if a fuse has blown in the fusebox, so you will know if
the current or signal was sent.

There are three ways to check the correct functioning:

 Live measures view using RaceStudio3.
 Checking the fusebox control channels in RaceStudio Analysis.
 Checking the red LEDs on the fusebox.

If a malfunction is detected, it is necessary to first check the corresponding wiring

or the device.

In the following tables is shown the fusebox analysis information:

 Channel name: There are 7 channels to analyse.
 Bit number: Each channel is able to control 8 fuses.
 Data value: Is the value you can check on data acquisition.

21

Downloaded from www.Manualslib.com manuals search engine

 Channel name Bit number Data value Description
bit8 -------8 Sadev pump
bit7 ------7- HR-ECU
bit6 -----6-- HR-Fuel pump
bit5 ----5--- Starter
FLAG_FBX_F5
bit4 ---4---- Radio
bit3 --3----- HR-Lambda
bit2 -2------ HR-Miscellaneous
bit1 1------- HR-Injectors
bit8 -------8 MR-ignition coils
bit7 ------7- Sadev-ELV
bit6 -----6-- Drink
bit5 ----5--- Switch panel / Aux. data connector
FLAG_FBX_F4
bit4 ---4---- Steering wheel
bit3 --3----- Gear Lever / GCU
bit2 -2------ Diagnosis connector
bit1 1------- Power steering ECU
bit8 -------8 ECU
bit7 ------7- Front fan
bit6 -----6-- MXG
bit5 ----5--- Blackbox / Gateway
FLAG_FBX_F3
bit4 ---4---- Differential
bit3 --3----- +30 Aux. connector
bit2 -2------ DSG
bit1 1------- ABS ELV
bit8 -------8 Wiper
bit7 ------7- Turn light
bit6 -----6-- Diagnosis connector / +15 aux. connnector
bit5 ----5--- Cockpit fan
FLAG_FBX_F2
bit4 ---4---- Window
bit3 --3----- Head lights
bit2 -2------ Transponder
bit1 1------- +15 signal
bit8 -------8 Wiper pump
bit7 ------7- Brake light
bit6 -----6-- Low beam
bit5 ----5--- Day light
FLAG_FBX_F1
bit4 ---4---- Low beam
bit3 --3----- Rear light
bit2 -2------ Rain light left
bit1 1------- Rain light right
bit8 -------8
bit7 ------7-
bit6 -----6-- Turn light L
FLAG_FBX_RELAY2 bit5 ----5--- Turn light R
bit4 ---4---- Cockpit fan
bit3 --3----- M relay
bit2 -2------ H relay

22

Downloaded from www.Manualslib.com manuals search engine

 bit1 1------- Starter
bit8 -------8 Drink
bit7 ------7- Wiper pump
bit6 -----6-- Brake light
bit5 ----5--- High beam
FLAG_FBX_RELAY1
bit4 ---4---- Rain light
bit3 --3----- Low beam
bit2 -2------ +15 signal
bit1 1------- Turn light

Example:
 In the acquisition screenshot bellow is shown the channel FLAG_FBX_1 in green. The value is 7
when braking and 0 when no braking. In this case, the conclusion is that there is a problem on the
brake light line.

Fuel level display

All new Audi RS 3 LMS cars have a fuel display to control the fuel remaining at the tank. It is tied to the roll
cage in the rear right door area. The display has to be set after each refuelling. This setting is very important
to get the correct fuel level because it is calculated by the fuel consumption sent from the engine ECU.
 There is a light sensor for automatic brightness trimming.
 Two sensitive zones below the four digits allow menu navigation.
 It is important not to touch the front panel when it is switching on due to the initial capacitance
setting during start up.
 Also take special care wiping with hand the front panel if device is switched on.
 Electrostatics charge could affect the sensitive touch and set undesired actions.

