Audi TT 2006 Workshop Manual

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Service Training

Audi TT Coupé ‘07

Self-Study Programme 380

All rights reserved.

Technical specifications subject to change without notice.

Copyright

AUDI AG

I/VK-35

[email protected]

Fax +49-841/89-36367

AUDI AG

D-85045 Ingolstadt

Technical status: 05/06

Printed in Germany

A06.5S00.25.20

Introduction

The first generation of the Audi TT Coupé, named after the legendary "Tourist Trophy" race in the UK, was a milestone in automotive design.

The design followed the pure geometry, with central motives being the circle, particularly distinctive on the wheel arches, the arches of the roofline, the front end and the rear end.Audi has taken this genetic code and developed it in authentic style.

In the new TT, the geometric shapes merge fluidly with one another.The concave and convex arches radiate dynamism and movement while lending the TT Coupé the character of an athletic sculpture thrusting forwards.

The front end of the new TT Coupé has gained in expressiveness and resoluteness, the most distinctive element being the singelframe radiator grille.

Unlike the predecessor model, the rear end has a completely different outline to the front end. The rear lights create a three-dimensional effect by virtue of their visual depth. The trapezoidal cut-out around the license plate continues the flowing lines of the boot lid. The powerful exhaust tailpipes, wide diffusor and central rear fog light are borrowed straight from motorsport.

The dynamic impression conveyed by the Audi TT Coupé also stems from its modified proportions.

On the exterior it is now: - 137 mm longer

- 78 mm wider

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Self-study programmes on the TT Coupé

SSP 380 Audi TT Coupé ‘07

– Body

– Occupant protection

– 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



Electrical and Infotainment Systems

– Networking

– Bus topology

– Convenience electronics

– Infotainment


SSP 383 Audi TT Coupé ‘07 - Body

– Audi Space Frame

– Production processes and joining methods

– Surface finish

– Electromechanical rear spoiler

– Repair concept

– Passive safety concept


Excellence in design & performance

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Running gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Infotainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

The self-study programme teaches the design and function of new vehicle models, new automotive components or new technologies.

The self-study programme is not a repair manual!

All values given are intended as a guideline only, and refer to the software version valid at the time of publication of the SSP.

For maintenance and repair work, always refer to the current technical literature.

Reference Note

Introduction

Overview

Dimensions of the Audi TT Coupé ‘07.

4


Permissible gross weight in kg

Kerb weight without driver in kg

Drag coefficient Cw

Fuel tank capacity in litres

Body type

Height of loading sill in mm

Luggage compartment volume in l

2.0l HS

1660

1260

2.0l s-tronic

1680

1280

3.2l HS qu

1810

1410

0.30

0.30

55

Audi Space Frame (ASF)

790

290 (700l with rear-seat back folded forward)

60

3.2l s-tronic qu

1830

1430

0.31

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Body / dimensions

Length in mm

Width in mm

Height in mm

Wheelbase in mm

Front track width in mm

Rear track width in mm

Number of seats

4178

1842

1352

2468

1572

1558

2 + 2

+ 137

+ 78

+ 6

+ 46

+ 26

+ 30

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5

6

Body

Audi Space Frame ASF of the Audi TT Coupé ´07

The development targets for the bodyshell of the Audi TT Coupé ‘07

With a weight advantage of 48 % over a comparable all-steel bodyshell, not to mention the optimised weight distribution, the new composite aluminium-steel spaceframe body of the TT Coupé marks yet another milestone in the development of modern Audi bodyshells.

Crash safety of the bodyshell is enhanced by load-bearing structures at the front, sides and rear end with a heavy emphasis on pedestrian safety.

To ensure efficient volume bodyshell production, various new joining and production techniques are employed.

The repair concept is to a large extent based on the well-known aluminium repair concept, although combining the materials aluminium and steel meant, of course, that new approaches had to be taken.

Sill section Audi TT Coupé ‘07

Four-chamber extruded section

Sill section Audi A8

Three-chamber extruded section

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Technological concept

Sheet-steel parts are used for the first time in the ASF of the Audi TT Coupé ‘07, in addition to aluminium castings, aluminium extruded sections and aluminium sheet-metal parts. Collectively they form the body structure. Vehicle weight distribution is optimised by using sheet-steel parts at the rear end of the body.

This has a direct bearing on sporting characteristics such as driving dynamics and acceleration, as well as safety characteristics such as stopping distance and driving stability Despite the partial use of sheet-steel parts, the total body weight of 277 kg including attachments, such as doors and lids, is approx. 48 % less than that of a comparable full steel body. Although the TT Coupé has grown considerably in size, the overall weight of the vehicle has been reduced through the use of the aluminium steel bodyshell.

The body structure of the Audi TT Coupé ‘07 has higher strength and 50 % higher torsional rigidity than its predecessor.

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Component parts overview

22 Aluminium castings

129 Sheet-aluminium parts

19 Extruded aluminium sections

107 Sheet-steel parts (galvanised)

Reference

For details of design and function, refer to Self-Study Programme 383

Audi TT Coupé ‘07 - Body.

7

Occupant protection

Occupant protection system in the Audi TT Coupé ‘07

The Audi TT Coupé ‘07 is a high-end sports car. However, the occupant protection system matches the vehicle's driving dynamics in every respect. Creating a sports car with a high occupant protection potential is always a big challenge. This challenge was met by the TT Coupé development team.

The occupant protection system of the Audi TT Coupé ‘07 is composed of the following components and systems:

– Airbag control unit

– Dual-stage driver and front passenger airbags

– Front side airbags

– Central crash sensor for front airbag, so-called "upfront" sensor for head-on collision detection

– Side impact detection sensors in the front doors

– Front belt tensioners

– Battery isolation igniter

– Belt switch, driver side

– Belt-on indicator

Due to the different criteria and statutory requirements set by the various markets, the equipment specifications can vary. This applies particularly to the US market.

8

Legend

E24 Driver side belt switch

E224 Front passenger side airbag deactivation key switch

G179 Side airbag crash sensor, driver side

G180 Side airbag crash sensor, front passenger side

G283 Driver side front airbag crash sensor (central)

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J234 Airbag control unit

J285 Control unit with display in dash panel insert

J393 Convenience system central control unit

J533 Data bus diagnostic interface (Gateway)

J623 Engine control unit

K19 Seat belt warning system warning lamp

K75 Airbag warning lamp

K145 Front passenger side airbag deactivated warning lamp (PASSENGER AIRBAG OFF)

N95 Airbag igniter, driver side

N250 Driver side airbag igniter -2-

N131 Front passenger side airbag igniter 1

N132 Front passenger side airbag igniter 2

N153 Driver seat belt tensioner igniter -1-

N154 Front passenger seat belt tensioner igniter -1-

N199 Side airbag igniter, driver side

N200 Side airbag igniter, front passenger side

N253 Battery isolation igniter

T16 16-pin connector, diagnosis connection

9


Airbag control unit J234

Airbag control unit J234 and integrated electronics have the task of detecting a collision.

In the Audi TT Coupé ‘07 the airbag control unit is attached to the vehicle body in the area of the handbrake lever.

The airbag control unit is integrated in the CAN powertrain data bus so that it can exchange information with other control units.

The airbag electronics basically have the following main tasks:

– Collision detection (front, side, rear)

– Defined deployment of the belt tensioners, airbags and battery disconnect

– Defined deployment of the second front airbag stage

– Evaluation of all input information

– Permanent monitoring of the complete airbag system

– Independent energy supply via capacitor for a defined period of time

(approx. 150 ms)

– Fault display via failure warning lamp

– Storage of error / and crash information

– Indication of a collision event to other system components via the powertrain CAN bus or discrete collision output (conventionally wired)

– Activate seat belt reminder

380_008

10

To find out which components need replacing after an accident, refer to the valid Workshop Manual in

ElsaWin.

An airbag control unit can only be replaced with a VAS tester running the "Guided Fault Finding" or "Guided

Functions" application.

Reference

For more information about the airbag control unit J234, refer to Self-

Study Programmes 323 Audi A6 `05 and 361 Audi Q7.

Belt-on warning

The Audi TT Coupé ‘07 has a belt-on warning function for the driver.

The airbag control unit evaluates the information from the driver side belt switch E24 after ignition "on". If the driver is not wearing a seat belt, a visual warning is given by the seat belt warning system warning lamp K19 integrated in the dash panel insert.If the system determines that the vehicle is moving, an audio warning is given in addition to the visual warning.As long as the ignition is on, the airbag control unit monitors the switched condition of seat belt switch E24. If seat belt status changes while terminal 15 is "on", the seat belt reminder will be reactivated.

Time diagram for seat belt reminder

Visual and audio signals

- Delayed seat belt fastening

ON

Terminal 15

OFF

V > 25 kph

Road speed v < 25 kph yes

Seat belt fastened

Seat belt warning system warning lamp

No

ON

OFF

ON

Audio signal

OFF

Driver side belt switch E24

The "belt-on warning" function needs information on whether the driver's seat belt is fastened or not.

Seat belt switch E24 in the belt buckle is a mechanically actuated open-close switch.

The airbag control unit uses a resistance measurement to establish whether the seat belt is fastened or not.

Time

361_016

380_065

11


Airbag

The Audi TT Coupé ‘07 has two-stage front airbags on the driver and front passenger sides.

The airbag control unit selects the time interval between the two ignition stages (approx. 5 ms to 30 ms) according to severity and type of crash.

The loads acting on the driver or front passenger during an accident can be reduced through time-staggered ignition of the propellant charges.

Both propellant charges are always ignited. This ensures that no propellant charge remains active after the airbag is deployed.

Driver airbag

Airbag igniter I, driver side N95

Airbag igniter II, driver side N250

A gas generator with two pyrotechnic propellant charges is integrated in the driver's airbag.

Igniter I is activated electrically by the airbag control unit J234. The igniter flame passes through the container and ignites the ignition charge in the container. If the pressure produced by the ignition of the ignition charge is high enough, the flame will break through the container and reach the propellant charge through the perforated tube. Propellant charge I ignites and combusts. The developing gas destroys the foil seal, and filtered gas flows through the air outlet into the airbag. After a defined interval has expired, the airbag control unit activates igniter II, which in turn ignites propellant charge II directly. The gas produced by combustion of the propellant material flows through the raised end cap into the combustion chamber of propellant charge I.

From here the gas flows through the filter into the airbag.

12

Casing

Perforated tube Ignition charge container Propellant charge II

End cap

Foil seal

Air outlet

Foil seal

Air outlet

Filter

Igniter I Propellant charge I Igniter II

Filter

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Front passenger airbag

Airbag igniter 1, front passenger side N131

Airbag igniter 2, front passenger side N132

An airbag module with a two-stage hybrid gas generator is used in the Audi TT Coupé ‘07 on the front passenger side.This module is already in use in the Audi Q7. However, it has been adapted for the TT Coupé.

Two pyrotechnic propellant charges integrated in a pressurised gas bottle are activated separately by the airbag control unit.

The so-called cold gas in the pressurised gas bottle is under approx. 250 bar of pressure and is a mixture of approx. 98 % argon and approx. 2 % helium.

Ignition charge I Propellant charge I Coil spring

Filter

Igniter I

Igniter II

Ignition charge II Propellant charge II Coil spring Rupture disc

Pressurised gas bottle

Gas: approx. 98 % argon approx. 2 % helium

Pressure: approx. 250 bar

361_002

Reference

For more information about the function of the front passenger front airbag, refer to Self-Study Programme

361 Audi Q7.

13


Side airbags

Side airbag igniter, driver side N199

Side airbag igniter, front passenger side N200

Airbag modules which cover both the body and head areas - so-called head-thorax airbags - are used as side airbags.

Tubular gas generators filled with solid propellant inflate the airbags with gas in the event of a crash.

14

380_004

The airbag control unit J234 energises the corresponding side airbag igniter. The ignition charge which is ignited by the igniter in turn ignites the actual propellant charge. The developing gas is treated and cooled by the metal filter, whereupon it unfolds and inflates the airbag.

Ignition charge Metal filter Air outlet

Detonator Propellant charge Air outlet

361_022

Driver seat belt tensioner igniter -1- N153

Front passenger seat belt tensioner igniter -1- N154

The Audi TT Coupé ‘07 is equipped with redesigned belt tensioners for the driver and front passenger.

