Signature series vehicles stasis engineering (28 pages)
Summary of Contents for Audi TT Coupé 207
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Service. The Audi TT Coupé Design and Function Self-Study Programme 207 For internal use only.
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The plant – the plants Ingolstadt plant The model series Audi A4 and Audi A3 are produced in Ingolstadt. A separate production line has been set up for the body in white of the Audi TT Coupé. The head office of Technical Development is also located in Ingol- stadt.
Contents Page A brief introduction to the TT ....4 Design needs no explanation Vehicle dimensions Vehicle identification Environmentally-friendly production Body ........9 Special features Vehicle safety .
Isle of Man - the only one of its kind in the world. The Audi TT is equally as unique as its legen- dary namesake. Engines As befits a sports car, the Audi TT is...
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There is no doubt that the real highlight of the Audi TT is its emotive design, both on the exterior and in the interior. The engineers at Audi had an ambitious development goal: to meet all functional and quality standards as well as the latest statutory requirements and Audi’s high standards of safety without com-...
A brief introduction to the TT Vehicle dimensions 1525 1507 (quattro 1503) 1764 1856 The “+ and –“ dimensions are refe- Track width rence values compared to the Audi A3 Front: +12 mm Rear: +12 mm Length: –111 mm + 8 mm quattro...
Vehicle identification AUDI HUNGARIA MOTOR KFT TRUZZZ8NZX1000301 1765 kg 1015 kg 850 kg Typ 8N T R U Z Z Z 8 N Z X 1 0 0 0 3 0 1 Key of manufacturing World manu- Part describing vehicle...
Most sheet-metal blanks are designed so as to minimise cutting waste after pressing. Recycling The recycling rate at Audi is now about 94% by weight. Metal cuttings from the press plant are used to manufacture small parts as far as Waste avoidance and reduction possible.
Body Special features Front bumper SSP207/74 The front bumper comprises two parts: the The guide profiles attached to the left and cover panel and a decorative grille. The bum- right wings ensure an even gap all round. per carrier is made of aluminium and bolted to A zero joint is created by attaching the bum- the side members by impact absorbing ele- per to the wing by means of threaded bolts as...
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Body Bonnet The bonnet is made of aluminium to save weight. SSP207/78 Tailgate The tailgate can only be opened from the interior by means of the switch in the central console or by radio-wave remote control. The tailgate does not have a lock cylinder or a handle.
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The door component carrier is made of alumi- nium and can be adjusted for length, height and inclination. The doors of the Audi TT Coupé are frameless and of two-piece construction. Additional side protection pads protect the The door panel is made of steel with a bolted pelvis area.
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In the case of a side impact, the serious accidents. strong cross members will also deform on the The Audi TT Coupé therefore complies with side of the body facing away from the impact the statutory crash requirements as well as to absorb some of the impact energy.
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B-pillar To absorb the load resulting from a side impact, the body structure is extremely rigid even though the B-pillar is not continuous. An additional transverse support extending from base of the B-pillar to the rear seat cross- member minimises cell deformation and the rate of intrusion into the side structure.
When the side airbag is tripped, the head and neck areas are thus provided with better pro- tection. In the Audi TT Coupé, the belt tensioners can be fired independently of the airbags depen- ding on how the trigger criteria are defined.
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For protection of the head, a padding is also integrated in the roof area. An additional deformation element has been welded onto the A-pillar. These measures have enabled Audi to comply with the new US head impact laws for the first time. SSP207/7 The rear seat has been approved as a Group 3 child seat (approx.
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Vehicle safety To minimise the risk of foot injuries in serious head-on collisions, the brake pedal is swung away from the foot area by means of a collap- sing support if severe deformation of the vehicle occurs. This function is determined by deformation of the engine bulkhead and is not dependent on operation of the brake pedal.
The hazard warning lights are activated automatically and the interior lighting is swit- ched on. The Audi TT Coupé is the first Audi to A restart function enables the engine to be be equipped with a fuel cut-off. restarted after an accident and it can be...