23

Downloaded from www.Manualslib.com manuals search engine

 Terminology:

Following, the terminology description to understand future command tables:

 Llp: Left long push (>1s)
 Rlp: Right long push (>1s)
 Lsp: Left short push (<1s)
 Rsp: Right short push (<1s)
 STout: Short Timeout (1s)
 LTout: Long Timeout (8s)

Fuel level adjustment:

This menu allows the following possibilities:

 Set fuel level to full tank value.
 Add/remove a fuel quantity to the actual value.
 Set an absolute quantity (litres without decimal).

 When the value is shown (and blinking), a right short push increases this value litre by litre and a
left short push decreases this value.
 Maintaining right/left long push, the value is increased/decreased 10 litres by 10 litres.

Set Full level value:

This menu allows setting the maximum tank level or predefined fuel level.

Brightness and bar graph set:

It is possible modify the brightness and bar graph settings.

24

Downloaded from www.Manualslib.com manuals search engine

 * Long left push will scroll menu on the other side.
** “Auto” will adjust automatically the brightness. Else, use right / left touch to increase / decrease light
level.
*** “dot” mode will light on only one led on the bar graph. “bAr” mode will light on all leds beginning
from the left side up to the level point. Note that the last led matches with the Full value set.

Auxiliary connectors

The main car wiring loom is prepared with some auxiliary connectors to make easier the connection of
auxiliary devices.
Free connectors inside the cockpit

3
2
1

#1: Auxiliary power supply

This connector is placed in the driver cockpit above the central tunnel (front). It could be used for user
requirements such as connecting the TCR scrutineering logger.

Auxiliary power supply

Matching connector 191 972 733
Pin-out Terminal
1 +30 up to 8A FS 2,8 x 0,8
2 GND FS 2,8 x 0,8
3 CAN H traction FS 2,8 x 0,8
4 CAN L traction FS 2,8 x 0,8
5 CAN H chassis FS 2,8 x 0,8
6 CAN L chassis FS 2,8 x 0,8

#2: Auxiliary analogic sensors

25

Downloaded from www.Manualslib.com manuals search engine

 Two connectors are available connected to the dash logger.

Auxiliary analogic sensors

Matching connector 191 972 713
Pin-out Terminal
1 5v FS 2,8 x 0,8
2 signal FS 2,8 x 0,8
3 GND FS 2,8 x 0,8

#3: Additional power supply

It can be used for any requirement.

Additional power supply

Matching connector 191 972 714
Pin-out Terminal
1 +30 up to 8A FS 2,8 x 0,8
2 +15 up to 5A FS 2,8 x 0,8
3 GND FS 2,8 x 0,8
4 GND FS 2,8 x 0,8

#4 and #5: Radio and drink

Behind the driver seat there are two free connectors associated with the steering wheel module. Connecting
here radio and drinking systems, both can be used through the steering wheel module.

Radio connector
Matching connector AMP Super-seal 4-way 282106-1
Pin-out Terminal
1 PTT 183024-1 or 183036-1
2 PTT 183024-1 or 183036-1
3
4
+30 up to 8A
GND
183024-1 or 183036-1
183024-1 or 183036-1 4 5
1
Drink connector
Matching connector AMP Super-seal 2-way 282104-1
Pin-out Terminal
1 up to 2.5A 183036-1
2 GND 183036-1

#6: Power supply cut

There is a fusebox power supply connector, so in case of
disconnection cuts all devices power supply.
6
You can unplug it in case of transport or for a more safe disconnection
in case of workshop big jobs.
See connector placement above the fusebox main connectors on the
picture beside.

Free connectors on the engine bay

26

Downloaded from www.Manualslib.com manuals search engine

 #7: Transponder
This auxiliary connector is placed behind the right front headlight. All Audi RS 3 LMS cars are provided
without transponder.

Transponder
Matching connector 357 972 762
Pin-out Terminal
1 12v FS 2,8 x 0,8 7
2 GND FS 2,8 x 0,8

#8: Additional headlights

This auxiliary connector is placed behind the left front headlight, under the engine ECU. All Audi RS 3 LMS
cars are provided without additional headlights but this connector is ready for a plug and play solution that
allows the driver to turn additional headlights from the steering wheel.

