The Manufacturing Strategy in São José dos Pinhais
The year 2015 marked a turning point in Audi's history in Brazil. Under the Inovar-Auto automotive
regime, which imposed 30 percentage point surcharges on the IPI (Industrialized Products Tax) for imported
vehicles outside the quota, nationalization became a matter of survival and competitiveness. Audi announced
a multi-million dollar investment to reactivate its assembly line within the Volkswagen industrial complex
in São José dos Pinhais, Paraná.
This move, however, was not just logistical. The engineering team at Audi do Brasil, in collaboration
with the headquarters in Ingolstadt, conducted an extensive testing and adaptation program to "tropicalize"
the A3 Sedan. The goal was to increase the vehicle's robustness to withstand the Brazilian road network,
notoriously more severe than the European one, and to adapt the powertrain for the use of ethanol.
The 1.4 TFSI Flex Engine: Global Pioneering
The national A3 Sedan debuted a global innovation for the brand: the first Audi engine with directly injected
Flex Fuel technology. Produced at the Volkswagen engine plant in São Carlos (SP), the 1.4 TFSI Flex engine
was heavily reworked compared to its Hungarian gasoline counterpart.
Engineering applied new materials to the valve seats and piston rings to resist the corrosiveness of
ethanol and increased the compression ratio to take advantage of this plant-based fuel's higher octane
rating. The high-pressure direct injection system (working above 200 bar) allowed ethanol to be sprayed
directly into the combustion chamber with such precision that it eliminated the need for any auxiliary cold
start system (like the old small gasoline tank or the heating lances in the manifold). The car started
instantly even in sub-zero temperatures.
The practical result was a notable leap in performance:
- Power: Increased from 122 hp to 150 hp (on both ethanol and gasoline).
- Torque: Rose to 25.5 kgfm, fully available from 1,500 rpm.
With this new heart, the national A3 Sedan 1.4 became much faster, reducing its 0 to 100 km/h time to
the 8.8-second range and reaching a top speed of 215 km/h, numbers that placed it far ahead of the naturally
aspirated mid-size sedans of the time.
The Great Technical Controversy: Gearbox and Suspension
Nationalization, although beneficial for the engine, brought alterations to the transmission and rear
suspension of the 1.4 versions that generated intense debates among purists and technical consumers. Audi
justified the changes based on durability and the Brazilian usage profile, although the reduction of
production costs is also an undeniable implicit factor.
The Transition from S-tronic to Tiptronic
In the versions equipped with the 1.4 Flex engine, Audi replaced the S-tronic dual-clutch gearbox
(DQ200) with the conventional 6-speed Tiptronic automatic gearbox (AQ250), supplied by Japanese company
Aisin.
- Technical Analysis of the Change: The dry dual-clutch DQ200 gearbox, while
brilliant in performance, had a history of sensitivity in heavy stop-and-go traffic, where the constant
coupling and uncoupling of the clutches could generate overheating and metallic noises. The Tiptronic
gearbox, with its hydraulic torque converter, eliminates direct mechanical friction on take-offs,
providing a smoother, "velvety," and more robust ride for the congested urban traffic of Brazilian
metropolises.
- The Market Verdict: Although it lost its sporty "bite" and lightning-fast
shifts, the Tiptronic proved to be indestructible and much simpler and cheaper to maintain, which today
adds value to these models in the used market as a rational and safe purchase.
The Rear Torsion Beam
The second structural alteration was the replacement of the Multilink rear suspension with a torsion
beam in the national 1.4 versions.
- Dynamic Implications: The torsion beam is a semi-independent system. When
one wheel goes over a pothole, part of the movement is transmitted to the other wheel through the
transverse beam. Theoretically, this reduces the tire's ability to maintain ideal camber in extreme
corners and decreases comfort on uneven surfaces.
- The Trade-off: To mitigate this and solve the European model's problem of
constant scraping on speed bumps, Audi raised the ride height of the national A3 by about 15mm. The
spring and shock absorber tuning was recalibrated to be softer and more progressive. In practice, for
95% of users, the car became more comfortable and "usable" in everyday Brazilian driving, absorbing
potholes better, even if it lost surgical precision on track days.
The Pinnacle of National Production: A3 Sedan 2.0 Ambition
In order not to alienate the enthusiast consumer who demanded the full technology, Audi launched the
national A3 Sedan 2.0 Ambition. This car represented the "state of the art" of local production, maintaining
the European chassis specifications.
Unlike the 1.4, the 2.0 Ambition was a completely different animal:
- Engine: 2.0 TFSI with 220 hp and 35.7 kgfm of torque (the same engine as
the Golf GTI Mk7).
- Gearbox: Retained the 6-speed S-tronic (DQ250). Unlike the 1.8's 7-speed
gearbox, this box features wet clutches, handling the high torque with extreme reliability and
maintaining shifting speed.
- Suspension: Retained the Multilink system at the rear, preserving the
sporty driving dynamics.
- Equipment: Introduced the "Open Sky" sunroof and the Audi Drive Select
system with driving modes.
This model, priced at the time around R$ 137,990, offered an unbeatable performance-to-cost ratio,
accelerating from 0 to 100 km/h in 6.9 seconds.
Evolution of Audi A3 Sedan Versions (2014-2020)
| Year/Model |
Origin |
Version |
Engine |
Power |
Gearbox |
Rear Suspension |
| 2014-2015 |
Hungary |
Attraction |
1.4 TFSI (G) |
122 hp |
S-tronic 7 (Dry) |
Multilink |
| 2014-2015 |
Hungary |
Ambition |
1.8 TFSI (G) |
180 hp |
S-tronic 7 (Dry) |
Multilink |
| 2016-2020 |
Brazil |
Attraction/Prestige |
1.4 TFSI (Flex) |
150 hp |
Tiptronic 6 |
Torsion Beam |
| 2016-2020 |
Brazil |
Ambiente/Prestige Plus |
1.4 TFSI (Flex) |
150 hp |
Tiptronic 6 |
Torsion Beam |
| 2016-2020 |
Brazil |
Ambition/Performance |
2.0 TFSI (G) |
220 hp |
S-tronic 6 (Wet) |
Multilink |