1.8-ltr. 5V turbocharged engine 132 kW AJQ Specifications Engine code: Type: 4-cylinder 5-valve four-stroke petrol engine with exhaust gas turbocharger Valve timing: Double overhead camshaft (DOHC) Displacement: 1781 cm Bore: 81 mm Stroke: 86.4 mm Compression ratio: 9.5 : 1 Torque: 235 Nm at 1950 - 4700 rpm...
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Drive units System overview – 1.8-ltr. 132 kW 5V turbocharged Sensors Hot-film air mass meter G70 Engine speed sender G28 Hall sender G40 Lambda probe G39 Throttle valve control unit J338 with angle sender G187 for throttle valve gear G186 Intake air temperature sender G42 Coolant temperature sender G2 and G62...
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Actuators Fuel pump relay J17 and fuel pump G6 Injection valves N30, N31, N32, Power output stage N122 and ignition coils N (1st cyl.), N128 (2nd cyl.), N158 (3rd cyl.) and N163 (4th cyl.) with integrated power output stage Solenoid valve for activated charcoal canister N80 Solenoid valve for charge pres- sure limitation N75...
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Function chart Turbocharged 1.8-ltr. 132 kW 5V engine Motronic ME 7.5 Components Auxiliary signals Battery Switch for cruise control system CAN-BUS H = Databus drive E227 Button for cruise control system CAN-BUS L = Brake light switch Clutch pedal switch Engine speed signal (out) Power steering (pressure switch) Fuel consumption signal (out)
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Drive units Charging Direction of travel 5V Turbo energised de-energised N249 SSP207/20 The turbocharging system comprises the follo- The result is an increase in power output for the wing components: same displacement and engine speed. – Exhaust emission turbocharger In the case of the 1.8-ltr. 5V turbocharged –...
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Charge pressure control J220 Waste gate valve 5V Turbo energised de-energised N249 SSP207/22 The engine control unit calculates the charge If the control fails, the maximum charge pres- pressure setpoint from the engine torque sure is limited to a basic charge pressure request.
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Drive units Air divert control in overrun Air recirculation valve (pneumatic) 5V Turbo energised de-energised N249 SSP207/23 When the throttle valve is closed, it produces As soon as the throttle valve is closed, the air a backpressure in the compressor circuit due recirculation valve briefly closes the compres- to the charge pressure still present.
1.8-ltr. 5V 165 kW APX turbocharged engine Specifications Engine code: Type: 4-cylinder 5-valve four-stroke-petrol engine with exhaust gas turbocharger Valve timing: Double overhead camshaft (DOHC) Displacement: 1781 cm Bore: 81 mm Stroke: 86.4 mm Compression ratio: 9 : 1 Rated output: 165 kW at 5900 rpm max.
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Drive units Extended system overview - 1.8-ltr. 165 kW 5V engine Lambda probe down- stream of catalytic con- verter G130 when EU III takes effect Motronic control unit J220 Secondary air pump motor V101 Secondary air pump relay J299 Secondary air injection valve N112 Heater for lambda probe SSP207/103 down-stream of catalytic...
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Extended function diagram - 1.8-ltr. 165 kW 5V engine J299 V101 G130 N112 λ J220 SSP207/27 As of series production launch, the 1.8-ltr. Legend G130 Lambda probe downstream of 165 kW engine will be equipped with extended catalytic converter when EU III comes system components to ensure it complies into effect with European exhaust emission standard...
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Drive units Quick-start sender wheel The quick-start sender wheel is attached to the On previous systems, it was not possible to initiate the first combustion cycle until a crank camshaft. It supplies a signal which enables the engine control unit to determine the posi- angle of approx.
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The control unit compares the phase sensor signal with the reference mark signal and thus ascertains the working cycle currently taking place in the cylinder. Low phase signal Compression cycle High phase signal Exhaust cycle SSP207/85 The signal which the engine speed sender G28 supplies enables the injection cycle to be initiated after a crank angle of approx.
Drive units Cooling circuit Coolant afterrun pump Coolant temperature sender G2/G62 Heating heat exchanger Exh. gas turbocharger Expansion tank Cylinder head Coolant pump Coolant regulator Oil cooler Coolant afterrun pump V51 Thermoswitch for radiator fan F18/F54 SSP207/37 Cooler The exhaust gas turbocharger is water-cooled The coolant afterrun pump protects the coo- and integrated in the cooling circuit.