Additional headlights
Matching connector AMP Super-seal 3-
way 282105-1
Pin-out Terminal
1 12v AMP 183024-1 8
2 GND AMP 183024-1
3 signal AMP 183024-1

Following two recommended solutions to install the headlights electrically:

Option 1:

Notes:

 Total maximum current 7 A.

 Mandatory to install a maximum 100 mA coil current relay. TE 3-1414773-5 recommended.
 Mandatory to install a freewheel diode on relay’s coil.
 When using the DRV signal pin, the headlights will switch on together with the standard high beam
when pushing the steering wheel dedicated button.
Option 2:

Notes:
 Total maximum current 7 A.

27

Downloaded from www.Manualslib.com manuals search engine

  As the DRV signal pin is not used, an independent activation switch must be installed in the cockpit
area.

Fire extinguisher

All Audi RS 3 LMS cars are delivered with an OMP fire extinguisher placed on the boot area. Fulfilling all
FIA safety regulations, the extinguisher can be detonated from the cockpit area using the push button of the
control box placed in the main console or from the outside by a switch on the lowest part of the windscreen.
The extinguisher is equipped with the mandatory anti-torpedo bracket bolted to the chassis.

Safety notes:
 Check the inner press bottle periodically. It has to be in the green area.
 Check periodically that the 9V inner battery is in good conditions.
 Do not forget to toggle ON the control box switch before sending the car into the track.

28

Downloaded from www.Manualslib.com manuals search engine

 4 SETTING ADJUSTMENTS

Standard set-up

Notes:
 Due to production issues, this recommended set up may differ from the car delivery set up. Audi
Sport recommends doing your own check.
 The use of ballast as fuel weight during set-up process is recommended to ensure the cross
weights.

29

Downloaded from www.Manualslib.com manuals search engine

 Steering rack centring

As the steering rack is electric, the steering angle sensor has to be electronically aligned with the wheels at
the aligning time.
Before aligning, it is necessary fix the steering wheel. To do it, it is recommended to use straps fixed between
the roll cage and the steering wheel.
The use of a rack centring stopper tool is not recommended because it is difficult to get the steering angle
sensor at 0 deg. The most important is to obtain the toe alignment with the sensor at 0 deg.
Proceed as following:
 Switch on main and ignition switches.
 Turn left and right to get the steer angle signal initialized.
 Fix the steering wheel when the steer angle is 0 deg.
 Switch off the ignition and main.
 Proceed now with the alignment jobs.
Note:
 With this process the steering angle signal will be 0 deg with the wheels aligned. This is very
important for the steering assistance behaviour.

Front camber and toe adjustments

The front suspension is very special on this car due its kinematic characteristics. To reach the front
suspension set-up value is recommended to proceed as following:
1. Car ride height: put the ride height at your choice through damper/spring adjustments.
2. Camber: to change the camber is recommended to move the steering rod first. The camber will
change quickly.
3. Toe: to change the toe enlarge or reduce the wishbone adjustment.
4. Check: adjust a second time if necessary.
Note:
 Although this process seems strange, it is the best and faster way to obtain the camber and toe
adjustments.
Underneath the front wishbone there is a bolt to control the adjustment movement. Unblock the four screws
that are fixing the camber regulator plate and proceed to the adjustment.

Notes:

 After any intervention, fix the wishbone regulator plate bolts in the right tighten.
 Maintain the wishbone regulation plate clean and oiled between plates.

Front regulation table:

30

Downloaded from www.Manualslib.com manuals search engine

 Wishbone regulation
Camber Toe regulation
1,5 turns = 10’ camber
-5.8° 9,5 turns 12 turns
-5,5° 7 turns 8,3 turns
-5° 3,5 turns 4,5 turns
-4,5° 0 0
-4° -3,5 turns -4 turns
-3,8° -6 turns -7 turns
Note:
 Take care with the maximum and minimum camber. Although physically the camber adjuster can
reach higher values, it is not recommended due the drive shaft limitations.