These belt tensioners are so-called "band tensioners".

The TT Coupé for the North American market is also equipped with these belt tensioners.

If the rear seats in the TT Coupé are equipped with

Isofix fixing eyelets, belt tensioners are also installed for these seats.

Seat belt

Foil

The workshop manual (ElsaWin) applicable to the vehicle describes the tests which must be made to detect an activated belt tensioner (band tensioner).

An activated belt tensioner can be detected, among other things, by virtue of the fact that the foil located on the side of the belt tensioner housing is detached from the housing.

Inertia-reel seatbelt

Belt tensioner unit

380_030

A metal band is wrapped around the seat belt retractor shaft.

Both open ends are connected to the seat belt retractor shaft.

The closed end is looped around the belt tensioner igniter.

Metal band

Seat belt retractor shaft

Electrical connector

Detonator

Metal band loop

380_027

15

16


The belt tensioner igniter is located inside the metal band loop.

When the igniter is activated by the airbag control unit, the resultant pressure causes the loop of the metal band to expand.The movement of the metal band exerts a pull on the seat belt retractor shaft, which thereupon begins to rotate, tensioning the seat belt.

Metal band

Electrical connector

Detonator


Metal band loop

380_028

The casing and casing cover surface between which the metal band moves are coated in a layer of silicon. When the metal band moves, it thrusts a part of this silicon layer ahead of itself and thereby ensures that a tight seal is maintained.

Pressure losses are thus reduced.

Casing

Silicon layer

Casing cover

Metal band

380_026

Battery isolation igniter N253

The battery isolation igniter has the task of disconnecting the starter and alternator leads from the vehicle battery in the event of a crash.

Use is made of a pyrotechnic component which is activated by the airbag control unit J234 whenever the airbag is deployed.

During a rear collision, only the belt tensioner and the battery isolation igniter are activated.

Battery isolation igniter

Pin

Connecting element with terminals

If the pyrotechnic propellant charge is ignited, the resultant gas pressure displaces the pin on a piston and disconnects the two terminals.

After deployment of the airbag, the battery isolation igniter must be replaced.

Detonator

332_030

361_024

Reference

Further information on the function of the battery isolation igniter, refer to Self-Study Programme 361

Audi Q7.

17

18


Additional functions and components of the occupant protection system for the North American market

The additional functions and components of the occupant protection system for the North American market are described on the following pages.

The occupant protection system is equipped with additional functions and components, e.g. second crash sensor for front airbag, so that the Audi TT Coupé ‘07 meets the statutory and marketspecific requirements for the US market.

Seat occupied detection, front passenger side

The front passenger side seat occupied recognition system was largely adopted from the Audi Q7.

The system basically comprises the following components:

– Seat squab

– Sensor mat for seat occupied recognition

– Pressure sensor for seat occupied recognition G452

– Seat occupied recognition control unit J706

– Front passenger side belt switch E25

– Seat belt force sensor for seat occupied recognition G453

– Front passenger side airbag deactivated warning lamp

K145 (PASSENGER AIRBAG OFF)

– Airbag control unit J234

These components form a single unit and must not be separated from each other.

Driver side belt switch E24

Front passenger side belt switch E25

The Audi TT Coupé ‘07 for the North American market is equipped with seat belt switches for beltfastened recognition on the driver and front passenger sides.

Seat belt switches E24 and E25 are integrated in the belt buckles on the front seats So-called "reed switches" are used. The reed switch remains open until the occupants have fastened their seat belts.

The airbag control unit J234 performs a resistance measurement from which it can determine whether the occupants have fastened their seat belts or not.

Depending on the position of the reed switch, the measurement is made using one or both resistors.

361_029

Reference

For further information about the seat occupied recognition system and the seat belt switch, refer to Self-

Study Programme 361 Audi Q7.

Knee airbag igniter, driver side N295

Knee airbag igniter, front passenger side N296

The Audi TT Coupé ‘07 for the North American market is equipped with knee airbags for the driver and front passenger sides.

Ignited knee airbags allow the occupants to participate earlier in the vehicle deceleration process. The airbag system of driver and front passenger front airbags in combination with knee airbags reduces the injury risk for the occupants.

On the driver side, the knee airbag is located in the footwell trim panel below the dash panel.On the front passenger side, the knee airbag is located behind the glove box lid.

After the airbags are activated, the airbag unfolds between the dash panel and the occupants' legs.

Gas generator

View inside the dash panel

Airbag

380_006

Hybrid gas generators have the task of inflating the airbags with gas.

The airbag control unit J234 activates the igniter in the gas generator. The resultant pulsation wave is directed to the rupture disc. The rupture disc breaks and the helium from the pressurised gas bottle flows into the airbag.

Filter

Detonator

Air outlet

Filter Air outlet Rupture disc Pressurised gas bottle

Gas: Helium

Pressure: approx. 600 bar

380_009

19

20


Belt force limiter, driver side G551

Belt force limiter, front passenger side G552

The front inertia-reel seatbelts have a two-stage belt force limiter. In the event of a collision, the belt tensioners (band tensioners) are ignited first. The inertia-reel seatbelt blocks the seat belt retractor shaft and prevents the seat belt from unreeling, which would occur due to the forwards movement of the occupants. The seat belt retractor shaft is designed as a torsion shaft. To limit the load which the seat belt places on the occupants, two torsion shafts allow controlled unreeling of the seat belt; belt force limiter.

After a defined interval, the airbag control unit activates the belt force limiter igniter.

The second torsion shaft is decoupled. The seat belt retractor shaft now counteracts the force which the seat belt exerts.

To ensure that the occupants are afforded a good level of protection, the belt tensioning function, the belt force limiting function and the front airbags are coordinated with each other.

Detonator

Spline end

Gear II


Gear I

Torsion shaft II

380_013

Gears I and II are permanently connected to the seat belt retractor shaft and the second torsion shaft respectively.

In the initial state, both gears are in mesh with one another.


Spline end

Gear II


Gear I

380_012

The belt tensioner retracts the seat belt to the extent possible, and the inertia-reel seatbelt locks the seat belt retractor shaft. The seat belt can no longer be pulled out.

If the occupant's body now accelerates forwards due to centrifugal force, the belt force limiter allows the seat belt to unreel as of a certain force.Both torsion shafts are rotated.


Spline end

Gear II

After a defined period of time, the belt force limiter igniter is activated. The spline end decouples gear II from gear I.

The belt force is now limited by the seat belt retractor shaft alone.The occupant can plunge into the fully inflated airbag.


Gear I

380_011


Spline end

Gear II


Gear I

380_010

Detonator

Spline end

Gear II



Gear I

380_016

21

Engine

Engine-gearbox combination

2.0l 4 cyl. TFSI MQ 350 6F / DQ 250 6F

22

3.2l VR6 MPI

380_044

Reference

For information about the design and function on the s-tronic, please refer to Self-Study Programme 386

6-speed Direct Shift Gearbox 02E.

380_045

380_042

MQ 350 6A / DQ 250 6A

380_060

380_045

380_060

2.0l TFSI

The engine number is located at the rear left of the engine block in the area of the gearbox flange.

Technical features

– Toothed belt drive with CTC toothed belt sprocket

– Selective petrol direct injection system (FSI)

– Turbocharging

– Pencil ignition coils

– 1 primary catalytic converter and 1 main catalytic converter

– 1 primary catalytic converter and 1 post-cat sensor

Torque/power curve

Max. torque in Nm

Max. power output in kW

380_042

Engine speed in RPM

Specifications

Engine code

Type of engine

Displacement

Power output

Torque

Bore

Stroke

Compression ratio

Cylinder spacing

Weight

Firing order

Engine management

Exhaust gas recirculation

Exhaust emission control

Exhaust emission standard

BWA

4-cylinder petrol engine

1984 cm

3

147 kW (200 bhp) at 5100 RPM

280 Nm at 1800 - 5000 RPM

82.5 mm

92.8 mm

10.5 : 1

90 mm approx. 152 kg

1 – 3 – 4 – 2

Bosch Motronic MED 9.1

Internal exhaust gas recirculation

1 ceramic pre-catalytic converter with heating function via homogeneous split dual injection, 1 main catalytic converter

EU 4 / ULEV

380_047

23

Engine

3.2l VR6 MPI

Technical features

– Chain drive on the transmission side

– Cylinder-selective injection system

– Fully variable adjustment of both camshafts

– Pencil ignition coils

– 2 primary catalytic converters and 2 main catalytic converters

Torque/power curve

Max. torque in Nm

Max. power output in kW

380_044

24

Engine speed in RPM

Specifications

Engine code

Type of engine

Displacement

Power output

Torque

Bore

Stroke

Compression ratio

Offset

Firing order

Engine management

Camshaft adjustment range

Exhaust gas recirculation

Exhaust emission control

Exhaust emission standard

BUB

VR6 petrol engine 15° vee angle

3,189 cm

3

184 kW (250 bhp) at 6,300 RPM

320 Nm from 2500 to 3000 RPM

84.0 mm

95.9 mm

11.3 : 1

15°

1 – 5 – 3 – 6 – 2 – 4

Bosch ME 7.1.1

Intake camshaft 52° crank angle

Exhaust camshaft 42° crank angle

Internal exhaust gas recirculation

2 primary catalytic converters and 2 main catalytic converters

EU 4

380_046

Fuel supply

The fuel system is basically adopted from the A3 `04.

The fuel tanks differ from one another in terms of their shape, which is dependent on the vehicle's drive concept.

They are made of HPPE (high-pressure polyethylene). To safeguard the fuel tank against destruction in the event of an accident, it is mounted in front of the rear axle. Here it is fixed to the underbody by means of ratchet straps. It is not necessary to disassemble the rear axle to remove the fuel tank. The front tank has a capacity of 55 litres, the quattro tank 60 litres.The US spec quattro tank has a capacity of 55 litres, because a different breather system is used due to the different statutory requirements which apply.

Front tank

Breather pipe quattro tank

Fuel tank breather pipe

Fuel filter

Fuel delivery unit to tank

Breather pipe

Breather pipe

380_020

Fuel tank breather pipe

Fuel filter

Breather pipe

Fuel delivery unit to tank

Suction jet pump

(entrainment pump)

+ 2nd fuel tank sender

380_001

25

26

Engine

Pressure regulation

The fuel filter is bolted to the exterior of the fuel tank. The pressure regulator is integrated in the fuel filter.

In case of excess pressure, the governed fuel is returned to the tank. The pressure regulator in the FSI engine cuts off fuel delivery at 6.4 bar (relative). In the case of the MPI engine, fuel cut-off is at 4 bar (relative). Both systems are returnless, with the distinction being that the pressure in the MPI engine is maintained at a constant 4 bar, while the FSI engine utilises a supply-on-demand fuel system.

Reference

Pressure regulation in the 3.2l and

2.0l engines is described in Self-

Study Programme 290 and Self-Study

Programme 332 respectively.

Fuel gauge sender

For the MPI and FSI engines, a fuel delivery unit with integrated fuel gauge potentiometer and a suction jet pump are arranged inside the fuel tank.


Fuel pump

380_021

In the case of the quattro tank, a second fuel gauge potentiometer is arranged inside the second half of the fuel tank.The second half of the fuel tank also houses the suction jet pump, which pumps the fuel into the fuel delivery unit reservoir. The suction jet pump is attached securely to the sender flange by means of clips. The thin line is the propulsion jet line. It is driven by the suction jet pump. The thicker line is the mixing tube, in which the intake fuel is pumped to the fuel delivery unit.

The fuel gauge senders are configured as slider potentiometers.


Fuel gauge sender

380_023

Fuel tank breather system, ROW spec (2.0l and 3.2l engines)

Tank connection, fuel

Tank connection, breather

Activated charcoal canister

Engine connection, fuel on 3.2l engine only

Fuel tank breather system, US spec (2.0l and 3.2l engines)

Tank connection, breather

380_034

Activated charcoal canister

Engine connection, fuel on 3.2l engine only Tank connection, fuel

Fuel system diagnostic pump

380_033

27

28

Engine

Soundpipe

A soundpipe is used on the 3.2l V6 engine to give the engine a sportier sound. The intake noise is transmitted to the vehicle body via a connecting line from the intake manifold to the plenum chamber and via a resonator.

