Self-Study Programme 207 Audi TT.pdf

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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 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
are carried out on every single Audi.
Electrical function test
Roller dynamometer
Exhaust emission test and optimal setup
Acoustic test bench
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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.
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.
Important.
Note.
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 legen-
dary namesake.
The interior styling matches the exterior per-
fectly - 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 influ-
enced 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.
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.
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
Safety is paramount:
That’s why the TT is equipped with front air-
bags for the driver and front passenger.
The TT already complies with the new Euro-
pean safety laws which will come into effect in
the year 2003 as well as the tougher require-
ments according to the US Head Impact Pro-
tection 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

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