Rear camber and toe adjustments

To reach the rear suspension set-up value is recommended to proceed as following:

1. Car ride height: put the ride height at your choice through damper/spring adjustments.
2. Camber: to change the camber is recommended to move the boomerang arm.
3. Toe: to change the toe enlarge or reduce the rear arm.
4. Check: Adjust a second time if necessary.

Notes:
 The rear camber regulation does not have relation with the toe movement, so it is possible to
change rear camber without any toe movement.
 After the camber adjustment job, check that the ball-joint is placed in the middle of its housing.

Rear camber regulation table:

Camber Arm regulation

-2° 1,5 turns
-2,5° 1 turns
-3° 0,5 turns
-3,5° 0
-4° -0,5 turns
-4,5° -1 turns
-5° -1,5 turns

Suspension

To set-up the suspension, the following spring range can be used in both front and rear axles:

Springs Nm Remark
170-60-120 120 Front use recommended
170-60-110 (car delivery - front) 110 Front use recommended

31

Downloaded from www.Manualslib.com manuals search engine

 170-60-100 100 Rear use recommended
170-60-90 (car delivery - rear) 90 Rear use recommended

The dampers specifications are the following:

Front dampers
Aluminium outer housing Bilstein damper
2-way adjustable with 10 clicks in bump and 10 in rebound
110 mm travel
20 mm upright height regulation
20 mm bump stop (5000 N / 4 mm)

Rear dampers
Aluminium outer housing Bilstein damper
2-way adjustable with 10 clicks in bump and 10 in rebound
119 mm travel
35 mm bump stop (5000 N / 4 mm)

32

Downloaded from www.Manualslib.com manuals search engine

 Adjustment range of front dampers:

33

Downloaded from www.Manualslib.com manuals search engine

 Adjustment range of rear dampers:

Anti-roll bars

Front anti-roll bars available: 22x2 and 22x3. Car delivery: 22x3.

FRONT ARB
⌀ (mm) 22 22
Thickness (mm) 2,0 3,0
Chassis Roll Stiffness from ARB
Hard (Nm/°Chassis) 1548 2021
Mid (Nm/°Chassis) 991 1293
Soft (Nm/°Chassis) 688 898
Rear anti-roll bars available: 22x3 and 22x4. Car delivery: 22x3.

REAR ARB
⌀ (mm) 22 22
Thickness (mm) 3,0 4,0
Chassis Roll Stiffness from ARB
Hard (Nm/°Chassis) 1252 1454
Mid (Nm/°Chassis) 1061 1232
Soft (Nm/°Chassis) 898 1043

34

Downloaded from www.Manualslib.com manuals search engine

 Kinematics

Front Rear
Wheel ratio 1 mm wheel / 0,9 mm damper 1:1

FRONT

35

Downloaded from www.Manualslib.com manuals search engine

 REAR

36

Downloaded from www.Manualslib.com manuals search engine

 Brakes

To set-up the brakes, the following pumps can be used in both axles:

Master cylinder Push Rod Remarks

AP 15 mm PRT 110
AP 15.9 mm PRT 110
AP 16.8 mm PRT 110
AP 17.8 mm PRT 110
AP 19,1 mm PRT 110 Car delivery front
AP 20,6 mm PRT 110
AP 22,2 mm PRT 110 Car delivery rear
AP 23,8 mm PRT 110
Notes:
 It is not advisable to use more than two pump diameters difference between front and rear.
 If the master cylinders are replaced, take care on the correct installation and functioning of the
brake balance bar. The following link shows how to assembly correctly:
tiltonracing.com/wp-content/uploads/2013/07/98-1250-600-Series-Balance-Bars.pdf
On the dashboard screen it is shown the front/rear pressure and the balance percentage. The recommended
percentage is 60% front as in car delivery. The brake balance channel appearing on the display has been
calculated using the following formula:
P_BRK_FRONT
BRK_BALANCE = ∗ 100
P_BRK_FRONT + P_BRK_REAR
To adjust the brake balance it is recommended to set first the rear brake proportioning valve on position 7
(lever backwards), where it is fully open, and to ensure that the hand brake is not locked. After that, set the
desired balance turning the yellow wheel on the main console. Remember not to press the brake pedal while
turning the wheel.