The soundpipe has been developed to accentuate the dynamism and sportiness of the 3.2l engine

The soundpipe produces a sporty sound in the vehicle interior without impairing comfort. The pressure pulsations are amplified by the gas exchange cycle via the soundpipe without exceeding the exterior noise limits. Unwanted noise emission from ancillary units and tire noise are to a large extent avoided by the fact that the occupant cell is well-insulated. As a result, comfortable travelling is still possible.

Secondary pipe Sound generator Primary pipe Air filter

380_014

Function

A soundpipe is connected between the air mass meter and the throttle valve unit in the air intake tract.

The soundpipe made up of three parts: the primary pipe, which is connected to the air intake tract, the sound generator and the secondary pipe, which is connected to the vehicle interior via the engine bulkhead. The primary and secondary pipes as well as the sound generator are configured in such a way that it is possible to influence the "bandpass characteristic"*, and hence the acoustic transmission range. However, the sound generator is the key component.The system is designed such that the sound becomes meatier when the driver demands more power from the engine.

The pressure pulsations which during the gas exchange cycle are transmitted to the membranes in the sound generator, where they are amplified by the sound generator and relayed to the vehicle interior. Another further task the membranes is to seal the gas flow between the air intake tract and the vehicle interior. The foam core in the sound generator has the task of maintaining the shape and position of the membranes.

* A bandpass characteristic is produced, for example, by connecting the highpass and lowpass filters in series. Only a defined range of frequencies is allowed to pass, depending on the circuit configuration.

Sound generator

Securing clip to vehicle interior

Secondary pipe Foam core

Primary pipe from intake manifold

Membranes O-ring

380_076

29

Suspension system


Overview

The Audi TT Coupé ‘07 is available with three different suspension systems. The dynamic suspension system represents the basic specification. The semi-active "Audi magnetic ride" suspension is optional. The driver can select between comfort and sport suspension settings at the touch of a button. quattro GmbH is also offering an S-Line suspension system, which is sportier than the dynamic suspension system.The main axle components are identical to those of the Audi A3 in respect of their design and function.

30

Front axle

An improved version of the McPherson suspension is used.The design of the front axle is identical to that of the Audi A3. Track width is 13 mm wider on each side than the Audi A3.

Detail modifications have been made to reflect the particularly sporty character of the Audi TT Coupé

‘07. In addition to the tuning parts (springs, dampers and anti-roll bars), the same axle components are used in all TT Coupé suspension variants.

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Rear axle

The rear axle of the Audi TT Coupé ‘07 is basically identical in design and function to the rear axle on the

Audi A3. The wheel carriers, damper bearings and wheel bearings are modifications on the components on the Audi A3.Track width has been increased by 15 mm on each side compared to the Audi A3. The suspension and damping components (springs, dampers and anti-roll bars) were adapted to the specific requirements of the TT Coupé. Additional stone chip protection is provided for certain markets. The trailing arms and spring links on these models are protected by plastic claddings.

Rear axle for front-wheel drive

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Rear axle for quattro models

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31


Brake system

Overview

ESP

TEVES Mk60E1 with optional low tyre pressure indicator

Front axle brake caliper

16" for all four-cylinder models

17" for all six-cylinder models

32

Brake servo

10", 11", 7/8" with contactless brake light switch without dual rate characteristic

Rear axle brake caliper

16" for all four-cylinder models

17" for all six-cylinder models

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33

34


Steering system

The electromechanical steering system EPS which has proved successful in the Audi A3 is also featured in the Audi TT Coupé ‘07. Various detail modifications have been made to adapt the steering system for use in the TT Coupé.

A mechanical steering column is fitted in the

Audi TT Coupé ‘07. The steering column is basically identical in design and function to the steering column in the Audi A3.

Various detail modifications have been made to adapt the steering column for use in the TT Coupé.

A redesigned steering wheel is used in the

Audi TT Coupé ‘07. All models are fitted with threespoke leather-bound steering wheels with an integral two-stage airbag module. In addition to the standard version, combinations are also available of multifunction, Tiptronic and leather stitching in various colours.

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Audi magnetic ride

The Audi TT is the first Audi to feature Audi magnetic ride - a new semi-active suspension system with magneto-rheologically controlled dampers. A sport or comfort damper set-up can be activated at the touch of a button.

Damper adjustment button

E387

ECD control unit (electronically controlled damping)

J250

Shock absorber damping adjustment warning lamp

K189

Damper adjustment valve

N336-339

Audi magnetic ride improves driving dynamics and driving comfort for the following reasons:

– reduced body movement (pitch and roll)

– optimised vibration behaviour

– improved road-holding

– improved handling

Vehicle level sender

G76-78, G289

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Reference

For details of the design and function of the suspension system, refer to


Audi TT Coupé ‘07 - Suspension

System.

35

36


Wheels and SST tyres (self supporting tires)

Engine

4-cylinder

Basic wheels

7.5J x 126 ET 45 (1)

Cast aluminium wheel painted

225/55 R 16

Optional wheels

8J x 17 ET 47 (3)


225/50 R 17 *

9J x 18 ET 52 (5)

Cast aluminium wheel polished bi-color

245/40 R 18 *

7J x 16 ET 47 (7)


225/55 R 16

Winter wheels

9J x 18 ET 52 (9)


245/40 R 18 *

6-cylinder 8.5J x 17 ET 50 (2)

Forged aluminium wheel painted

245/45 R 17 *

9J x 18 ET 52 (4)


245/40 R 18 *

8.5J x 17 ET 50 (6)


245/40 R 18 *

7J x 17 ET 47 (8)

Forged aluminium wheel painted

225/50 R 17 *

* also available optionally as SST wheel

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SST tyres have run-flat capability because of their modified design compared to conventional tyres.

Much stiffer tyre sidewalls enable the vehicle to drive on for up to 50 km at a maximum speed of 80 kph even after a total loss of pressure.

Special wheels are used for the SST tyres due to the modified tyre geometry. The special 17" wheels on the

Audi TT Coupé ‘07 can be used both for conventional tyres and for SST tyres. In the case of the 18" wheels, conventional tyres are available in combination with conventional rims. SST tyres are always combined with the low tyre pressure indicator.

Low tyre pressure indicator

In all markets except North America, the

Audi TT Coupé ‘07 comes with an upgraded version of the low tyre pressure indicator previously featured in the Audi A3. Being an indirect measuring system, no tyre pressure sensors are installed in the wheels.

Using a new evaluation method, it is now possible to detect simultaneous pressure loss to at multiple wheels. Tyre pressures are monitored simultaneously using two different concepts.

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37

38

Electrical system

Topology and networking

Engine control unit

J623

Direct shift gearbox mechatronics

J743

Selector lever

E313

ABS control unit

J104

Airbag control unit

J234

Four-wheel drive control unit

J492

Tyre pressure monitor control unit 2

J793*

Power steering control unit

J500

Steering angle sender

G85

Steering column electronics control unit

J527

Multi-function steering wheel control unit

J453

ECD control unit

(electronically controlled damping)

J250

Headlight range control, control unit

J431

Power output module for left headlight

J667

Power output module for right headlight

J668

Diagnostic port

Data bus diagnostic interface

J533

Driver door control unit

J386

Front passenger door control unit

J387

Parking aid control unit

J446

Convertible top operation control unit

J256

Auxiliary air heater control unit

J604

Climatronic control unit

J255

Convenience system central control unit

J393

Onboard power supply control unit

J619

Tyre pressure monitor control unit

J502**

Control unit with display in dash panel insert

J285

Anti-theft alarm system sensor

G578

Alarm horn

H12

Wiper motor control unit

J400

Rain and light detector sensor

G397

* for tyre pressure monitoring system 2 only (ECE = Europe)

** for tyre pressure monitor only (SAE = North America)

Telephone transmitter and receiver unit

R36

Digital satellite radio tuner

R190

Digital sound package control unit

J525

TV tuner

R78

Radio

R

Control unit with display for radio and navigation

J503

CD changer

R41

Powertrain CAN bus infotainment CAN bus

Convenience CAN bus

Dash panel insert CAN bus

Diagnostics CAN bus

LIN bus

Subbus system

Panasonic bus

382_044

39

40

Electrical system

Installation overview - control units

9

10

11

12

Legend

3

4

5

1

2

6

7

8

13

Garage door operation control unit J530

Direct shift gearbox mechatronics J743

Power steering control unit J500

Engine control unit J623

ABS control unit J104

Wiper motor control unit J400

Alarm horn H12

Onboard power supply control unit J519

Headlight range control, control unit J431

Data bus diagnostic interface J533

CD changer R41

Tyre pressure monitor control unit 2 J793 /

Tyre pressure monitor control unit J502*

Control unit with display in dash panel insert

J285

Radio R

Control unit with display for radio and navigation J503

Climatronic control unit J255

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15

16

17

18

19

20

21

22

23

24

14

25

Steering column electronics control unit J527

Steering angle sender G85

Multi-function steering wheel control unit

J453

Rain and light detector sensor G397

Driver door control unit J386

Front passenger door control unit J387

Anti-theft alarm system sensor G578

Telephone transmitter and receiver unit R36

Airbag control unit J234

ECD control unit (electronically controlled damping) J250

Digital satellite radio tuner R190

Digital sound package control unit J525

Convenience system central control unit J393

Parking aid control unit J446

TV tuner R78

Radio controlled clock receiver J489

* for tyre pressure monitor only SAE

41

Air conditioning

Overview

The air conditioning system of the

Audi TT Coupé ‘07 is an improved version of the system used in the Audi A3 ’04. The automatic air conditioning system is configured as a single-zone air conditioning system. The TT Coupé has only one climate zone with no temperature differential between the driver and front passenger sides.

The TT Roadster is available with a heating-only system, in addition to the automatic air conditioning system.

The TT vehicles with petrol engine have no auxiliary heater and, therefore, no electrical PTC heater element.

The Climatronic control unit J255 has a rotary knob for temperature selection, but no digital display.

The system has an air recirculation function, which can be activated either by the occupants or automatically as soon as the "on" conditions for air recirculation have been met.

The automatic air recirculation function by means of an air quality sensor G238 was not implemented; no air quality sensor G238 is fitted.

The fresh air intake duct temperature sensor G89 is not fitted. Information on ambient temperature is supplied only by the ambient temperature sensor

G17 via CAN data bus from the dash panel insert.

Air conditioner in Audi TT Coupé ‘07

Fresh air/ ram air flap

Air flow flap control motor

V71

Defroster flap

Chest vent right

Chest vent centre

Chest vent left

Air recirculation flap

Air recirculation flap control motor

V113

Temperature flap control motor, right

V159

42

Defroster flap control motor

V107

Temperature flap control motor, left

V158

Central flap control motor

V70

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Climatronic control unit J255

The setpoint for the temperature flap is set using the "Temperature" rotary knob. The rotary knob is infinitely variable and activates the "Maximum cool" function in the lowest setting and the "Maximum heat" function in the highest setting.

Automatic mode of the air conditioning system can be deactivated with the "Air flow" or "Air distribution" rotary knob or by pressing the DEFROST or AC key.

The air conditioner compressor of the system can be switched on or off by pressing the AC key; the LED is on or off. The system is active without cooling function when the air conditioner compressor is off.

"Temperature" rotary knob

DEFROST function key REAR WINDOW DEFROSTER function key

"Air flow" rotary knob "Air distribution" rotary knob

SEAT HEATER left function key

AUTO function key AIR RECIRCULATION function key

AC function key

SEAT HEATER right function key

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The seat heater is optional equipment with the Audi TT Coupé ‘07. The three heater settings can be set by pressing the function keys.

In setting 0 the seat heater is off; setting 0 cannot be selected directly from setting 3; it can only be activated by pressing the "Minus" key several times.

The function keys are backlit and currently active functions are indicated by integrated LEDs. The control unit with display in dash panel insert J285 provides the dimming signals terminal 58d for the function LEDs and terminal 58s for the key backlighting via CAN bus.

The LEDs of the function keys and the key backlighting cannot be switched individually.

43

44


Components of the air conditioning system in the Audi TT Coupé ‘07

Air conditioner compressor

Single acting wobble plate compressor with

6 cylinders and variable delivery rate, without magnetic coupling, externally controlled.