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Coolant afterrun pump V51 SSP207/38 Function in vehicle with air conditioning The pump starts via radiator fan control unit The coolant afterrun pump V51 is atta- J293 when the ignition is turned “On“. A timer ched to the radiator fan housing. module integrated in the control unit J293 ensures that the pump V51 runs on for approx.
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flow through the exhaust gas the basic engine of the Audi TT Coupé turbocharger, it was necessary to accommo- developing 132 kW. date a second, parallel charge air cooler on the left-hand side of the vehicle.
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Vacuum box for charge Secondary air system pressure control valve Combi-valve 5V Turbo energised de-energised J299 V101 N122 J220 SSP207/21 The vacuum box for the charge pressure con- In the cold start phase, the exhaust trol valve is controlled in the cold start phase gases contain a high proportion of by the electro-pneumatic secondary air con- uncombusted hydrocarbons.
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Drive units Secondary air injection valve N112 The secondary air injection valve is an electro- pneumatic valve. It is switched by the Motro- nic control unit and controls the combi-valve. To open the combi-valve, the secondary air injection valve releases the intake manifold vacuum.
Subsystems of the Motronic Lambda control in EU III 165 kW Lambda control in the EU III An additional lambda probe (G130), which is located downstream of the catalytic converter, was integrated in the system to comply with EU III. Its purpose is to test the function of the catalytic converter.
Subsystems of the Motronic Torque-oriented engine management The Motronic ME 7.5 has a torque-ori- External and internal torque requests are co- ented functional structure. ordinated by the engine control unit, making The new electronic throttle control allowance for efficiency and implemented with function makes this possible.
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Torque-oriented functional structure In contrast to previously known systems, the All - internal and external - torque requests are ME 7.5 is not limited to the output of torque combined to form a nominal torque. variables to the networked control units (ABS, automatic gearbox).
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Subsystems of the Motronic Accelerator position senders G79 and G185 The accelerator position sender transmits the The accelerator position sender transmits to driver inputs to the Motronic. the Motronic an analogue signal correspon- ding to the accelerator pedal position. To ensure the functional reliability of the electro- nic throttle control, the accelerator position sender has two independent potentiometers...
Electrically actuated throttle valve (electronic throttle control function) With Motronic ME 7.5, there is no longer a The engine control unit positions the throttle mechanical throttle control cable between the valve via an electric motor. The engine control accelerator pedal and throttle valve. This has unit is provided with continuous feedback on been replaced by an electronic control unit the throttle valve position.
Different fuel tanks are used in the front-wheel The filler neck cannot be separa- drive and quattro versions of the Audi TT. ted from the fuel tank. Both fuel tanks are made of plastic and have a capacity of 55 ltr.
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Gravity float valves for vehicles with front- wheel drive and quattro power train Filler expansion cham- Main expansion chamber to ACF system SSP207/117 The gravity float valve prevents fuel from The filler expansion chamber as well as the entering into the ACF system when cornering main expansion chamber are combined at the at high speed or if the vehicle rolls over.
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Fuel system Fuel tank for front-wheel drive version Air vent valve Gravity float valve Filler expansion chamber Filler neck Main expan- sion chamber to activated charcoal filter Filler breather Main breather SSP207/118 When refuelling the fuel tank, the gas mixture The vapours are conveyed to the activated is conveyed via the filler breather directly into charcoal filter via the closed filler neck, the...
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The fuel is transferred to the engine by a high- performance fuel pump with a pressure increase from 3 to 4 bar. In the event of a crash, the fuel pump is swit- ched off by the fuel pump relay. A single-stage fuel pump is used in vehicles with front-wheel drive.
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Fuel system Fuel tank for quattro vehicles The breather system is designed in the same way as for front-wheel drive vehicles. Air vent valve Filler expansion chamber Gravity float valve Main expansion chamber Filler neck Main breather Filler breather SSP207/120 Located in the quattro fuel tank on the left- hand side is a suction jet pump which pumps the fuel from the left-hand fuel tank part upst-...