The different positions and settings for each position of the proportioning valve can be seen on the next
pictures:

37

Downloaded from www.Manualslib.com manuals search engine

 Aerodynamics

It is strongly recommended checking periodically that all bodyworks and their fixations are in good conditions.

Rear wing:
 The rear wing has extensive regulation. Zero is the standard setting for the car.
 Wing angle -5° has considerable influence on the rear down force.
 Wing angle -10° has big influence on the rear down force as well as in drag.
 Lateral plates are individually adjustable.
Front splitter:
 Check periodically the fixations. It has to be in good conditions.
 Check the front splitter angle that has to be at 0° when pitch is 0°.
Pitch:
 Measure the pitch angle on the body shell over the door sill.

38

Downloaded from www.Manualslib.com manuals search engine

 Driving position

On the following chapter how to adjust the driving position is explained.

Seat
Audi Sport customer racing PS-3 FIA GT3 homologated safety seat
2 sizes available upon request: Standard and S size
3 seat to chassis brackets different in length available: 30, 60 and 80 mm. (car delivery)
6 different fixation points to the chassis

Belts and net

Schroth window net meeting latest FIA Standards
6-points OMP safety belts to be used with HANS
Following some instructions to adjust the belts for different drivers:
Option A: recommended for small drivers Option B: recommended for tall drivers

Notes:

39

Downloaded from www.Manualslib.com manuals search engine

  Check the homologation label expiry date.
 Check always that the belts and the driver are well fixed.

Steering column
Height and length adjustable
3 steering column hubs different in length available: 100, 120 and 140 mm (car delivery)
AIM MXG display bracket adjustable in 2 positions: high and low (car delivery)

Steering column
locking lever

Steering column
hub

AIM MXG adjustable bracket

Pedal box
Length adjustable in 5 position (car delivery - medium position)
Tilton racing pedal assembly with brake balance bar
90° foot stopper on throttle pedal right side

40

Downloaded from www.Manualslib.com manuals search engine

 Pedal box adjustment points

41

Downloaded from www.Manualslib.com manuals search engine

 5 WORKSHOP MAINTENANCE

First roll-out

Audi Sport checks all the cars in a roll-out before customer delivery. This roll-out consists in:
 5 circuit laps.
 High speed in a long straight.
 Start rev limiter checking simulating a standing start.
 Speed limiter function checking.
 After the roll-out, Audi Sport engineers check the data acquisition and all car functions.
Note:
 Although Audi Sport does a roll-out, it is strongly recommended to carry out a suspension check
before first customer roll-out and after the first practice. Pay speciall attention to sub-frame, power
train, engine brackets, fixations, etc.

Check-list

After any rebuild or main job is recommend to carry out a check-list. It is possible to do it using the Live
Measures view in RaceStudio3 and a lap top or directly using car’s display.

Check-list with engine stopped OK

Oil level On the dipstick mark / T_oil > 70⁰C
ENGINE
Coolant level On the bottle mark
BRAKES Brake fluid On the bottle mark
CLUTCH Clutch fluid On the bottle mark
Steering wheel functions OK
FCY
Cockpit fan
Display change
Safety brake signal
STEERING
High beam / Flash
WHEEL
Wiper
Windscreen water
Rain light
Starter
AIM Live Check-list with engine at idle speed OK
T_WATER 87°C / 92°C (thermostat cycle)
Fan Active at 92°C
P_ENG_OIL (WT<25°C) 4 bar
ENGINE P_ENG_OIL (WT>25°C) 2,5 bar
P_FUEL > 4,1 bar
Battery voltage > 13,5 volts
Boost pressure 0,3 bar @ 2500 rpm
Speed limiter Check all speed limits
Tip
Gear display
GEARBOX
Potentiometer values
P_CLUTCH
FLAG_FBX_1 0
FLAG_FBX_2 0
FUSEBOX FLAG_FBX_3 0
FLAG_FBX_4 0
FLAG_FBX_5 0

42

Downloaded from www.Manualslib.com manuals search engine

 Body-shell and engine identification

V.I.N. (Vehicle Identification Number) is welded on the roll cage.