The air conditioner compressor is not a carry-over part from the Audi A3.

The compressor stroke volume is regulated via the air conditioning system compressor regulating valve N280 by means of the PWM signal, depending on cooling power requirements.

Air conditioning system compressor regulating valve N280

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Ambient temperature sensor

(directly before the condenser)

Ambient temperature sensor G17

Only one ambient temperature sensor is used to evaluate the ambient temperature.

The ambient temperature sensor G17 is located at the front end, on the right-hand side behind the bumper, directly in front of the condenser.

Its value is provide by the control unit with display in dash panel insert J285 via CAN bus.

If the ambient temperature sensor G17 is faulty, the ECON function is activated. This means that the active cooling function is deactivated and the AC

LED goes out.

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Dash panel temperature sensor

Dash panel temperature sensor G56

The dash panel temperature sensor is integrated in the housing of the Climatronic control unit J255 and is ventilated by a suction blower. The temperature sensor can take on values from -50 °C to +77 °C.

The dash panel temperature sensor is deactivated if the temperature sensor or ventilation motor is faulty. An entry is made in the data memory, and the

Climatronic control unit J255 uses saved substitute values depending on the temperature set at the control panel.

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Outlet temperature sensor

For the driver side, one outlet temperature sensor is installed in the air duct of the chest vent and in the footwell duct. For the front passenger side, only the outlet temperature sensor is installed in the footwell duct.

The Climatronic control unit J255 evaluates the outlet temperature sensor in dependence on the air distribution and determines from this the actual outlet temperature.

If an outlet temperature sensor is found to be faulty, the temperature control is generally not deactivated. Depending on the operating mode

(Heat or Cool) and the side of the vehicle on which the fault occurs (the front passenger side has only one outlet temperature sensor, in the footwell duct), the Climatronic control unit J255 decides whether the temperature control can remain active or has to be deactivated.

If air distribution is in the DEFROST setting, the outlet temperature control is deactivated.

Outlet temperature sensor

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Combined filter in the Audi TT Coupé ‘07

A combined activated charcoal filter is standard on in the Audi TT Coupé ‘07.

The combined filter is accessible from the front passenger footwell. The filter can be replaced without tools.

The cover in the front passenger footwell is fixed in place with two wing bolts and the pollen filter air duct cover is located in position using a slide mechanism.

The combined filter has two predetermined bending points.This makes the filter easy to bend and simplifies installation of the filter into the air conditioner.

Dust and pollen filter

Cover

Fastening bolts

Pollen filter air duct cover

380_051

45


Function diagram of the automatic air conditioning system

G261 G262 G263 G385* G386** G107

J255

Signal, left

Signal, right

46

V70 G112

Evaluation for driver's seat heating

Evaluation for front passenger's seat heating

V71 G113 V107 G135

Legend

G56 Dash panel temperature sensor

G65 High pressure sender

G107 Sunlight penetration photo sensor

G112 Central flap control motor potentiometer

G113 Air flow flap control motor potentiometer

G135 Defroster flap control motor potentiometer

G143 Air recirculation flap control motor potentiometer

G220 Left temperature flap control motor potentiometer

G221 Right temperature flap control motor potentiometer

G261 Vent temperature sender, left footwell

G262 Vent temperature sender, right footwell

G263 Evaporator out-flow temperature sender

*G385 Front left chest vent temperature sender

(lefthand-drive vehicles only)

**G386Front right chest vent temperature sender

(right-hand drive vehicles only)

J126 Fresh air blower control unit

J255 Climatronic control unit

Terminal 75

Terminal 30

Terminal 15

Terminal 31

PWM

N280

V113

G65

PWM

V42

G143 V158

V2 J126

PWM Diagnosis

G56 Dash panel temperature sensor

G220 V159 G221

Positive 5 V

Earth

Termin

380_037

N280 Air conditioning system compressor regulating valve

V2 Fresh air blower

V42 Temperature sensor blower

V70 Central flap control motor

V71 Air flow flap control motor

V107 Defroster flap control motor

V113 Air recirculation flap control motor

V158 Temperature flap control motor, left

V159 Temperature flap control motor, right

Input signal for J255

Output signal from J255

Positive 5 V / 12 V

Terminal 13 / earth

CAN data bus

47

48

Infotainment

Radio navigation systems at a glance

Audi Navigation (BNS 5.0) Audi Navigation plus (RNS-E)

General

Radio

CD/MP3

6 inch dot matrix display, monochrome 6.5 inch TFT colour display

Light dimming via CAN bus

Display in driver information system

MMI operating logic can be operated via optional multifunction steering wheel

6 function keys

CD drive for navigation CD, audio CD or MP3 CD

9 languages

German, English, French, Italian, Dutch,

Portuguese, Swedish, Spanish and Czech can be loaded via CD

Clock in status bar

8 function keys (incl. Name, Car)

DVD drive for navigation DVD or audio CD or MP3 CD

6 languages

(German, English, French, Italian, Spanish,

Portuguese)

2-DIN housing

Integrated 2 x 20 W power module, Audi sound system with auxiliary amplifier as standard

Mute function via Power button (hierarchical mute function)

--Version display via CAR menu

--Optional voice recognition system for radio, CD, navigation and telephone

2-tuner FM/MW/LW with TMC

Dynamically updated station list

Diversity aerials

---

---

--TP Memo function

Navigation CD drive reads audio CDs and MP3 CDs

6-CD autochanger or iPOD connectivity

2 integrated MMC/SD card slots for MP3 files

MP3 playlist support

Table cont'd

Audi Navigation (BNS 5.0) Audi Navigation plus (RNS-E)

Navigation

Telephone

Telephone (with optional Audi mobile phone adaptor)

Options

Service

CD navigation system incl. Major Roads of Europe DVD navigation system, single-DVD drive

Dynamic navigation system with RDS and TMC

Turning instructions and directional arrow display in driver information system

Destination input options: postcode, place name, street name, POIs, latitude and longitude

Destination input options: postcode, place name, street name, POIs, cursor, address book

Shortest/optimum/quickest route are selectable max. 6 intermediate destinations are possible

---

---

---

--max. 3 route options are given max. 3 intermediate destinations are possible

Colour screen incl. Birdview, split screen and POIs

Geometric motorway exit display

Intersections map

List display of the next three route recommendations

Intelligent Speller (last city history)

---

---

Corridor function allows audio or MP3 CDs to be played while navigating

Mute function for hands-free telephone via cable or CAN

Loudspeaker control unit for hands-free telephone, adjustable volume control unit for calls

Display of reception level, network provider and roaming symbol

"accept call", "reject call" and "hang up" functions

Telephone number entry via Speller

Telephone number selection from the mobile phone phonebook

Bluetooth symbol appears in the status bar if the mobile phone is connected to the mobile phone adaptor via Bluetooth.

Voice control functions of mobile phone adaptor active

---

Voice control system integrated in mobile phone adaptor or voice recognition system

Telephone number selection from the address book

BOSE sound system

Mobile phone adaptor

--Analog TV tuner

All amplifiers can be encoded for GALA, while

BOSE Sound amplifiers are encoded as standard for Audio-Pilot

No auxiliary input (AUX-In)

Audi Sound System has GALA while the BOSE

Sound System has Audio Pilot

Vehicle-specific sound curves can be encoded

Diagnostics via CAN (A3, TT) or L-wire (A4)

4-digit radio code incl. convenience code

Transport mode via CAN

System software is flashable by CD in service workshops

Transport mode via adaption channel or CAN

System software is flashable by navigation DVD

49

50

Infotainment

Radio systems at a glance

chorus concert symphony

2-DIN housing

Three-line graphic display, light dimming via CAN can be operated via optional multifunction steering wheel

Station frequency display in the driver information system

FM/AM tuner

FM tuner with phase diversity

---

RDS (Radio Data System) with EON (Enhanced Other Network)

-- Traffic Information Messages

(TIM = TP Memo)

Integrated single-CD drive,

CD text capable

Integrated single-CD drive for audio CDs and MP3 CDs , CD text capable

Integrated 6-disc CD changer for audio CDs and MP3 CDs, CD text capable

Control unit for external 6-disc CD changer or auxiliary iPod adaptor

AUX input (code-activatable)

Mute function for hands-free telephone

Loudspeaker control unit for hands-free telephone

Diagnostics via CAN (A3 8P, TT) or L-wire (A4 8E)

Transport mode (reduced power demand)

Anti-theft device with convenience coding

Integrated 2 x 20 watts power module (not used for concert and symphony radios in the Audi TT)

--Auxiliary sound amplifier connected

--Connectivity for optional auxiliary BOSE Surround Sound amplifier

Volume adjustment as a function of road speed (GALA)

Basic sound set-up via encoding of vehicle type (saloon/Avant/Cabrio), interior trim (fabric/leather) and engine type (petrol/diesel engine)

US variant

RDBS FM/AM radio (FM/MW)

Control unit for optional digital satellite tuner

Reference

For detailed descriptions of radios and navigation systems, refer to Self-Study Programme 382

Audi TT Coupé ‘07 - Electrical and

Infotainment Systems

Introduction

The first generation of the Audi TT Coupé, named after the legendary "Tourist Trophy" race in the UK, was a milestone in automotive design.

The design followed the pure geometry, with central motives being the circle, particularly distinctive on the wheel arches, the arches of the roofline, the front end and the rear end.Audi has taken this genetic code and developed it in authentic style.

In the new TT, the geometric shapes merge fluidly with one another.The concave and convex arches radiate dynamism and movement while lending the TT Coupé the character of an athletic sculpture thrusting forwards.

The front end of the new TT Coupé has gained in expressiveness and resoluteness, the most distinctive element being the singelframe radiator grille.

Unlike the predecessor model, the rear end has a completely different outline to the front end. The rear lights create a three-dimensional effect by virtue of their visual depth. The trapezoidal cut-out around the license plate continues the flowing lines of the boot lid. The powerful exhaust tailpipes, wide diffusor and central rear fog light are borrowed straight from motorsport.

The dynamic impression conveyed by the Audi TT Coupé also stems from its modified proportions.

On the exterior it is now: - 137 mm longer

- 78 mm wider

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– Body


– Engine




– Infotainment




– Front axle

– Rear axle


– Brake system




– Networking

– Bus topology


– Infotainment





– Surface finish


– Repair concept





Service Training





Copyright

AUDI AG

I/VK-35


Fax +49-841/89-36367

AUDI AG




A06.5S00.25.20


Service Training

Audi TT Coupé ´07 - Suspension System




Copyright

AUDI AG

I/VK-35


Fax +49-841/89-36367

AUDI AG




A06.5S00.26.20

The new TT by Audi is a thoroughbred sports car.

The suspension system is one of the features key to meeting this high standard. The basic TT has a conventional steel-sprung suspension - the so-called

"dynamic suspension system". The new Audi magnetic ride system is optional. It is a semi-active suspension system with magneto-rheologically controlled dampers.

Sport or comfort damper settings can be selected at the touch of a button.

The S-line suspension by quattro-GmbH has been developed to meet the growing customer demand for vehicle customisation. This suspension is sportier than the dynamic suspension and reduces vehicle ride height by 10 mm.

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Contents

Axles

Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake system

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

System components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

ESP


Operation and displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Steering system

Electromechanical steering system EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Audi magnetic ride

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24


Special functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

CAN data exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Scope of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Wheels/tyres

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Self Supporting Tires (SST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Low tyre pressure indicator 36

Tyre pressure monitoring system (US spec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44



All values given are intended as a guideline only and refer to the software version valid at the time of preparation of the SSP.


Reference Note

Axles

Front axle

Overview

An improved version of the McPherson suspension is employed. The design of the front axle is identical to that of the Audi A3. Track width is 13 mm wider on each side than the Audi A3.

Detail modifications have been made to reflect the particularly sporty character of the Audi TT. In addition to the tuning parts (springs, dampers and antiroll bars), the same axle components are used in all

TT suspension variants.

Damper

Swivel bearing

Spring

Coupling rod

Ball joint

Wishbone

Subframe

Anti-roll bar

Wheel bearing

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4

System components

Subframe

The aluminium subframe bears the wishbones, the anti-roll bar and the steering gear of the electromechanical steering system. The two brackets for mounting the wishbones are now common parts.