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SSP207/121 The suction jet pump is driven by the two- The fuel lines and left-hand tank sender are stage fuel pump. connected to the baffle housing in the tank. The suction jet pump can only be removed after de-taching the fuel lines and tank sender from the baffle housing.
Power transmission Three gearbox variants are used for power transmission: 132 kW 5-speed front-wheel drive 2-shaft gearbox 02J.N 5-speed quattro drive 02M.3 3-shaft gearbox 165 kW 6-speed quattro drive 02M.1 Technical features of the gearboxes 5-speed manual gearbox The 5-speed and 6-speed quattro gearboxes are identical as regards their design, whereby Compared to the standard version (A3), the 5- the change gear for 6th gear in the 5-speed...
6-speed manual gearbox 3 shafts The triple-shaft design permits a space-saving The use of magnesium as a housing material and highly compact design. results in a weight reduction of 30% due to its lower density (aluminium has a density of A distinction is made between two gearbox 2.695 g/cm and magnesium has a density of...
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Power transmission 3-shaft gearbox MQ 350 in 6-speed version Reverse gear 2nd drive shaft Gears 5-6 1st drive shaft Engine drive Gears 1-4 Spur gear SSP207/122 The spur gear is riveted to the differen- For more detailed information on the manual tial.
Power transmission Haldex viscous coupling The four-wheel power train used in the Audi TT Coupé quattro is a logical progression on the proven four-wheel drive concept. A new feature of the power train is the slip- dependent force distribution control on both axles by means of a Haldex viscous coupling.
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The system configuration Plate coupling Coupling output end (rear axle differential input) Piston of SSP207/11 Working piston Input end annular piston pump (propshaft) The Haldex viscous coupling is accommoda- The housing is filled with oil and hermetically ted in a closed housing and mounted in front sealed against the atmosphere.
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Power transmission The hydraulics Working piston Plate set Two parallel annular piston pumps Pre-pressurising pump Input Output Cam disc Oil filling Safety valve Control valve SSP207/12 Torque is transmitted to the rear axle drive by In the event of a breakdown, this means that means of the plate coupling .
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The control system Low coefficient of friction Wheel speed front right > front left Wheel speed rear right > rear left Engine control unit Haldex control unit Haldex viscous coupling ABS/EDL hydraulic unit SSP207/10 Motive force, front Motive force, rear High coefficient of friction ABS/EDL control unit The Haldex viscous coupling does not have...
Running gear Steering The safety steering column is adjustable for rake and reach as standard. SSP207/2 The maintenance-free rack and pinion steering The vibration-optimised attachment of the gear is power-assisted. The steering gear steering column to the dash panel cross-mem- stroke is transmitted directly to the swivel bea- ber keeps the steering wheel free of undesira- ring due to the fact that the track rods are opti-...
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Pressure switch for power steering The pressure switch for power steering is located on the vane pump. It informs the engine control unit when the vane pump is subjected to a load. The vane pump is driven by the engine by means of a the ribbed V-belt.
Running gear Front axle To enhance track stability, newly developed Incorporating double wishbones, subframe cast steel-swivel bearing with modified track and transverse anti-roll bar, the McPherson rod attachments as well as a new forged strut axle is designed as a sports suspension. cross-member are used.
Rear axle Front-wheel drive Torsion beam axle with anti-roll bar Wheel housing support Wheel bearing Double ball bearing requiring no adjustment 25° Positioning inclined 25 25° SSP207/115 – Track width: 1507 mm The shock absorbers are supported in the wheel housing and the coil springs are sup- –...
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Running gear Rear axle Quattro drive Dual link trailing arm axle (DLTA) with Haldex viscous coupling Damper Anti-roll bar Subframe Rubber bea- Haldex viscous Trailing arm ring coupling Trailing link SSP207/4 – The dual link trailing arm axle is fixed via New tool for mounting rear wheel bea- the subframe (4-point attachment) and rings.
Brake system 132 kW 165 kW Diagonal-split dual circuit brake system Anti-lock Braking System (ABS) with elec- tronic brake force distribution (EBFD) Traction Control System (TCS) Disc brakes at front and rear Ventilated at front Ventilated at front and rear Brake servo 10“...