Engine number
CJX-XXXXXX

Engine seals: boost, distribution and oil sump

43

Downloaded from www.Manualslib.com manuals search engine

 Fluids

Area Fluid Quantity

Engine RAVENOL VMP SAE 5W-30 5,7 l
Gearbox RAVENOL Racing gear oil 1,75 l
Clutch RAVENOL Racing brake fluid R325+ -
Drive shaft GKN grease 100 gr
RAVENOL LGC
Coolant 5l
VW AG G13 10% add./90% dist. water
Brake fluid RAVENOL Racing brake fluid R325+ -
Fuel Min 98 RON -
Windscreen Free -

Notes:
 Standard fuel minimum 98 RON from petrol stations may be used.
 Is recommended not to mixt fuels, they could contaminate one from the other.
 Gearbox is delivered with correct oil level. It is not necessary any level control if there is no leakage.

Engine

Control routine before start to run:

 Check the oil level: with oil temperature up to 70°C, stop the engine and wait 2 minutes, then check
the oil dipstick. The oil level must be at the top of the marked zone.
 Check the water level before start.
 With the engine running, check that there is not any oil, water or fuel leakage.
 Check the fan functionality. Operating range 92°C to 87°C.
Maintenance routine:
 Change the engine oil and oil filter at the indicated mileage.
 Engine spare parts must be from VW group or Audi Sport original parts, detailed on the Audi RS 3
LMS Spare Parts Catalogue.
 Use always the fluids detailed above, User Manual point 5.4.
 Clean and check the air filter at least once per event. At urban circuits, clean or replace it more
frequently. It is recommended to have two or three air filters and replacing it during the weekend.
Changing it is strongly recommended in case of rain.
 Check that the alternator belt is clean and that there are not small stones inside the Poly-V.
 Clean the radiator and intercooler panel often.
 If any doubt, contact Audi Sport technical assistance department.
 Check that the seals are in good conditions, if a replacement is needed contact Audi Sport.
Parts subject to frequent service:

Engine Torque Remarks

Oil drain plug By hand
Oil filter plastic cover 25 Nm
Oil filter Moisten the O-ring
Spark plug 28 Nm Use only original parts
For detailed parts substitution information download the Workshop Manual from Audi Sport website.

Air filter

Standard air filter cleaning procedure:

1. Remove the air filter from the car and plug opening to throttle body with a clean rag to stop any
crud getting where it shouldn't.

44

Downloaded from www.Manualslib.com manuals search engine

 2. Disassemble filter assembly by removing the four small screws at the bottom (intake side) of the
outer-body and pull out the filter element.
3. Tap the filter gently to dislodge the larger debris that have collected, do not use compressed air as
you could damage the paper elements.
4. Apply detergent to the filter. Squirt the fluid down the elements from the outside while holding the
filter at an angle over a bucket. Don't re-distribute the detergent that's collected in the bucket
through the filter again.
Once you covered the whole filter leave the filter to stand for ten minutes to allow the detergent to
break down the old oil in the filter.
5. Using another bucket rinse filter with cold water until no more debris collects appear at the bottom
of the bucket.
6. Pat your filter dry and place somewhere with good air flow and allow the filter to dry naturally. Do
not use compressed air or place in a very warm area as this could damage the filter element.
7. Once you have applied two coats of oil along both sides of the filter pleats, hold the filter and ensure
the filter is an even red colour.