The Audi TT is living proof that sportiness and lightweight design go hand in hand. The illustration shows the aluminium components of the front axle.

Swivel bearing

Wishbone

Self-aligning support

Subframe

Brackets

381_002

5

Axles

Swivel bearing, wheel bearing

The aluminium swivel bearing manufactured using

Cobapress technology* is a new part.Its geometric design allows a wider track width to be achieved.

Steel bushes are press fitted into the swivel bearing at the track rod and ball joint mounting points.

The third generation wheel bearing is bolted to the swivel bearing.

The wheel bearings are carry-over parts from the

Audi A3. The screws are now coated with a chromium-6 free material to protect the environment.

The suspension strut is connected to the swivel bearing by a clamp coupling.

Suspension strut

Wheel bearing

Swivel bearing

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6

Note

Note: Special tool 3424 must always be used to widen the clamp when installing and removing the damper!

*: The Cobapress process is a casting process in which the component subsequently undergoes a forging process. The result is high strength and toughness.

Wishbones, ball joint and bracket

The ball joint is connected to the wishbone at three bolting points. Compared to the Audi A3, the fastening bolts are integral parts of a separate retaining element. The bolts and retaining element are inserted from above through the wishbone and ball joint.

The wishbone is attached directly to the subframe at the inside front and to the body at the inside rear by means of an aluminium bracket.

Swivel bearing

Retaining element

Wishbone

Ball joint

381_004

Subframe

Bracket

Wishbone

381_005

Note

Note: after undoing the threaded connection between the ball joint and wishbone, always replace the retaining element.

7

Axles

Wishbones, ball joint and bracket

The ball joint is in a lower position than on the Audi

A3. The result is a higher centre of roll. This improves roll stabilisation and gives particularly sporty handling.

The centre of roll is the level with the front axle in the centre of the vehicle about which the body pivots when subjected to lateral forces, e.g. when cornering.

8

= position of the ball joint in the Audi A3

= lower position of the ball joint in the Audi TT

= position of the centre of roll in the Audi A3

= higher position of the centre of roll in the Audi TT

Anti-roll bar

A tubular anti-roll bar is used on models with frontwheel drive, while a solid bar is used on quattro models.

The link rod is a carry-over part from the Audi A3.

381_006

Link rod

Anti-roll bar

381_007

Rear axle

Overview

The rear axle of the Audi TT is basically identical in design and function to the rear axle on the Audi A3 .

The wheel carriers, damper bearings and wheel bearings are modified versions of the components used in the Audi A3. Track width has been increased by 15 mm on each side over the Audi A3.

The suspension and damping components (springs, dampers and anti-roll bars) have been adapted to the specific requirements of the Audi TT. Additional stone chip protection is provided for certain markets. The trailing arms on these models are protected by plastic claddings.

Rear axle for front-wheel drive

381_008

Rear axle for quattro models

381_009

9

Axles


Wheel carrier, wheel bearing

The wheel carrier has been modified geometrically in order to increase track width. Front-wheel-drive models use a second-generation wheel bearing which is larger than the bearing on the Audi A3.The diameter of the wheel carrier bearing journal has been adapted to match the internal diameter of the wheel bearing.

Ribbed washers are used for attaching the track link, upper wishbones and damper to the wheel carrier.

These washers are required to achieve the necessary surface pressures.

Wheel bearing

Wheel carrier

381_010

10

Ribbed washers

Note

Note: Always replace the ribbed washers during removal and installation of parts in the service workshop.

381_011

Wheel alignment

Front axle

Toe and camber can be adjusted at the front axle.

The toe-out values are adjusted at the track rods.

Unlike on the Audi A3, left and right camber can be adjusted separately.

The camber is adjusted at the connection between the wishbone and the guide bearing. For this purpose, the holes in the guide bearing are oblong in shape.

Track rod

Wishbone

Rear axle

The camber and toe can be adjusted at the rear axle.The adjustment procedure is the same as for the Audi A3.

Guide bearing

381_012

Camber adjustment

Toe adjustment

381_013

11

Brake system

Overview

Front axle brake caliper:

16" for all four-cylinder models

17" for all six-cylinder models

ESP:

TEVES Mk60E1 with optional Tyre Pressure Monitor

12

Brake servo:

10", 11", 7/8", with contactless brake light switch without dual rate characteristic

Rear axle brake caliper:

16" for all four-cylinder models

17" for all six-cylinder models

381_014

13

14

Brake system

Front axle

Engine

Minimum wheel size

Brake type

Number of pistons

Piston diameter (mm)

Brake disc diameter (mm)

R4-4V 2.0l TFSI

16"

FN3

1

54

312

VR6 3.2l MPI

17"

FNR-G

1

57

340

Rear axle

Engine

Minimum wheel size

Brake type

Number of pistons

Piston diameter (mm)

Brake disc diameter (mm)

R4-4V 2.0l TFSI

16"

CII 38

1

38

286

VR6 3.2l MPI

17"

CII 41

1

41

310


Front axle wheel brake

The brake calipers are identical in design and principle of operation to the brake calipers on the

Audi A3. A zinc-nickel coating is now applied. Brake calipers are optionally available in a grey finish. The brake discs for the 16" system have been adopted from the Audi A3. The brake discs for the 17" system are a modified version of the discs used on the Audi

A3. This change was necessary due to the modified rim geometry of the SST wheels.

The Audi TT has new brake hoses with modified holders on the swivel bearing compared to the Audi

A3.The 16" and 17" splash plates have been adopted from the Audi A3. Break pad wear is measured in a conventional fashion on the interior lining of the left wheel brake. The 17" system is equipped with a vibration damper. The damper is attached to the brake caliper by the lower fastening bolt.

16" wheel brake

381_015

17" wheel brake

381_016

15

16

Brake system

Rear axle wheel brake

The brake calipers are identical in design and principle of operation to those on the Audi A3. The brake carriers have been modified since the Audi TT has wider rims than the Audi A3 and, because of this, the requisite clearance for the handbrake cable would not have been assured had the A3 brake carrier been adopted unchanged.

Compared to the Audi A3, the brake calipers have been shifted 10 mm further inwards. Two new 16" and 17" splash plates are used. The brake hoses have been modified. In the Audi TT the transition point from brake hose to brake line is located on the side member (it is located on the subframe in the

Audi A3) .

16" wheel brake

381_017

17" wheel brake

381_018

Power brake unit / brake servo

In the case of the 16" systems, 10" single brake servos are used on left-hand-drive models and 7/8" tandem brake servos on right-hand drive models.

Vehicles with 17" systems are equipped with 11" single brake servos for left-hand-drive models and with

7/8" tandem brake servos for right-hand drive models.

For the Audi TT, no dual rate characteristic* was applied to the brake servo.

The OHB-V function known from the Audi A3 * was implemented on vehicles with 3.2l VR6 engine and dual-clutch gearbox.

* dual rate and OHB-V are described in SSP 313

Like in Audi A3 models after November 2005, the contactless brake light sensor is used on the Audi

TT. Brake light and brake test switches are no longer required on the brake pedal.

The pedal assembly has been adopted from the

Audi A3.

381_019

Brake light sensor

381_020

17

ESP


ESP unit

The Audi TT features a new ESP generation by Continental-Teves with the designation Mk60E1.

As with the Mk25E1 in the current Audi Q7, the

Mk60E1 has analogised switch valves

(4 intake valves and 2 block valves) and an integrated pressure sensor. In the case of analogised switch valves, the port cross-section is determined by the activation current. Unlike systems with conventional switch valves with the valve positions open and closed, more precise brake control is possible.

In the ESP control unit has the same integrated functions as in the Mk60 control unit on the Audi

A3, however these functions have been adapted to the Audi TT. The hill hold assist (hha) and driver steering recommendation (dsr) functions will be implemented at a later date. The Audi A3 system has been modified with regard to the operation of the ESP Off key.

Note

Due to the use of linearised switch valves, it is no longer possible to disconnect the control unit from the hydraulic unit in the service workshop.

381_022

Block valve

18

Inlet valve

Linearised switch valves

ESP hydraulic unit

(excerpt showing the hydraulic control device for a wheel brake)

381_023

Sensor unit G419

The sensor unit comprises senders G200 (lateral acceleration sender), G202 (yaw rate sender) and, on models with quattro four-wheel drive, G251 (longitudinal acceleration sender) . The sensor unit has been adopted from the Audi A3. The service procedures for calibrating the sensors are the same as for the Audi A3.

Wheel speed sensors G44 - G47

The wheel speed sensors for wheel speed measurement have been adopted from the Audi A3.

Steering angle sender G85

The steering angle sender is identical in design and function to the sender on the Audi A3.

381_024

381_026

19

ESP

Operation and displays

The functions of button E256 for ESP and TCS were extended as follows:

20

Briefly pressing the button (<3 s) deactivates only the TCS function. TCS OFF improves traction when starting from a stop on loose surfaces (e.g. on snow or sand).

TCS OFF is active up to a road speed of 70 kph. TCS is switched on automatically when this speed is exceeded.In all-wheel-drive models, TCS is automatically switched off again when the vehicle's road speed drops below 70 kph. In front-wheel-drive models, TCS is not automatically switched off when the vehicle's road speed drops below this threshold.

If the button is pressed for longer than 3 s, the ESP function is switched off.

When the brake is applied, TCS and ESP are switched on again for the duration of the braking manoeuvre and remain active until a stable driving condition is restored.

The ESP function is activated automatically if faults are diagnosed in the magnetic ride system or when actuating the rear spoiler.

If the button is pressed for longer than 10 s, the ESP function is switched on again and cannot be switched off again until the ignition has been turned off and on again.

TCS OFF

381_027

ESP

SWITCHED

OFF

381_027a

381_025

ESP / TCS ON

381_027b

Steering system

Electromechanical steering system EPS

The electromechanical steering system EPS which has proved successful in the Audi A3 is also featured in the new Audi TT. The following modifications have been made compared to the Audi A3: new track rod outer joint with larger joint diameter and modified journal geometry reduced steering angle, steering rack shortened from 80 mm to 78 mm new control unit due to new control software without dsr function

In the case of the Audi TT, the power steering assist maps

are determined by the powertrain type (front wheel drive or quattro) In the case of the Audi A3, the weight of the front axle is the determinant factor.

381_028

Reference

For detailed information on the design and function of the EPS system, refer to SSP 313.

21

Steering system

Steering column

A mechanical steering column is used in the Audi

TT. The steering column is basically identical in design and function to the steering column in the

Audi A3. The following modifications have been made compared to the Audi A3:

Shear element for crash safety adapted to TT

22

Longer drive shaft

Steering wheel

A redesigned steering wheel is used in the Audi

TT.All models are fitted with three-spoke leatherbound steering wheels with integrated two-stage airbag module. In addition to the standard version, combinations are also available of multifunction,

Tiptronic and leather stitching in various colours.

The skeleton is made of magnesium. The diameter of the steering wheel rim is 5 mm less than on the

Audi A3. As in the Audi A3, the airbag unit is bolted.

A new feature is the use cage nuts are used for tolerance compensation.The airbag module is centred in the steering wheel with two locating pins.

Larger adjustment range:

Longitudinal adjustment: ± 30 mm

Height adjustment: ± 25 mm

381_029

381_030


Overview

The Audi TT is the first Audi to feature Audi magnetic ride - a new semi-active suspension system with magneto-rheologically controlled dampers.

Sport or comfort damper settings can be selected at the touch of a button.

Shock absorber damping adjustment warning lamp K189

Shock absorber damping adjustment button E387

ECD control unit (electronically controlled damping) J250

Shock absorber damping adjustment valves N336-339

Vehicle level senders

G76-78,G289

Audi magnetic ride improves driving dynamics and driving comfort for the following reasons:

– reduced body movement (pitch and roll)

– optimised vibration behaviour

– improved road-holding

– improved handling

381_031

23


Operating principle

The damping function is based on the magneto-rheological effect. The prerequisite for this is the use of a special damping fluid. This magneto-rheological fluid is a suspension consisting of a hydrocarbonbased synthetic oil in which soft magnetic particles with a diameter of 3-10 µ m are held in suspension.

To stabilise the fluid, various additives are added.

Applying a magnetic field changes the properties of the magneto-rheological fluid. The magnetic particles are aligned in the direction of the magnetic field lines. This alters the flux voltage of the fluid.

Magneto-rheological fluid in non-magnetised state

Magneto-rheological fluid in magnetised state

Magnetic particles Magnetic field

381_032

Piston bores

24

Magnetic coil not activated

When the magnetic coils are not activated electrically, the magnetic particles are arranged irregularly in the damper oil.During the piston stroke, the individual particles are forced with the fluid through the piston bores. The particle-laden suspension damping fluid has a low resistance to the movement of the piston. As a result the damping force is low.

Magnetic coil activated

381_033

When the magnetic coil is activated electrically, the magnetic particles are aligned with the magnetic field lines. Thus, long particle chains form in the vicinity of the piston.

These particle chains are aligned cross-wise before the fluid enters the piston bores. During the piston stroke, individual particles break up and are forced with the fluid through the piston bores. To "break up" these chains, force must be applied, i.e. work must be done. The resistance which the piston must overcome is greater than in the case of a non-energised magnetic coil, and is dependent on the amount of electrical current and the strength of the magnetic field.

This allows greater damping forces to be achieved.


Damper

The magneto-rheological dampers are much simpler in design than conventional dampers. The complex conventional damping valves are no longer required. These have been replaced by bores in the piston through which the fluid is displaced. In addition, single-tube dampers are used. The magnetic coils are integrated in the pistons.

Power is supplied through the hollow piston rods along discrete lines from control unit J250. Depending on engine type (4 cylinder or 6 cylinder engines), different front axle dampers are used.A single damper is used for all engine types on the rear axle.

Connector

Front axle damper

Bores

Pistons

Cable to electrical control device

Connector

Rear axle damper

381_034

25


Damper

Variable activation of the solenoid valve allows the shock absorber damping force to be adjusted over a wide range.

Damping force adjustments are made within milliseconds. This allows the damping force to be adapted to requirements during the bump and rebound cycles.

0

Comparison of the damping force characteristics of Audi magnetic ride and conventional dampers

Tension (rebound)

Sport setting

Comfort setting

Sport setting

Compression (bump) Damping speed [m/s]

Adjustment range of Audi magnetic ride

Conventional damper

ECD control unit (electronically controlled damping) J250

The control unit receives the measured data from the vehicle level sender, as well as information on the current driving condition from the ESP. The control unit processes the data and thus determines the momentary activation currents for the dampers.

Each damper is activated individually. The dampers are not activated when the vehicle is stationary. The control unit is located under the front passenger seat.

381_035

381_036

26

Vehicle level senders G76-78, G289

The vehicle level senders are identical in design and function to those used in the Audi A6 and Audi A8.

The sampling rate is 800 Hz. Design and function are described in detail in SSP 343. Measured data is read in by control unit J250 across discrete lines, processed and relayed to the headlight range control, control unit via the CAN bus.

Shock absorber damping adjustment button E387

Warning lamp K189

The button is used to select a damper setting. In standard operation the dampers are configured for comfort. A sport damping characteristic can be activated pressing the button. The LED indicator integrated in the button indicates that the sport setting is active. Depending on dash panel variant, an additional text message may appear.The signal from the button is read in by the control unit across a discrete line.

Warning lamp

System faults are indicated by a warning lamp in the dash panel insert.The warning lamp is checked whenever the ignition is turned on.

The warning lamp also comes on if the dash panel insert has been coded incorrectly.

381_037

381_038

381_039

27


Special functions

Temperature model

The suspension damping becomes softer with increasing magneto-rheological fluid temperature.

A software module for temperature compensation is integrated in the control unit. The rising temperature is compensated by increasing the magnetic coil activation current.

Likewise, the activation current is reduced at low ambient temperatures.

Temperature is determined indirectly by measuring the resistance of the magnetic coil.

A current of 3A is applied to the coil for the duration of 40 ms.

The required voltage is determined and the resistance is calculated.

The basic value is the resistance measured in a vehicle which has been shut off for at least 6 hours. The following measurements are correlated with the basic value. Based on the change in resistance, the control unit determines the actual temperature in the shock absorber damper.In addition, the temperature of the control unit is calculated. This is done by evaluating the electrical currents provided by the control unit to activate the coils.

Temperature shut-off

The magnetic coil activation current must be increased in order to compensate for the effect of temperature increase in the dampers. However, increasing the electrical current causes further heating of the magnetic coil.Upwards of a defined threshold temperature of (90°C), therefore, it is no longer possible for the driver to select 'Sport' mode.

In 'Sport' mode, higher damping forces are produced by increasing the magnetic coil activation current. Activating the 'Sport' mode would, therefore, cause a further increase in the already high temperature in the suspension damper. The control unit is shut down when its temperature exceeds

110°C.

Emergency operation in case of failure in electrical activation of the magnetic coil

In case of failure in electrical activation of multiple magnetic coils, the magnetic coils of all suspension dampers are no longer activated.

In this case, the most comfortable suspension damping characteristic is set.

Tension (rebound)

Suspension damper force characteristic of Audi magnetic ride

0

28

Compression (bump) Damping speed [m/s]

Adjustment range of Audi magnetic ride Most comfortable damper setting

381_040

Shock absorber test

When the button is pressed for longer than 5 s, the magnetic coils are activated by the application of a constant electrical current.In this state, the shock absorbers can be tested on the test bench.

The indicator LED in the button flashes when the

"shock absorber test" mode is active. The system exists the mode automatically when the button is pressed again, after ignition on/off or when driving at a speed of at least 10 kph.

381_041

29


Function diagram

30

Positive

Earth

Powertrain CAN bus

Input signal

Output signal

381_042

J250 ECD control unit (electronically controlled damping)

G76-78,G289 Vehicle level senders

N336-339 Damper adjustment valves

E387 Shock absorber damping adjustment button

CAN data exchange

J250 ECD control unit (electronically controlled damping)

System status (2,5,8)

Activation of warning lamp, text display (8,5)

Position of button E387 (2,5,8)

Height front right, front left, rear right, rear left (4)

Automatic activation ESP (2,5,8)

J533 Diagnostic interface (8)

Date, time

Terminal 15 -counter

Mileage (km)

Time not in use

J519 Onboard power supply control unit (9)

Status of terminal 50

Information sent by control unit J250

Information received and evaluated by control unit J250

J220 Motronic control unit (1)

Momentary position of brake light switch, brake test switch

Coolant temperature

Intake air temperature (ambient temperature)

Engine torque

Driver torque input

J104 ESP control unit (2)

ESP on or off

ESP system status

Momentary vehicle speed

ABS active

Lateral acceleration

Brake pressure

Yaw rate

J527 Steering column electronics control unit (3)

G85 Wheel angle sender

Max. steering angle

Steering speed

Status of terminal 30

J431 Headlight range control, control unit (4)

(receiver only)

J285 Control unit with display in dash panel insert (5)

Time not in use of the vehicle

Status of combined light (terminal 58d)

Ambient temperature

VIN

381_043


Dash panel insert CAN bus

Convenience CAN bus

31


Service work

Address

The system can be addressed in the diagnostic tester under the address: 14 Wheel damping.

Coding

The coding tells the control unit the powertrain type and engine type of the vehicle. The control unit accepts the new coding after ignition on/off.

1 = heavy engine (6-cylinder)

3 = lightweight engine (4-cylinder)

3 = coupé with front-wheel drive

8 = coupé quattro

32

System initialisation - teaching in the new standard position

The system initialisation must be performed when the control unit J250 and/or one or more vehicle level senders is replaced. The characteristic curves of the vehicle level sender are stored in the control unit

During the system initialisation procedure, the control unit is informed which vehicle ride heights at the wheel positions match the actual measured values generated by the vehicle level sender. If these assignments are known to the control unit, then all measured values generated subsequently by the vehicle level sender can be converted to vehicle ride heights. The basic system initialisation procedure is identical to the procedure for initialising the aas systems in the A6 and A8. The system initialisation can only be performed when the code control unit is coded.

381_046

381_045

Final control diagnostics

The shock absorber dampers can be activated selectively in the final control diagnostics.

The shock absorber dampers are activated by applying a current of 2A.

Data blocks

The data blocks are used to check key system status information.The temperature values calculated for the dampers and control unit, for example, are represented in data block 28.

Cold starting

When control unit J250 or shock absorber dampers are replaced, the control unit must determine the electrical resistance values of the damper coils at ambient temperature. The control unit saves these values as "standard values" for purposes of temperature compensation (refer to "Special functions - temperature model").

This function is activated automatically after ignition on, provided the vehicle has been out of use for at least 3 hours (e.g. even after a a cold start in the morning) . During this time not in use, the temperatures of the dampers have adjusted to the ambient temperature. If the mechanic has fitted shock absorber dampers which are already at ambient temperature (e.g. parts sourced directly from the spare parts warehouse), the resistance measurement function can be started immediately by activating the "Cold start" function with the diagnostic tester.

Flashing

The control unit software can be flashed by an external data carrier (CD, online interface) .

33

Wheels and tyres

Overview

34

Engine

4-cylinder

Basic wheels

7.5J x 16 ET 45 (1)

Cast aluminium wheel painted

225/55 R 16

Optional wheels

8J x 17 ET 47 (3)


225/50 R 17

9J x 18 ET 52 (5)

Cast aluminium wheel polished, bicolor

225/50 R 17

6-cylinder 8.5J x 17 ET 50 (2)

Forged aluminium wheel painted

245/45 R 17

9J x 18 ET 52 (4)


245/40 R 18

9J x 18 ET 52 (6)


245/50 R 18

7J x 16 ET 47 (7)


225/50 R 17

Winter wheels

9J x 18 ET 52 (9)


245/40 R 18

7J x 17 ET 47 (8)

Forged aluminium wheel painted

225/50 R 17

381_047 also available optionally as SST wheel

Self Supporting Tires (SST)

SST tyres have run-flat capability because of their modified design compared to conventional tyres.

Much stiffer tyre sidewalls enable the vehicle to drive on for up to 50 km at a maximum speed of

80 kph even after a total loss of pressure.

Due to their modified tyre geometry, special wheels with the designation EH2 (extended hump 2) are used for SST tyres.To prevent inward displacement of the tyre beads in case of loss of tyre pressure, the bead seating has been modified substantially in comparison with conventional wheels. The bead is seated in a recess which supports the tyre towards the inside of the rim.

The special 17" wheels on the Audi TT can be used both for conventional tyres and for SST tyres. In the case of the 18" wheels, conventional tyres are available in combination with conventional rims. SST tyres are always combined with the low tyre pressure indicator.

381_048

Conventional wheel geometry extended hump 2

381_049

Note

Tyres run in "limp home" mode must always be replaced!

Special tools must be used to fit and remove

SST tyres.For detailed information, refer to the

"Workshop Equipment" catalogue

35


Low tyre pressure indicator

Overview

In all markets except North America the Audi TT features a newly developed low tyre pressure indicator.

Being an indirect measuring system, no tyre pressure sensors are installed in the wheels.

J285

J533

J793

J104

E492

G44

36

G45

J285

J533

J793

E492




Tyre pressure monitor display button

J104 ESP control unit

G44-47 Wheel speed sensor

G47

G46



381_050

Design and function

Data processing in the Audi TT is performed by control unit J793, and is no longer an integral part of the ESP control unit. The control unit is located behind the dash panel insert.

Tyre pressure monitor display control unit 2 J793

381_051

37

38



Using a new evaluation method, it is now possible to detect simultaneous pressure loss to at multiple wheels. Tyre pressures are monitored simultaneously using two different concepts.

1. Tyre circumference monitoring

– Tyre circumference decreases as a function of loss of pressure. As a result the wheel must rotate more quickly to cover the same distance as a fully inflated tyre. Wheel speeds are transmitted to control unit J793 by the ESP control unit. In the current Audi A3, the wheel speeds of the diagonal wheels are added and both diagonal sums are correlated with one another. In this way, allowance is made for different wheel speeds when cornering. In the Audi TT, the tyre circumferences are compared axle by axle and side by side.

Allowance is made for yaw rate and steering angle when cornering.

