Audi Service Training The Audi Tt Coup
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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.
Special trucks were developed for transferring the body-
shells to Györ for final assembly.
High-tech from Györ
Qualified specialists and a good infrastructure are key factors for the
Audi production shop in Györ.
Audi has been manufacturing four-cylinder 5V, V6 and V8 engines
here since 1997. Final assembly of the TT has also been taking place
here since 1998.
Axle and steering geometry measurement 100% reliability is ensured through a series of systema-
tic checks integrated in the production process.
Watertightness test
Functional tests are an integral part of the production
process
Mounted parts are tested for accuracy of fit, build quality
and functionality after each stage of assembly.
Quality that is measurable
After final assembly, extensive tests and adjustments
Electrical function test are carried out on every single Audi.
Roller dynamometer
Exhaust emission test and optimal setup
Acoustic test bench
2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Occupant protection
Fuel cut-off
Drive units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Engine and gearbox combinations
1.8-ltr. 132 kW 5V turbocharged engine AJQ
1.8-ltr. 165 kW 5V turbocharged engine APX
Subsystems of the Motronic . . . . . . . . . . . . . . . . . . . 37
Lambda control in the EUIII
Torque-oriented engine management
Accelerator position sender
Electrically-activated throttle valve
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5-speed manual gearbox
6-speed manual gearbox
Haldex viscous coupling
Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Steering
Front axle
Rear axle
Brake system
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Vehicle electrical system
Interior monitoring
Immobiliser
Sound system
Heating/air conditioning system . . . . . . . . . . . . . . . . 76
Overview
Expansion valve
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Flexible service interval indicator
Oil level sensor
Specifications
Special tools
New. Important.
Note.
The Self-Study Programme provides you with information
regarding design and function.
The Self-Study Programme is not a Workshop Manual.
Please refer to the Service Literature for all the relevant
maintenance and repair instructions.
3
A brief introduction to the TT
Design needs no explanation The interior styling matches the exterior per-
fectly - a fact reflected in the features of the
The name alone suggests that this is an Audi dash panel, the styling of the instruments, the
with a difference. The Audi TT was named air nozzles and controls.
after the legendary Tourist Trophy race on the The styling of some parts has also been influ-
Isle of Man - the only one of its kind in the enced by the use of aluminium.
world.
The Audi TT is equally as unique as its legen-
dary namesake.
Engines
As befits a sports car, the Audi TT is
powered by a four-cylinder 5-valve
turbocharged engine developing
180 bhp with a sports gearbox in
the front-wheel drive and quattro
versions. A four-cylinder 5-valve
turbocharged engine
developing 225 bhp is
available for the
quattro version.
Running gear
The running gear also underscores Audi’s
total commitment to the sports car concept.
The front axle kinematics were revised with
regard to steering quality and response.
This, in combination with the Audi TT’s sporty, The basic version is equipped with 16-inch
stiff suspension tuning, ensures excellent wheels shod with size 205/55 R 16 tyres.
handling and a high standard of driving safety. A 17-inch suspension is standard with the
quattro and available as optional equipment
for all other engine variants.
4
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-
promising the design concept and while retai-
ning the car’s full viability for everyday use.
Quattro power train
The TT will feature a new generation of Audi
technology and the new Haldex viscous cou-
pling, further emphasising the vehicle’s sporty
character.
SSP207/1
Safety Design
Safety is paramount: We at Audi firmly believe that the most
That’s why the TT is equipped with front air- important thing about designing is that
bags for the driver and front passenger. actions speak louder than words. Suffice to
The TT already complies with the new Euro- say, a good design speaks for itself.
pean safety laws which will come into effect in The TT has a “wheel-hugging” design, that is
the year 2003 as well as the tougher require- to say the entire body is styled around the
ments according to the US Head Impact Pro- wheels. That also goes for the front and rear
tection Act. bulges as well as the roof and window lines
and the low-slung passenger cabin.
5
A brief introduction to the TT
Vehicle dimensions
1354
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
Width: +45 mm Wheelbase: –93 mm
Height: –69 mm –85 mm quattro
828
959
762
876 2419 (quattro 2427) 746
(quattro 738)
4041
1209
950
1412
1221
900
6
Vehicle identification
AUDI HUNGARIA MOTOR KFT
2111008
1
1000
TRUZZZ8NZX1000301
1765 kg
kg
1- 1015 kg
2- 850 kg
Typ 8N
TRUZZZ8NZX1000301
* *
Key of manufacturing World manu- Part describing vehicle Part identifying vehicle
plants within the Group facturing code
in digit position 11:
A Ingolstadt Filler Model year, alphanumeric as prescri-
N Neckarsulm constant = Z bed by law
1 Györ Digits 1 + 2 vehicle Manufacturing plant within
X Poznan class. acc. to struc- the Group (as at 04/94)
K Karmann/Rheine ture table
Serial No. beginning
with:
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Audi Hungaria Motor Kft:
TT/TTS * T R U Z Z Z 8 N Z X 1 0 0 0 0 0 1
Audi AG:
A3 * W A U Z Z Z 8 L Z X A 0 0 0 0 0 1
A4 * W A U Z Z Z 8 D Z X A 0 0 0 0 0 1
A6 (incl. SKD Poland) * W A U Z Z Z 4 B Z X N/X 0 0 0 0 0 1
A8 * W A U Z Z Z 4 D Z X N 0 0 0 0 0 1
Cabrio * W A U Z Z Z 8 G Z X K 0 0 0 0 0 1
Audi 100 (C3, CKD) * W A U Z Z Z 4 4 Z X A 0 0 0 0 0 1
* Vehicles to US specification
(USA, Canada, Saudi Arabia, tourists)
On the VIN (behind the windscreen), the certification label and on official documents, the fillers (Z) are repla-
ced by a vehicle code (digits 4-8) or by a test mark (digit 9). This (18-digit) number is the official vehicle identi-
fication No. (VIN) in the countries listed above.
7
A brief introduction to the TT
Environmentally-friendly
production
Produce locally - think global:
Environmental protection is firmly rooted in
Audi’s corporate strategy. During the vehicle Audi lays great store by waste avoidance,
development process, all environmental crite- reduction and recycling.
ria are incorporated into the product and pro-
– Almost all production resources and
duction concept from the outset. Economic
supplied parts are delivered in re-usable
goals and ecological needs are balanced so
packaging.
that no conflicts of aims arise.
– 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
Waste avoidance and reduction are used to manufacture small parts as far as
possible. The resulting scrap is returned to the
From 1998 onwards, Audi will use only water- steelworks, where steel and zinc are separated
soluble paints in a effort to make its produc- from one another.
tion process more environmentally-friendly.
This step will see a dramatic reduction in sol- Other waste materials such as paper, card-
vent emissions. Today’s fillers and base coats, board, timber, polystyrene, etc. are collected
for example, contain up to 45% solvent. By separately and fully recycled .
comparison, the solvent content in water-solu-
ble systems is only about 6%.
8
Audi Service Training The Audi Tt Coup
Full download: http://manualplace.com/download/audi-service-training-the-audi-tt-coup/
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
ments. well as nut and washer combinations.
Rear bumper
SSP207/75
The rear bumper comprises a total of 4 parts: The rear cover is available in two versions
the bumper panel, the rear cover, the alumi- depending on engine variant (TT has one
nium cross-member and the central locating tailpipe, the TTS two). A seamless transition to
element. the body side section (zero joint) is produced
by means of 2 bolts on each body side section.
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