8. Once it is evenly coated, leave it stand for 30 minutes. Carefully pat the excess off the filter with
paper towels.
9. Rebuild your filter taking care that the screw holes match up and fit it back in the car.

Parts subject to frequent service:

Air filter Torque Remarks

Substitution By hand Be careful tightening the small bolts over plastic
Cleaning Clean the cotton air filter following the procedure shown
above.
Do not use compressed air or high-pressure air to clean.
Use only recommended oil for cotton filters.

Notes:
 The air filter type and measurements are identified on the Technical Form. It is not allowed any
modification or change.
 A clean and properly oiled air filter is basic to ensure engine’s life. It is strongly recommended to
follow the cleaning procedure as well as the replacement frequency.
 After rain conditions use, it is strongly recommended the cleaning or replacement.

SADEV ST82-17 gearbox

Control routine before start:

 Check that there is no oil leakage.
 Operating range 70°C to 135°C. Do not load the engine until the temperature is above 70°C.
Routine maintenance:

45

Downloaded from www.Manualslib.com manuals search engine

  Change the gearbox oil and clean the filter at the indicated mileage. The oil must be the
recommended one. It can be done with the gearbox mounted on the car, use the following A and B
plugs to drain the oil and the C to fill it again.

 It is strongly recommended reading the SADEV ST82-17 Technical Manual on the Audi Sport
website.
 Make sure that the clutch pedal stopper stud exits 11,8 mm from its support.

11,8 mm

Potentiometer adjustment:
Using the display or the live measures label of the RaceStudio3 software with a lap top adjust the
potentiometer if any malfunction has been detected.
Potentiometer regulation table:

Acquisition channel Gear Value

R 572 mV
N 1100 mV
1 1630 mV
2 2160 mV
U_GCU_GEAR
3 2700 mV
4 3230 mV
5 3765 mV
6 4300 mV

Differential

The differential is a self-locking type, with 6 frictions faces on each side and pressure plates with ramps,
acting either for power or braking. The running clearance in the differential is 0.1±0.05mm.
The preload may be adjusted by tightening/untightening the preload nut (see the picture below).

46

Downloaded from www.Manualslib.com manuals search engine

 External preload adjustment process:
It is important to know that the lock nut must be pushed while turning (the tool must push the lock nut
completely straight in order to be able to move the nut all the necessary travel). Note that it is made by clicks
(20 clicks per revolution). Then, it is therefore to stop on a click to be sure of the good lock nut desired
position.
 It is not necessary to remove the left driveshaft.
 Lock the right driveshaft or wheel.
 Use the hex-head spanner of 8 mm in order to tighten/untighten the nut rounded on the previous
picture. Then you can adjust the preload:
o By turning clockwise in order to decrease the preload.
o By turning anti-clockwise in order to increase the preload.
Note:
 There is a second way to adjust the preload:
o Push the lock nut with the 8 mm hex-head spanner and hold it by hand.
o Turn the right wheel forward to increase the preload or backwards to decrease.
Preload checking process:

 Lock the left wheel using the driveshaft bolt spanner with a dynamometer.
 Turn the right wheel and check on the dynamometer the preload value.
Notes:
 Recommended preload range between 50 and 150 Nm. The cold measured preload is
approximately 15% higher than warm measure.
 Preload decreases from approximately 15% after first 50 kilometres of running.
 Different ramps are available on Audi RS 3 LMS SEQ Spare Parts Catalogue. Only the ramps
homologated on the Audi Sport RS 3 LMS SEQ Technical Form can be used: 60/30, 45/30 and
35/30.
 Different preload springs with a different working range are available on Audi RS 3 LMS SEQ Spare
Parts Catalogue.
 For detailed information see the SADEV ST82-17 Technical Manual on the Audi Sport website.

Fuel tank

The 100l FIA FT3 fuel tank is working with one unique fuel pump and a Venturi hoses system. The pump is
controlled through a PWM fuel control module.
Refuelling tool:
The fuel tank is served with a FIA approved fast coupling plug. The socket is the necessary connecting-tool
for refuelling the tank. This part is available on the Spare Parts Catalogue.