2. Tyre vibration monitoring

– Torsional vibration is excited in each tyre while rolling, due to road surface unevenness. These vibrations can be determined by evaluating the wheel speed signals. When the tyre pressure decreases, the vibration characteristics change.This monitoring concept, which is an additional feature compared to the Audi A3, it is now possible to reliably detect simultaneous loss of pressure at multiple wheels, as for example occurs over time at all four wheels due to diffusion.


Tyre pressure monitoring is activated with the SET key. This function must always be activated when tire pressures are changed or different wheels/tyres are fitted to the vehicle. This can only be done when the ignition is on and the vehicle stationary. The

SET key must be pressed for at least 5 seconds in order to activate the tyre pressure monitoring function.

381_061

Warnings are always indicated by the warning lamp in the dash panel insert.

For this purpose, the warning lamp is activated in two colours.

381_054

The following displays are possible:

– In the event of a rapid loss of pressure at a single wheel (tyre damage), the red warning lamp is activated. If the vehicle a driver information system, an additional text display appears indicating the position of the wheel affected.

– In case of slow loss of pressure, which occurs gradually at multiple wheels due to diffusion, the red warning lamp is also activated. In this case, the optional text display appears but no positional information is given. The displays are activated when the tyre pressure drops below an a coded minimum value.

– When system faults are detected, the yellow warning lamp is activated.

39

40



The teach-in process is performed once after the

SET key is pressed for the low tyre pressure indicator. During the next trip, the control unit saves the measured wheel speeds and the vibration characteristics of the wheels in various vehicle operating states. The vehicle operating states are basically defined by the following parameters: vehicle speed, steering angle, transverse acceleration and yaw velocity. These teach-in values subsequently make up the target data which is used for monitoring.

After approximately 10 minutes of driving, it is already possible to detect a breakdown (rapid loss of pressure) . Approximately 60 minutes of driving are required to detect diffusion loss (slow loss of pressure).

381_061

Service work

Address

The system can be addressed in the diagnostic tester under the address:

4C Tyre pressure monitor II.

Vehicle self-diagnostics

Select diagnostic function

Display all diagnostic functions

02 - Query fault memory

05 - Clear fault memory

06 - End of output

07 - Encode control unit

Encoding the subbus system

08 - Read data block

16 - Access authorisation

Read out Challenge immobiliser IV

Activate immobiliser IV

Identification services

4C - Tyre pressure monitor II

8J0907274 8J0907274

J793 TPM+

Coding 614100

H03 --- 0100

Dealership number 98765

Goto Print

381_056

Coding

The coding tells the control unit the system variant, powertrain type, gearbox type, wheel size and type of tyre used on the vehicle. The control unit accepts the new coding after ignition on/off.

Tyre type and size (16"-18", standard tyre, SST tyre)

Powertrain type (front, quattro, gearbox variant)

6 = PR No. 7K6 (= low tyre pressure indicator)

Data blocks

The data blocks are used to check key system status information.

41



42

Positive

Earth


Input signal

Output signal

A

B

C

D

J793 Tyre pressure monitor control unit 2

J104 ESP control unit

E492 Tyre pressure monitor display button

Signal from wheel speed sensor, rear right

Signal from wheel speed sensor, rear left

Signal from wheel speed sensor, front right

Signal from wheel speed sensor, front left

381_057

CAN data exchange

J793 Tyre pressure monitor control unit 2

System status (all)

Activation of warning lamp, text display (7,6)

J533 Diagnostic interface (7)

Date, time

Terminal 15 -counter

Mileage (km)

Reversing light switch

Trailer detected

J285 Control unit with display in dash panel insert (6)

Displayed vehicle speed

Handbrake activated

Error status, ambient temperature

Information sent by control unit J793

Information received and evaluated by control unit J793

J220 Motronic control unit (1)

CCS status

Clutch switch

Coolant temperature

Engine torque

Engine speed

Gearbox variant

J104 ESP control unit (2)

ESP system status

ABS active

EBD, EDL and ESP intervention

TCS and EBC request

TCS shift control

Brake light sensor

Lateral acceleration

Yaw rate

J527 Steering column electronics control unit (3)

G85 Wheel angle sender max. steering angle

J217 Automatic gearbox control unit (4)

Selector mechanism active

Target gear or selected gear

Selector lever position/driving program

Torque converter lock-up clutch

J492 Four-wheel drive control unit (5)

Error status

Clutch open

Clutch torque

Clutch stiffness



381_058

43


Tyre pressure monitoring system (US spec)

Overview

The Audi TT for the North American market uses an improved version of the tyre pressure monitoring system as featured previously in the Audi A6 (USA)

.It is a direct measuring system with tyre pressure sensors in the wheels.

J285

J533

J502

E492

44

G222 G223

J285

J533

J502

E492




Tyre pressure monitor display button

G222-225 Tyre pressure sensors

G224 G225

Dash panel insert CAN


381_059


In the Audi TT the rear tyre pressure monitor aerial

R96 is integrated in the tyre pressure monitor control unit J502.The control unit is fitted in the low tyre pressure indicator behind the dash panel insert. In the case of the tyre pressure monitoring system, communication with the vehicle periphery via the convenience CAN bus.

Trailer

Tyre pressure monitoring system J502

The aerial receives the radio signals from tyre pressure sensors G222-G226. The sensors operate at a radio frequency of 315MHz. The sensors are identical in design and function to those on the Audi A6.

A new feature is the use of the valve body as a transmitter antenna. The valve body and sensor can no longer be separated. As with the current models

A4, A6 and Q7, the sensors do not start to transmit until the wheels being to turn. To meet the countryspecific statutory requirements, the battery service life is 10 years. The tyre pressure of the spare wheel is not monitored. When the customer orders a fullsize spare wheel, the sensor is already installed in the wheel if the vehicle is equipped with a tyre pressure monitoring system.

The E492 button used in the tyre pressure monitoring system is identical to the button used by the low tyre pressure indicator. Pressing the button displays the actual tyre pressures as new target pressures.

As with the low tyre pressure indicator, the button is connected to the control unit by discrete lines.

381_051a

381_060

381_061

45

46



Tyre pressure warnings are indicated by the yellow warning lamp in the dash panel insert. No positionrelated warning is given. Warnings are indicated in accordance with country-specific statutory requirements at a residual tyre pressure of 75% or less.Tyre pressures are determined taking into account the tyre air temperature.

381_054

Service work

The main changes to the service work on the low tyre pressure indicator are listed in the following.

Coding

The coding tells the control unit the system variant, powertrain type, gearbox type, wheel size and type of tyre used on the vehicle. The control unit accepts the new coding after ignition on/off.

Target pressure ,Y bar

Target pressure X, bar

Tyre (standard, limp-home, extra load)

8 = PR No. 7K8 (= tyre pressure monitoring system)

Adaption

The control unit learns the new tyre pressure sensors automatically when the ignition is turned on after the vehicle has been shut off for at least 20 minutes. When new tyre pressure sensor identification numbers are recognised, the fault indicator lamp is activated. The driver enable monitoring of the actual tyre pressures by pressing the SET key.

The system is now ready for operation again.

The tyre pressure sensor identification numbers can be transmitted manually to the control unit using the function "10 Adaption". This bypasses the waiting period. Each identification number is indicated on the tyre pressure sensor housing.

Note

The handheld transmitters for the tyre pressure monitoring system VAS 6287 cannot be used on the tyre pressure monitoring system of the

Audi TT.

47


Service Training

Audi TT Coupé ´07 - Suspension System




Copyright

AUDI AG

I/VK-35


Fax +49-841/89-36367

AUDI AG




A06.5S00.26.20


Service Training

Audi TT Coupé ‘07 -





Copyright

AUDI AG

I/VK-35


Fax +49-841/89-36367

AUDI AG




A06.5S00.27.20

Innovations in the electronics, electrical and infotainment systems in the Audi TT Coupé ‘07

Self-Study Programme 382 describes the new features of the convenience electronics in the

Audi TT Coupé ‘07. The proven electronic technology of the Audi A3 ‘04 has been adopted for the TT Coupé. The most striking new feature is the automatic extending rear spoiler activated by the convenience system central control unit.

In the TT Coupé, the driver information system (DIS) in the centre display of the dash panel insert has an extended settings and query menu.

The customer can use the settings menu to configure functions and make adjustments. This was previously possible only in vehicles with MMI.

382_014

The Audi TT Coupé ‘07 offers the customer a multitude of functions and equipment options, with the result that the number of control units has increased considerably compared to the predecessor model.

To ensure smooth interaction between control units, the control units communicate with one another across various bus systems.

The networking structure is largely identical to that of the Audi A3 `04. In this self-study programme you will be informed about the network topology of the

TT Coupé and about the installation locations of the various control units as well as their functions.

382_044

The Audi TT Coupé ‘07 comes with new generation

2plus radios. The radios feature a new reception concept as well as

MP3 compatible CD drives.

The TT Coupé, as do the Audi A3 and A4, comes with a BNS 5.0 radio navigation system with MMI user interface and CD navigation.

The BOSE Surround Sound system, which includes

12 loudspeakers driven by a 255 watt amplifier, sets new standards in this vehicle class.

382_032




– Body


– Engine




– Infotainment




– Front axle

– Rear axle


– Brake system




– Networking

– Bus topology


– Infotainment





– Surface finish


– Repair concept



Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Topology and networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation overview - control units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Electrical system and convenience electronics . . . . . . 10

Data bus diagnostic interface J533 (gateway). . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Control unit with display in dash panel insert J285 . . . . . . . . . . . . . . . . . . . . . . . 13

Onboard power supply control unit J519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Front outside light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Rear outside light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Convenience system central control unit J393 . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Parking aid control unit J446. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Infotainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chorus, concert and symphony radios in 2-DIN housing . . . . . . . . . . . . . . . . . . 36

MP3 basics - ID3 day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Audi Navigation (BNS 5.0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Sound systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Apple iPod adaptor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Aerials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52



All values given are intended as a guideline only, and refer to the software version valid at the time of publication of the SSP.


Reference Note

4

Overview

Topology and networking


J623


J743

Selector lever

E313

ABS control unit

J104


J234


J492


J793*


J500

Steering angle sender

G85

Steering column electronics control unit

J527

Multi-function steering wheel control unit

J453

ECD control unit

(electronically controlled damping)

J250


J431

Power output module for left headlight

J667

Power output module for right headlight

J668

Diagnostic port


J533

Driver door control unit

J386

Front passenger door control unit

J387

Parking aid control unit

J446

Convertible top operation control unit

J256

Auxiliary air heater control unit

J604

Climatronic control unit

J255


J393


J619


J502**


J285


G578

Alarm horn

H12


J400


G397

* for tyre pressure monitoring system 2 only (ECE = Europe)

** for tyre pressure monitor only (SAE = North America)

Telephone transmitter and receiver unit

R36

Digital satellite radio tuner

R190

Digital sound package control unit

J525

TV tuner

R78

Radio

R

Control unit with display for radio and navigation

J503

CD changer

R41

Powertrain CAN bus infotainment CAN bus

Convenience CAN bus

Dash panel insert CAN bus

Diagnostics CAN bus

LIN bus

Subbus system

Panasonic bus

382_044

5

6

Overview

Installation overview - control units

382_067

9

10

11

12

Legend

3

4

5

1

2

6

7

8

13

Garage door operation control unit J530

Direct shift gearbox mechatronics J743

Power steering control unit J500

Engine control unit J623

ABS control unit J104

Wiper motor control unit J400

Alarm horn H12

Onboard power supply control unit J519

Headlight range control, control unit J431

Data bus diagnostic interface J533

CD changer R41

Tyre pressure monitor control unit 2 J793 /

Tyre pressure monitor control unit J502*

Control unit with display in dash panel insert

J285

Radio R

Control unit with display for radio and navigation J503

Climatronic control unit J255

15

16

17

18

19

20

21

22

23

24

14

25

Steering column electronics control unit J527

Steering angle sender G85

Multi-function steering wheel control unit

J453

Rain and light detector sensor G397

Driver door control unit J386

Front passenger door control unit J387

Anti-theft alarm system sensor G578

Telephone transmitter and receiver unit R36

Airbag control unit J234

ECD control unit (electronically controlled damping) J250

Digital satellite radio tuner R190

Digital sound package control unit J525

Convenience system central control unit J393

Parking aid control unit J446

TV tuner R78

Radio controlled clock receiver J489

* for tyre pressure monitor only SAE

7

8

Overview

Fuses and relays

The fuse and relay carriers

In the Audi TT Coupé ´07 the fuse and relay carriers are located in the following positions:

– Electronics box in engine compartment, front left

– Fuse carrier, dash panel left hand side on A-post

– Onboard power supply control unit and auxiliary relay carrier below dash panel on left

– Main fuse box directly on the battery

– Auxiliary relay carrier in the boot on the right, below the boot trim

For details of fuse and relay assignments, please refer to the current service literature.