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Running gear Anti-lock Braking System ABS ITT/Mark 20 IE K14/33 J104 SSP207/31 For a brief description of the Brake circuit Output signals components, please refer to function diagram Brake circuit Input signals The basis of the ABS system is a dual-circuit The EBPD is entirely software-supported and brake system.
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Electronic stability brake system - ESBS The electronic stability brake system improves It utilises the sensors and actuators of the ABS the track stability and steerability of braked system. ESBS is a software development in the ITT vehicles by applying each brake as required. Mark 20 IE control unit.
Electrics The vehicle electrical system The electrical/electronic connector stations as well as the necessary control units are decen- tralised to meet the requirements. Lateral acceleration sen- Socket (power windows, This ensures an optimum wiring configura- sor, passenger’s side radio, CLS-ATA light, mirror tion.
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Telephone operating electronics control unit Control unit for headlight J412 range control J431 Central locking control unit J429 Control unit for navigation system and CD J401 Lateral acceleration sen- sor, driver’s side c r o Socket (power windows, loudspeaker, radio, central locking, anti-theft alarm) Fuse carrier SSP207/112...
Electrics Interior monitoring The vehicle interior is monitored by an ultra- The system is safeguarded against false alarms, e.g.: sonic monitoring system. It gives the alarm audibly via the horn of the – knocking on the roof of the vehicle or against the window anti-theft warning system and visually via the hazard warning lights.
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Functional description The sensor unit comprises a sender, a receiver and the evaluation electronics. The sensor unit is located behind the interior lighting in the vehicle headliner. In its activated state, the transmitter module sends out sound waves at a frequency of 40 kHz (imperceptible to the human ear) and receives the echo a short time later via the SSP207/69...
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The 3rd generation immobiliser differs from the previous immobiliser in the following the 3rd generation and will be gradually pha- sed into the Audi TT. It prevents the vehicle respects: from being operated by unauthorised persons –...
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Functional description After turning on the ignition, the key transpon- The engine control unit has a set of equations. der sends the fixed code to the immobiliser It is also stored in the immobiliser control unit, control unit. If this is identified as correct, a according to which the variable code is con- variable code is generated in the immobiliser verted into a secret code.
Electrics Immobiliser III Communication Immobiliser control unit Transponder (key ) °C Communication via single lines Ignition On Power supply Fixed code If fixed code is OK Same fixed code storage locations as in immobiliser II Generate variable code Variable code Calculate according to Calculate according to equation set A...
Electrics Sound system Fitting locations for radio, Bose amplifier, 6- disc CD changer, loudspeaker, aerial and car phone system: Telephone operating electronics control unit J412 (on the rear floorpan assembly) Car phone aerial Rear window radio aerial Bose subwoofer 9 Rear loudspea- Aerial amplifier ker (Bose)
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The Audi TT Coupé has been prepared for the The door loudspeakers of the audio system Chorus and Concert radio series which are are also used by the navigation system and already featured in the A6. the hands-free car phone.
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Electrics Chorus/Concert and Concert audio systems with optional equipment Window aerial amplifier Door, front left tweeter/subwoofer Door, front right tweeter/subwoofer Rear left Active tweeter/subwoofer Rear right Passive Radio Tweeter/subwoofer CD player Car phone Optional equipment Navigation Legend Navigation Car phone Car phone announcements are played back In connection with the navigation system, the via the front-left door loudspeaker.
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Concert with Bose amplifier audio system and optional equipment Window aerial amplifier Door, front left tweeter/subwoofer Door, front right tweeter/subwoofer Bose Rear right amplifier subwoofer Rear left Radio subwoofer Central loudspeaker Car phone Optional equipment Navigation Optional equipment 6-disc CD changer Audi concert Scan MODE BASS...
The fully automatic air conditioning system Press the “Defroster“ button, and the air recir- operates according to Audi’s tried and tested culation mode will be disabled automatically. principle. The sensors and actuators provide automatic temperature and air flow rate con- trol.
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Air conditioner Air flow flap Fresh air/air recirculation flap J126 SSP207/34 G192 This overview shows the component parts of the heater: Fresh air intake duct temp. sensor The air conditioner may only be remo- ved after evacuating the coolant cir- G192 Footwell vent temp.
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Heating/air conditioning system Sensors Photosensor for sun G107 Dash panel temperature Operating unit for air sensor G56 conditioning system E87 with blower for temperature sensor V42 not replaceable Ambient temperature sen- sor G17 Fresh air intake duct tempe- rature sensor G89 Footwell vent temp.
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Actuators Actuating motor for defroster flap in footwell V85 with potentiometer G114 Control motor for central flap V70 with potentiometer G112 Control motor for temperature flap V68 with potentiometer G92 Positioning motor for air flow flap V71 with potentiometer G113 Fresh air blower V2 with blower control unit J126 Auxiliary signals:...
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Heating/air conditioning system Air distribution Fresh air Dash panel outlets left - right - centre Air recirculation Defrost SSP207/39 Footwell...
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Ventilation control In fresh air mode, the air flow flap is closed depending on the selected fresh air blower motor speed and vehicle road speed. Fresh air ventilation produced at high engine speeds is kept at an almost constant value by controlling the closing of the air flow flap.
Heating/air conditioning system Expansion valve The expansion valve is located directly in front of the evaporator between the high pres- sure and low pressure sides of the refrigerant circuit. Gas-filled thermostatic valve element to compressor from evaporator Diaphragm Push rod Pressure equalisation bores to evaporator...
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The temperature at the evaporator outlet is higher due to the cooling load increase. Pressure rise (P ) of the gas filling in the thermostatic valve element. SSP207/49 The cross-section of the ball valve is enlarged via the diaphragms and push rod.
flexible service inter- If the remaining distance until the next service val indicator in the Audi TT Coupé. By compa- rison with fixed maintenance intervals, the is less than 2,000 km or if a year has elapsed, a message appears on the combi-display every flexible service interval indicator will enable...
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Signal waveform and evaluation Oil level The electronically controlled measuring ele- The oil level in mm can be calculated from the ment is heated up slightly for a short period of cooling-down period during the cooling-down time as a function of the momentary oil tem- phase by means of a sensor equation.
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Service Specifications of the Audi TT 1.8 T 1.8 T quattro (132 kW) (165 kW) Engine/electrics Engine code AJQ (EU II + 3D standard) APX (EU 3D standard) Engine type In-line 4-cylinder, four-stroke petrol engine, exhaust gas turbocharger Five valves per cylinder; double overhead camshafts (DOHC)
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1.8 T 1.8 T quattro (132 kW) (165 kW) Steering Power-assisted, maintenance-free rack and pinion steering system, track-stabilising kingpin offset No. of steering wheel 2.79 revolutions lock to lock Steering ratio 15.67 Turning circle 10.45 Brake system, front/ Diagonal-split dual circuit hydraulic Diagonal-split dual circuit hydraulic rear brake system, anti-lock braking...
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Service 1.8 T 1.8 T quattro (132 kW) (165 kW) Length of luggage com- 1397 1360 partment with rear seat folded down Height of luggage comp. Luggage compartment vol. 272/547 218/493 Vert. headroom, 49/-87 front/rear Max. seating height, 959/828 front/rear Elbow room, front/rear 1412/1221 Weights...
Special tools Order No. T10027 SSP207/127 Wheel bearing puller for quattro rear axle comprises: Order No. Sleeve T10030/1 Tube T10030/2 Spindle T10030/3 Thrust piece T10030/4 Cross piece T10030/5 Tube T10030/6 SSP207/128 Adapter Order No. T10031 SSP207/134...
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Service Socket Order No. T10035 SSP207/130 Attachment for SW 3300A (front-wheel drive vehicles only) Order No. T10036 SSP207/131 Additinal tool for set V.A.G 1459B Thrust piece VAS 5146 SSP207/132 Spring retainer (in preparation) + Gear wneel...
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By reading this Self-Study Programme, you will have now familiarised yourself with the technical innovations of the new Audi TT. The appearance of this SSP is in accordance with the CI for Audi’s own Self- Study Programmes. The section on Service provided you with information regarding new special tools and service highlights, among other things.
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All rights reserved. AUDI AG Department I/VK-5 D-85045 Ingolstadt Fax +49 841/89-6367 840.2810.26.20 Technical Status 06/98 Printed in Germany...
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