Service. The Audi TT Coupé. Design and Function. Self-Study Programme 207. For internal use only. - PDF

Service. The Audi TT Coupé Design and Function Self-Study Programme 207 For internal use only. The plant the plants Ingolstadt plant The model series Audi A4 and Audi A3 are produced in Ingolstadt. A separate

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Service. The Audi TT Coupé Design and Function Self-Study Programme 207 For internal use only. 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 Ingolstadt. Special trucks were developed for transferring the bodyshells 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 Final assembly of the TT has also been taking place here since Axle and steering geometry measurement 100% reliability is ensured through a series of systematic 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 Electrical function test After final assembly, extensive tests and adjustments 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 Design needs no explanation Vehicle dimensions Vehicle identification Environmentally-friendly production Body Special features Vehicle safety Occupant protection Fuel cut-off Drive units 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 Lambda control in the EUIII Torque-oriented engine management Accelerator position sender Electrically-activated throttle valve Fuel system Power transmission speed manual gearbox 6-speed manual gearbox Haldex viscous coupling Running gear Steering Front axle Rear axle Brake system Electrics Vehicle electrical system Interior monitoring Immobiliser Sound system Heating/air conditioning system Overview Expansion valve Service Flexible service interval indicator Oil level sensor Specifications Special tools The Self-Study Programme provides you with information regarding design and function. New. Important. Note. 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 name alone suggests that this is an Audi with a difference. The Audi TT was named after the legendary Tourist Trophy race on the Isle of Man - the only one of its kind in the world. The Audi TT is equally as unique as its legendary namesake. The interior styling matches the exterior perfectly - a fact reflected in the features of the dash panel, the styling of the instruments, the air nozzles and controls. The styling of some parts has also been influenced by the use of aluminium. 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. 4 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, stiff suspension tuning, ensures excellent handling and a high standard of driving safety. The basic version is equipped with 16-inch wheels shod with size 205/55 R 16 tyres. A 17-inch suspension is standard with the quattro and available as optional equipment for all other engine variants. 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 compromising the design concept and while retaining 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 coupling, further emphasising the vehicle s sporty character. SSP207/1 Safety Safety is paramount: That s why the TT is equipped with front airbags for the driver and front passenger. The TT already complies with the new European safety laws which will come into effect in the year 2003 as well as the tougher requirements according to the US Head Impact Protection Act. Design We at Audi firmly believe that the most important thing about designing is that actions speak louder than words. Suffice to say, a good design speaks for itself. The TT has a wheel-hugging design, that is to say the entire body is styled around the wheels. That also goes for the front and rear bulges as well as the roof and window lines and the low-slung passenger cabin. 5 A brief introduction to the TT Vehicle dimensions The + and dimensions are reference values compared to the Audi A3 Length: Width: Height: 111 mm +45 mm 69 mm (quattro 1503) 1856 Track width Front: Rear: Wheelbase: +12 mm +12 mm + 8 mm quattro 93 mm 85 mm quattro (quattro 2427) (quattro 738) Vehicle identification AUDI HUNGARIA MOTOR KFT TRUZZZ8NZX kg kg kg kg Typ 8N * TRUZZZ8NZX * Key of manufacturing plants within the Group in digit position 11: A Ingolstadt N Neckarsulm 1 Györ X Poznan K Karmann/Rheine World manufacturing code Part describing vehicle Filler constant = Z Digits vehicle class. acc. to structure table Part identifying vehicle Model year, alphanumeric as prescribed by law Manufacturing plant within the Group (as at 04/94) Serial No. beginning with: Audi Hungaria Motor Kft: TT/TTS * T R U Z Z Z 8 N Z X Audi AG: A3 * W A U Z Z Z 8 L Z X A A4 * W A U Z Z Z 8 D Z X A A6 (incl. SKD Poland) * W A U Z Z Z 4 B Z X N/X A8 * W A U Z Z Z 4 D Z X N Cabrio * W A U Z Z Z 8 G Z X K Audi 100 (C3, CKD) * W A U Z Z Z 4 4 Z X A * 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 replaced by a vehicle code (digits 4-8) or by a test mark (digit 9). This (18-digit) number is the official vehicle identification No. (VIN) in the countries listed above. 7 A brief introduction to the TT Environmentally-friendly production Environmental protection is firmly rooted in Audi s corporate strategy. During the vehicle development process, all environmental criteria are incorporated into the product and production concept from the outset. Economic goals and ecological needs are balanced so that no conflicts of aims arise. Produce locally - think global: Audi lays great store by waste avoidance, reduction and recycling. Almost all production resources and supplied parts are delivered in re-usable packaging. Most sheet-metal blanks are designed so as to minimise cutting waste after pressing. Waste avoidance and reduction From 1998 onwards, Audi will use only watersoluble paints in a effort to make its production process more environmentally-friendly. This step will see a dramatic reduction in solvent emissions. Today s fillers and base coats, for example, contain up to 45% solvent. By comparison, the solvent content in water-soluble systems is only about 6%. 