47

Downloaded from www.Manualslib.com manuals search engine

 Refuelling process:
1. Prepare an external bottle with the desired amount of fuel. It is recommended using a ground cable
on the bottle to avoid static electrical discharges.
2. Open the fuel tank cover, connect the refuelling hose with the socket to the fuel tank plug (#1 on
the picture below) and the fuel will flow inside.
3. Set the fuel level display with the fuel amount inside the tank. This value will be shown also on the
AIM MXG display. For more info about the fuel level display check point 3.5 above.
Fuel tank placed on the car:

1. Fuel tank refill plug 1 2

2. Fuel pump connector
3. Battery supply
4. Fuel level display 3

4
Fuel draining tools:
On the car there is a FIA fast coupling plug placed on the engine bay ready for safe draining use.

There are two tools available on the Spare Parts Catalogue. First, there is a contra-connector D-6 socket
available to connect in the fuel line plug that opens the circuit for draining.

48

Downloaded from www.Manualslib.com manuals search engine

 Secondly, Audi Sport has developed a new electronic tool to activate the fuel tank pump both manually or
with an automatic function.

Fuel draining process:

1. Connect the electronic tool on the fuel pump connector (#2 on the picture above), placed on the
fuel tank, and the power supply on the auxiliary battery connector (#3).
2. Connect the fuel socked connector on the engine bay.
3. Switch on the electric tool in automatic or manual mode. If the automatic mode is selected the tool
will stop the draining process when there is no more fuel inside the tank.
Flow fuel pump filter cleaning process:
1. Drain out the fuel tank completely.
2. Open the fuel tank right side cover (picture 1).
3. Raise a little bit the plate and disconnect the pipes and wirings.
4. Turn the fastening elements and pull up the pump from the reservoir (picture 2). Pull hard to
disconnect the black hoses from the main pump. Remember to clip them hard again when
mounting.
5. Remove the green mesh filter and clean it (picture 3).
In case you need to take out the reservoir, unclip the three green plastic brackets and pull-up the reservoir
(picture 4).
Picture 1 Picture 2

Picture 3 Picture 4

49

Downloaded from www.Manualslib.com manuals search engine

 Engine fuel filter replacing process:
The engine fuel filter is placed inside the fuel cell fixed to a bracket by a tie-wrap, the fuel pipes are connected
by fast couplings.
1. Drain out the fuel tank completely.
2. Open the right cover of the fuel tank.
3. Remove the fuel pump and the reservoir as explained above.
4. Cut the tie-wrap, disconnect the fuel pipes and take out the fuel filter.
5. Fix the new filter on the bracket, reconnect the fuel pipes, assemble the reservoir and close the fuel
tank again.

Airjacks

The Audi RS 3 LMS is provided with a three ⌀ 50mm Krontec airjack system. The connecting valve is placed
on the rear right side, inside the road car refuelling cover.

Airlance and car plug dismounted view:

50

Downloaded from www.Manualslib.com manuals search engine

 Airjack dismounted view:

Notes:
 Maximum air pressure is 30 bar.
 Inlet thread of the airlance is M16x1.5
 IMPORTANT: never work under a vehicle supported only by airjacks unless safety props are fitted.
 Jacks must be vertical during operation. Mounting brackets or clamps to be fitted to threaded
section of body only. Do not loosen or remove the adaptors.
 Do not use petrol or paraffin for cleaning the airjacks as this will damage the rubber seals. Use an
alcohol based cleaning fluid and silicone spray or silicone grease when internal lubrication is
necessary.

51

Downloaded from www.Manualslib.com manuals search engine

 6 PARTS MILEAGE

To check the car mileage, use the odometer available on the AIM MXG display. A reset can be done through the display menu or using RaceStudio3 on a laptop.

52

Downloaded from www.Manualslib.com manuals search engine

 53

Downloaded from www.Manualslib.com manuals search engine

 54

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine