Audi TT Coupé ´07 383 Service
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Audi TT Coupé ´07 383 Service

Audi TT Coupé ´07 383 Service

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Service Training
Audi TT Coupé ´07 - Body
Self-Study Programme 383

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Summary of Contents for Audi TT Coupé ´07 383

  • Page 1 Service Training Audi TT Coupé ´07 - Body Self-Study Programme 383...
  • Page 2 With a weight advantage of 48 % over a comparable all-steel bodyshell, in addition to an optimised weight distribution, the new composite aluminium-steel spaceframe body of the Audi TT marks yet another mile- stone in the development of modern Audi bodyshells.

  • Page 3: Table Of Contents

    Contents Audi Space Frame of the Audi TT Dimensions ............4 Technological concept .

  • Page 4: Audi Space Frame Of The Audi Tt

    Audi Space Frame of the Audi TT Dimensions 383_002 Audi TT Coupé ’ 07 3,2 quattro Transmission Manual gearbox S tronic Manual gearbox S tronic Kerb weight without driver in kg 1260 1280 1410 1430 Max. perm. gross weight in kg...

  • Page 5: Technological Concept

    Sheet-steel parts are used for the first time in the Although the new TT has grown in size, the gross ASF of the new Audi TT in addition to aluminium weight of the vehicle has been reduced through the castings, aluminium extruded sections and alumin- use of the aluminium-steel bodyshell.

  • Page 6: Contact Corrosion

    Contact corrosion 383_004 383_005 Schematic of contact corrosion with example In the case of the Audi TT, the following anti-corro- Contact corrosion can only be prevented by taking sion measures have been taken: measures to stop the flow of electrical current induced by the potential difference between –...

  • Page 7: Combination Of Steel And Aluminium

    One of the challenges for the development of the Thermal joining processes such as MIG welding can Audi TT bodyshell was the attachment of the sheet- be ruled out because it is not possible by these steel rear-end parts to the aluminium body assem- means to make a joint which has the requisite struc- blies.
  • Page 8 Audi TT.In aluminium-steel joints, therefore, highest standards this way, the mating materials are superficially insu-...
  • Page 9 This illustration shows clearly what effects contact The aluminium sheet shown here exhibits severe corrosion can have if adequate corrosion protection contact corrosion, which has resulted in mechanical is not provided. A this joint, the flange was sealed in failure of the punch riveted joint. the bodyshell without using adhesive.

  • Page 10: Comparison Of Asf Concepts

    Audi Space Frame of the Audi TT Comparison of ASF concepts ➔ Audi A8 (2003 Aluminium extruded sections Sheet aluminium parts Aluminium castings 383_013 383_014 383_017 Sill section Audi A8 A-post, Audi A8 Three-chamber extruded section Single-chamber extruded section...
  • Page 11 ➔ Audi TT (2006 Aluminium extruded sections Sheet aluminium parts Aluminium castings Sheet-steel parts 383_009 383_016 383_015 A-post, Audi TT Sill section, Audi TT Sheet-aluminium sections (interior/exterior) Four-chamber extruded section...

  • Page 12: Joining Techniques And Production Processes

    In addition to well-known processes such as MIG welding or punch riveting, the joining techniques of Flow Drill screwing and Kerb-taper riveting are used for the first time on the Audi TT. In the production process, a laser cleaning method is used for cleaning before the roof drip moulding is attached by welding.

  • Page 13: Punch Riveting

    Punch riveting Punch riveting is one of the principal joining techniques used on the bodyshell of the new Audi TT. This tech- nique is used for joining aluminium body parts and for joining aluminium body parts to steel body parts.

  • Page 14: Mig Welding

    Joining techniques and production processes MIG welding Aluminium parts have largely been joined by means of metal inert gas welding since the launch of the Audi aluminium bodyshell in the Audi A8 (1994) . This technique is principally used to make joints between castings and extruded sections, as well as sheet-metal parts.

  • Page 15: Structural Bonding

    Structural bonding In certain areas, adhesive bonding is used supplementary to clinched joints and punch riveted joints, solid punch riveted joints, Flow Drill screw connections and resistance spot welds. This improves joint strength. Adhesive bonding is also used for strengthening of seam joints, e.g. in the rear wheel arch. In other areas of the body, adhesive beads are used for sealing and insulation between aluminium and steel sheets, as well as for noise reduction.

  • Page 16: New Joining Technique: Solid Punch Riveting (Kerb-Konus Riveting)

    Joining techniques and production processes New joining technique: solid punch riveting (Kerb-Konus riveting) Solid punch riveting or Kerb-Konus riveting involves the use of aluminium or coated stainless steel rivets. In contrast to punch riveting, the rivet is punched through both sheets to be joined. Unlike steel rivets, aluminium solid punch rivets can be reworked mechanically.

  • Page 17: New Joining Technique: Flow Drill Screwing

    New joining technique: Flow Drill screwing Automatic direct screwing enables joints to be made between any materials, even if these materials can be accessed from one side only. A special coated screw is driven under high surface pressure through a hole in the outer part to be joined.

  • Page 18: New Joining Technique: Aluminium Laser Welding

    (invisible roof seam) Laser welding has been used for joining aluminium body parts since the launch of the Audi A2. In most cases, sheet-metal parts are welded onto castings or extruded parts. The invisible joint in the roof area is joined using a new joining technique: laser welding.
  • Page 19 To ensure consistent laser welding of aluminium parts, the parts to be welded must have a perfectly clean sur- face. This is achieved either by washing the component parts followed by chemical pickling or by using the new Laser Clean process. A controlled laser beam removes all residues from the surface by heating it for a short time.

  • Page 20: Repair Concept

    The repair concept for the all-aluminium body parts If the vehicle structure is damaged, beam 1 can also is similar to that for the repair of previous Audi alu- be replaced by undoing the screw connection. All fur- minium-bodied vehicles.
  • Page 21 The four-chamber extruded section is located A dual-chamber genuine part developed specially beneath the sill moulding.A special repair method for this repair solution is welded to the remainder of was developed for damaged outer chambers. When the sill profile using a continuous MIG weld seam at repair work is needed, the extruded section is split the top and bottom.

  • Page 22: Steel Repairs

    Repair concept Steel repairs The rear end of the Audi TT is only area where it is This also applies to painted aluminium parts! Red possible to carry out repair work involving only steel hot steel parts can damage the paintwork and steel...

  • Page 23: Aluminium-Steel Repairs

    Aluminium-steel repairs In the case of body side or rear-end damage, both Two-component car body adhesive DA 001 730 A1 aluminium and steel body parts may become dam- and rivets or screws are used for joining. As in aged. This is the case, for example, when the body series production, an insulating layer is placed side section (aluminium) and rear wheel arch (steel) between the two materials to prevent contact corro-...

  • Page 24: Workshop Equipment

    Aluminium inert gas welder VAS 6388 Aluminium inert gas welder V.A.G 2001B There are now two appliances with modern control systems which are ideal for welding work on the Audi aluminium body. The welding appliances, when used properly, pro- Reference duce perfect aluminium welded joints which have optimum strength.

  • Page 25: Qualification Of Aluminium

    Occupant protection, airbags and belt ten- sioners BS 310 Selective use of technical information BS 360 Vehicle diagnosis, testing and information system VAS 5051 383_049 Reference For further information on the qualifications in aluminium technology, refer to the Audi Service Net.

  • Page 26: Head-On Collision, Side Impact And Rear Collision

    Car body safety concept Head-on collision, side impact and rear collision Likewise, in terms of crash safety, the new TT makes The simulation provides information on the collision no compromises. The front beams consist of alu- behaviour of the body structure at a very early stage minium extruded sections and aluminium castings.
  • Page 27 To check the theoretical results and to meet statu- Various test conditions are simulated on the basis of tory requirements, actual tests are conducted. the applicable standard. 383_041 Euro NCAP head-on collision (64 kph with partial overlap) 383_042 Euro NCAP side impact (50 kph) 383_043 ECE and Japan rear collision (50 kph)

  • Page 28: Pedestrian Safety

    Various measures were implemented in the new attached to a stable design which yields to absorb head impacts. This is achieved by the honeycomb- Audi TT in order to meet the safety requirements. like structure of the car body inner panelling. 383_034...
  • Page 29 The development tools "Simulation" and "Testing" were used for design. Headform (head impact) Lower legform (leg impact) 383_035 Head impact To test the head impact a hemisphere which repre- sents the head is catapulted onto the bonnet. The relevant physical variables are determined, on the basis of which conclusions are drawn regarding impact loads.

  • Page 30: Electromechanical Rear Spoiler

    Electromechanical rear spoiler The new Audi TT has as standard an electrically The unit consisting of the rear spoiler module and extendable rear spoiler. The extended rear spoiler the spoiler wing is integrated in the boot lid of the significantly increases driving stability at high Audi TT.
  • Page 31 – Engine – Suspension system – Electrical system – Air conditioning – Infotainment Order number: A06.5S00.25.20 SSP 381 Audi TT Coupé ‘07 - Suspension System – Front axle – Rear axle – Shock absorber system – Brake system Order number: A06.5S00.26.20 SSP 382 Audi TT Coupé...
  • Page 32 Vorsprung durch Technik www.audi.de All rights reserved. Technical specifications subject to change without notice. Copyright AUDI AG I/VK-35 Service.training@audi.de Fax +49-841/89-36367 AUDI AG D-85045 Ingolstadt Technical status: 05/06 Printed in Germany A06.5S00.28.20...

This manual is also suitable for:

2007 tt coupe

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