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 possible. The resulting scrap is returned to the steelworks, where steel and zinc are separated from one another. Other waste materials such as paper, cardboard, timber, polystyrene, etc. are collected separately and fully recycled. 8 Body Special features Front bumper SSP207/74 The front bumper comprises two parts: the cover panel and a decorative grille. The bumper carrier is made of aluminium and bolted to the side members by impact absorbing elements. The guide profiles attached to the left and right wings ensure an even gap all round. A zero joint is created by attaching the bumper to the wing by means of threaded bolts as well as nut and washer combinations. Rear bumper SSP207/75 The rear bumper comprises a total of 4 parts: the bumper panel, the rear cover, the aluminium cross-member and the central locating element. The rear cover is available in two versions depending on engine variant (TT has one tailpipe, the TTS two). A seamless transition to the body side section (zero joint) is produced by means of 2 bolts on each body side section. 9 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. The tailgate has a single-joint hinge. SSP207/77 If the electrical system fails, the tailgate can be released in an emergency by means of the cable pull located below the rear central console cover. SSP207/76 10 Doors SSP207/47 The doors of the Audi TT Coupé are frameless and of two-piece construction. The door panel is made of steel with a bolted high-strength side reinforcement integrated in the door. The door component carrier is made of aluminium and can be adjusted for length, height and inclination. Additional side protection pads protect the pelvis area. Fuel filler flap The fuel filler flap is made of aluminium. It can only be opened electrically via a switch in the central console. The fuel filler flap is attached from the exterior with three anti-theft-protected bolts plus four decorative bolts. SSP207/72 If the electrical system fails, the fuel filler flap can be opened via an emergency release mechanism in the luggage compartment. For this purpose, it is necessary to open the flap in the side trim panel on the right-hand side of the luggage compartment and pull the cable in the direction indicated on sticker. Taillights To replace the filament lamps, the complete taillight unit is removed without needing any tools. Flaps are attached to the luggage compartment linings on the left and right. The light cluster is secured on the inside by means of 2 captive knurled bolts. On the outside, the taillight is engaged in a ball head. The light cluster can be adjusted along the vehicle s longitudinal axis by means of the threaded sleeves. SSP207/56 11 Body Dash panel SSP207/79 When removing the cross-tube, please note that one of the fastening bolts is located on the outside in the plenum chamber. To remove this bolt, it is necessary to remove the wiper linkage. Structure SSP207/15 The vehicle front-end area deforms in a predefined manner, absorbing the impact energy without impairing the stability of the occupant cell. The side members are manufactured from 2-, 3- and 1.5-mm-thick mash-welded metal plates. In the case of a side impact, the strong cross members will also deform on the side of the body facing away from the impact to absorb some of the impact energy. The body structure of the vehicle rear-end area is designed in such a way that, firstly, the integrity of the fuel system remains largely intact and, secondly, the load on the occupants is kept to a minimum even in serious accidents. The Audi TT Coupé therefore complies with the statutory crash requirements as well as the laws relating to frontal and side impacts due to enter into effect in the EU and USA. 12 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 crossmember minimises cell deformation and the rate of intrusion into the side structure. This leads to low occupant loads. SSP207/9 Side reinforcements in the doors Since the deformation path for energy absorption is very limited during a side impact, various design measures are necessary to perform this task effectively. These include the side reinforcements made of high-strength extruded aluminium sections in the doors. The double-rectangular section can absorb large mounts of energy. SSP207/5 During a side impact, the forces acting on the vehicle are distributed via the side reinforcements in the doors to the sill and the A- and B- pillars. Door sill The strong sill also absorbs energy and simultaneously transmits this energy to the stable floorpan assembly. The sill trim is made of steel and is secured to the sill with 17 bolt + washer combinations. SSP207/45 Be careful when placing the car on a lift support, otherwise the door sill may become dented. 13 Vehicle safety Occupant protection The Audi TT Coupé has head-thorax side airbags for the driver and front passenger. These side airbags are integrated in the seat backrests and extend from the rib cage area up to the head when inflated. When the side airbag is tripped, the head and neck areas are thus provided with better protection. In the Audi TT Coupé, the belt tensioners can be fired independently of the airbags depending on how the trigger criteria are defined. SSP207/80 The Audi TT Coupé has a disable function for deactivating the front passenger airbag. When using Reboard child seats on the front passenger seat, the driver must disable the front passenger airbag with the vehicle key via the key switch located inside the glove box (see Operating Manual Audi TT Coupé). SSP207/81 A yellow indicator light in the central console indicates when the airbag is deactivated. 14 During a side impact, the vehicle occupant is inevitably subjected to a relative movement towards the force application point and away from the deformation path. Therefore, it is very important to ensure that the contact surface between the occupant and the vehicle is large and energy-absorbing. SSP207/6 The side protection paddings made of plastic foam protect the vehicle occupants in the pelvis and rib cage areas. Deformation element Roof padding 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 years) and is compliant with ECE-R44. Children of heights ranging from 1.30 m to 1.50 m without raised seat swab. SSP207/73 15 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 collapsing 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. In the event of a frontal crash, the foot controls are displaced towards the central tube. This causes the collapsing support to deflect and the piston rod to buckle. The pedal footplate is swung up to 170 mm away from the foot area. The buckling of the piston rod and the deformation work resulting from this dampens the angular movement of the braking foot. This reduces the acceleration forces (braking foot) which normally arise considerably. SSP207/126 16 Fuel cut-off The fuel tank is made of plastic and is housed in a protected position in front of the rear axle. The Audi TT Coupé is the first Audi to be equipped with a fuel cut-off. In connection with an airbag trigger mechanism (crash signal output), the Motronic control unit switches the fuel pump off. The central locking control unit receives this signal simultaneously and unlocks the vehicle doors. The hazard warning lights are activated automatically and the interior lighting is switched on. A restart function enables the engine to be restarted after an accident and it can be moved from the danger zone under its own power. J234 J220 J17 Airbag control unit Motronic control unit Fuel relay J379 Central locking control unit and anti-theft warning system E3 F G6 Hazard warning switch Door locking unit Interior lighting Fuel pump 17 Drive units Engine and gearbox combinations Engine Gearbox Code MQ speed front 02J.N DZF 1.8-ltr. 5V turbocharged AJQ 132 kw/180 bhp SSP207/53 MQ speed quattro 02M.3 DXW SSP207/ ltr. 5V turbocharged APX 165 kw/225 bhp SSP207/33 MQ speed quattro 02M.1 DQB 18 SSP207/14 SSP207/33 1.8-ltr. 5V turbocharged engine 132 kw AJQ Specifications SSP207/13 Engine code: AJQ Type: 4-cylinder 5-valve four-stroke petrol engine with exhaust gas turbocharger Valve timing: Double overhead camshaft (DOHC) Displacement: 1781 cm 3 Bore: 81 mm Stroke: 86.4 mm Compression ratio: 9.5 : 1 Torque: 235 Nm at rpm Rated output: 132 kw/180 bhp at 5500 rpm Engine management: ME 7.5 Fuel: Premium unleaded 98 RON (RON 95 can be used, but reduces power output) Output [kw] Torque [Nm] Technical modifications: Basic 110 kw (150 bhp) EU II + D3 electronic throttle control Tumble duct (For details of the tumble duct in the intake system, refer to SSP 198) Engine control unit (characteristic curves adapted) CAN-BUS with TCS/EDL/ESP electr. activated air divert control valve Engine speed [rpm] SSP207/62 19 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 Knock sensor 1 (cyl. 1-2) G61 Knock sensor 2 (cyl. 3-4) G66 Accelerator pedal module with accelerator position sender G79 and G185 Brake light switch F and brake pedal switch F47 Clutch pedal switch F36 Auxiliary signals: Pressure switch for power steering F88 Cruise control Intake manifold pressure sender G71 20 Actuators Fuel pump relay J17 and fuel pump G6 Injection valves N30, N31, N32, N33 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 pressure limitation N75 Throttle valve control unit J338 with throttle valve gear G186 Air recirculation valve for turbocharger N249 Heater for lambda probe Z19 SSP207/46 EPC Fault lamp for electronic throttle control K132 Auxiliary signals 21 Function chart Turbocharged 1.8-ltr. 132 kw 5V engine Motronic ME 7.5 Components A Battery E45 Switch for cruise control system E227 Button for cruise control system F Brake light switch F36 Clutch pedal switch F88 Power steering (pressure switch) G6 Fuel pump G28 Engine speed sender G39 Lambda probe G40 Hall sender with quick-start sender wheel G42 Intake air temperature sender G61 Knock sensor 1 G62 Coolant temperature sender G66 Knock sensor 2 G70 Air mass meter G71 Intake manifold pressure sender G79 Accelerator position sender G186 Throttle valve gear (electronic throttle control) G187 Throttle valve drive angle sender 1 G888 Throttle valve drive angle sender 1 J17 Fuel pump relay J220 Motronic control unit K132 Fault lamp for electronic throttle control M9/10 Stop lights N Ignition coil N Injection valves N75 Solenoid valve for charge pressure limitation N80 Solenoid valve for activated charcoal canister N128 Ignition coil 2 N158 Ignition coil 3 N163 Ignition coil 4 N249 Air recirculation valve for turbocharger P Spark plug socket S Fuse Q Spark plugs Z19 Heater for lambda probe Auxiliary signals CAN-BUS H = CAN-BUS L = A B C D E F G } Databus drive Engine speed signal (out) Fuel consumption signal (out) Road speed signal (in) Air-conditioner compressor signal (in-out) Air conditioning ready (in) Crash signal (in) from airbag control unit Alternator terminal DF/DFM (in) W- line (in-out) For the applicable Fuse No. and amperage, please refer to the current flow diagram. Input signal Output signal Positive Earth Bidirectional 22 + - S S S
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