Auxiliary relay carrier below the boot trim

Electronics box

Main fuse box


Fuse carrier

382_030

9

10

Electrical system and convenience electronics

Data bus diagnostic interface (gateway) J533

Tasks

The gateway represents the interface between the various bus systems, i.e. it facilitates communication between the control units of various bus systems. Every Audi TT Coupé ´07 has a powertrain CAN bus, dash panel insert CAN, diagnostics CAN bus, convenience CAN bus and infotainment CAN bus.

Master functions

– Powertrain CAN bus run-on

– Sending the 'Sleep' command


Diagnostics CAN bus

Powertrain

CAN bus

Infotainment CAN bus

Convenience CAN bus

382_047

Installation location

The gateway is installed under the dash panel adjacent the pedal bracket and can be accessed from the driver's footwell.

382_061


The function diagram is identical to that of data bus diagnostic interface as featured on the Audi A3 ´04.

The dash panel insert J285 and the data bus diagnostic interface J533 can wake each other from idle via the bidirectional wake-up line. The dash panel insert CAN between the dash panel insert and the data bus diagnostic interface is a highspeed

CAN and, unlike the convenience CAN bus, is not wake-up capable via the CAN line.

Onboard voltage is applied to the wake-up line when terminal 15 is "on".

This wake-up function is required to wake up the dash panel insert CAN without "terminal 15 on" after the CAN bus has been in idle state.

For example, to be able to display date, time and mileage in the dash panel insert after opening the driver's door, but before turning on the ignition.

Wake-up line

382_062

Transport mode

The Transport mode, which keeps power consumption to a minimum while the vehicle is being transported, is implemented in the gateway on the Audi TT Coupé ´07.

Transport mode can be activated and deactivated using the diagnostic testers. This can be done both using the Services function in the vehicle selfdiagnostics and using the gateway test plan in the

Guided Functions mode or in the Guided Fault

Finding mode.

Vehicle self-diagnostics

Services

Select diagnostic function

Query fault memory - overall system

Clear fault memory - overall system

Activate Transport mode

Deactivate Transport mode

Goto Print Help

382_060

Reference

For further information on the

Transport mode, refer to Self-Study

Programme 312.

11


Master function for terminal 15 across the powertrain CAN-bus

As in the Audi A3 ´04, information transmitted across the powertrain CAN bus includes a run-on function.

This allows the various control units to transmit information relevant to safety even when the ignition is off.

With regard to terminal 15 run-on, there are three different groups of powertrain CAN bus control units:

Active and passive control units as well as control units without run-on.

Active control units are control units which are able to keep the powertrain CAN bus awake.

Passive control units remain awake until the gateway signals it is ready to enter Sleep mode, but cannot independently keep the powertrain CAN bus awake.

Control units without run-on function shut off immediately after "ignition off".

12 active


J623


J743

ESP control unit

J104


J500


J533 passive

Steering angle sensor

G85

Selector lever

E313

Coding the gateway

Difference to the Audi A3 ´04

When coding the gateway, the derivative (body version) "Coupé, sports car" must be selected for the

Audi TT Coupé ´07.

Reference

For information on coding the gateway, refer to Self-Study

Programme 312. without


J492


J431


J234

ECD control unit (electronically controlled damping)

J250


J793

382_045

Control unit with display in dash panel insert J285

382_019

Variants of the control unit with display in dash panel insert J285

Lowline variant

The Lowline variant is the basic version. The basic version has, in lieu of a centre display, dedicated warning lamps which indicate warnings and fault conditions in the system to the driver. The low washer fluid warning lamp, previously available only in the Highline variant, has been added.

Midline variant

The Midline variant is only used in vehicles with automatic gearbox which do not have a driver information system (DIS). In the Midline variant, the centre display is used only for gear indication and ambient temperature display. The ambient temperature display is standard equipment in the Audi TT Coupé ´07.

Highline variant

The Highline variant has a centre display with a resolution of 64 x 88 pixels in lieu of the warning l;lamps.

Warnings and fault conditions are indicated by yellow and red icons on the centre display.

The Highline variant is fitted automatically in combination with the following optional equipment:

●

●

●

Screen navigation

Mobile phone adapter with multifunction steering wheel

Cruise control system

13


Immobiliser IV

The immobiliser is integrated in dash panel insert J285.

The immobiliser data is stored in the FAZIT database of AUDI AG.

The immobiliser IV can be adapted using the Audi diagnostic testers in the "Guided Fault Finding" and in the

"Guided Functions" modes.

The diagnostic tester must be online in order to make a connection to the FAZIT database.

The dash panel insert is addressed via the address word 17 and the immobiliser via the address word 25.

This means that data blocks, adaption channels and fault memories are handled separately.

Reference

For further information on immobiliser IV as well as the FAZIT database, refer to Self-Study

Programme 294.

New features of the onboard computer

The onboard computer has the following new features:

● In the Audi TT Coupé ´07 the mileage since the last reset of the onboard computer is indicated on onboard computer levels 1 and 2.The maximum range of the mileage indicator is 9999.9 kilometres and the resolution is 100 metres.

●

●

The driving time display range was extended from 99:59 h to 999:59 h on both onboard computer levels.

Each individual display variable of the onboard computer can be deactivated separately in the convenience menu under "SET". This applies to both onboard computer levels.

● All display variables of the onboard computer can be reset in the convenience menu under "SET".

14

Note

The new features described in this section of control unit with display in dash panel insert J285 of the

Audi TT Coupé ’07 will also be introduced in the current Audi A3 ‘04 after the transition from model year

2006 to 2007.

Display of cruise control system speed setting

When the cruise control system is active, the current speed setting is indicated on the centre display of the dash panel insert in the Audi TT Coupé ´07. If one of the two onboard computer levels is shown on the centre display, the set speed is indicated continuously. The speed is normally displayed in the position where the ambient temperature is indicated.

If the digital speedometer is shown on the centre display or if it is currently being used by the navigation system, the set speed is displayed after activating the cruise control system for 3 seconds, after which the display returns automatically to the original screen.

After "terminal 15 on", the function shown on the dash panel insert centre display before "terminal 15 off" is restored. In the example below, the digital speedometer is displayed.

On-board computer

Level 1

On-board computer

Level 2

DISPLAY TYPE

SET

QUERY

>MENU OFF

HELP

START SCREEN Navigation display

Description of the various options

4

5

6

1

2

3

Press Reset key on onboard computer

Press Reset key on onboard computer when cruise control system is inactive

Press Reset key on onboard computer when cruise control system is active

Set a speed when the cruise control system is active

Cancel set speed when the cruise control system is active automatically after 3 seconds

382_020

15

16


The extended convenience menu - menu option "SET"

It is possible to go from onboard computer levels 1 and 2 and the digital speedometer to the menu shown by pressing the Reset key on the onboard computer:

In the menu option "SET" the driver can change the settings of the control unit with display in dash panel insert or onboard computer, and can also make settings in different control units. In this way it is possible to set for example the central locking system and acoustic parking system. The windscreen wipers can also be adjusted to the service position in this way.

DISPLAY TYPE

>SET

QUERY

MENU OFF

HELP

382_009

All setting options are shown below in the associated menu structure:

SET

Clock

Current time

12h or 24h mode

Current Date

Date display mode

Computer

Computer 1

Reset all values in onboard computer 1

Display range on / off

Display driving time on / off

Display mileage on / off

Display average fuel consumption on / off

Display average speed on / off

Display current fuel consumption on / off

Computer 2

Reset all values in onboard computer 2

Display range on / off

Display driving time on / off

Display mileage on / off

Display average fuel consumption on / off

Display average speed on / off

Display current fuel consumption on / off

Speed alarm

Switch speed alarm on or off

Set speed alarm threshold (in increments of 10 kph)

Language

German

English

Francais

Italiano

Espanol

Portugues

Units

Display distances in kilometres or miles

Fuel consumption display in l/100km or in km/l

Temperature display in °C or °F

Lights

Indicating

Convenience indicator (= motorway indicator function) on or off

Wiper

Front

Service position on or off

Window

Convenience opening on or off

Doors

Unlocking

Unlock driver's door or all doors

Horn mode on or off

Lock

Switch Autolock on or off

Horn mode on or off

Control unit

Rear

Volume:

Pitch:

Levels 1, 2, 3, 4 or 5

Levels 1, 2, 3, 4 or 5

The extended convenience menu - menu option "QUERY"

All querying options are shown below in the associated menu structure:

QUERY

Service

Service in: x kilometres y days

Vehicle ID

VIN

Engine oil temperature

Engine oil temperature: x degrees

DISPLAY TYPE

SET

>QUERY

MENU OFF

HELP

382_009

The extended convenience menu - menu option "MENU OFF"

To return to the display of onboard computer variables, select the menu option "MENU OFF", press the Reset key on the onboard computer and return to onboard computer level 1.

DISPLAY TYPE

SET

QUERY

>MENU OFF

HELP

382_009

17

18


Onboard power supply control unit J519

Function

The onboard power supply control unit in the Audi

TT Coupé ´07 basically has the same main functions as the control unit in the Audi A3 ´04.

The onboard power supply control unit controls:

– the outside light

– the charge indicator lamp

– terminal 58s

– the load management system

– terminals 15, 50 and 30G

– the electric fuel pump II relay

– the windscreen wiper

– the heated rear window

– the signal horn

– the interior light

382_059

Installation location

The onboard power supply control unit is housed under the dash panel on the left, and can be accessed by removing the dash panel trim in the driver footwell.

System overview

The onboard power supply control unit is integrated in the convenience CAN bus within the vehicle networking system.

It also performs the function of the LIN master for the wiper motor control unit and the rain and light detector sensor.


J519


J400


G397

382_046

Reference

For further information on the outside light control, activation of the charge indicator lamp, the dimming function (terminals 58s and 58d), the load management system, the terminal management system as well as the fuel pump relay control, refer to Self-Study Programme 312.

Battery

The battery is installed in the boot on the right and can be accessed by removing the cargo-area floor.

The Audi TT Coupé ´07 does not have a slave start connector because the battery is directly accessible.

Therefore, battery charging and auxiliary power supply are via the battery terminals.

For trickle charging of showroom vehicles, a suitable charger, e.g. VAS 5059A, VAS 5900 or

VAS 5903 must be connected in order to conserve battery power.

If the battery is discharged or faulty, the boot lid can be released using an emergency release device. For information on the emergency release device, refer to the Audi TT Coupé ´07 Owner's Manual.

The following batteries are used

●

●

●

61Ah / 330A

72Ah / 380A

75Ah / 420A (dry-cell battery for the North

American market)

● 80Ah / 380A

The choice of battery is dependent on

– engine variant

– trim package

– country spec package

Battery test

The battery acid level is tested in the conventional manner by visual inspection.

If the acid level in the battery cells is too low, then the battery must be replaced.

As in the predecessor model, battery voltage is measured under load using battery tester

VAS 5097A.

382_066

Reference

For further information as well as safety instructions, please refer to the current service literature.

19


Front outside light

Headlight

Generally, in the case of the Audi TT Coupé ´07, a distinction is made between three variants:

●

●

●

Halogen headlight

Bi-xenon headlight

Bi-xenon headlight with AFS

Configuration of the front lamps in the halogen headlight variant

Low beam headlight

Main-beam headlight

Side reflector

Indicator

The following bulbs are used in the halogen headlight variant:

12 V bulb

Side light

Low-beam headlight

Main-beam headlight

Indicator

Sidemarking lights (SAE*)

W5W

H7

H7

H21W

WY5W

Type

Side light / sidemarking light (SAE*)

382_022

5 watts

55 watts

55 watts

21 watts

5 watts

Rated power

20

* country-specific variant for the North American market

Configuration of the front lights in the bi-xenon headlight and bi-xenon headlight with AFS variants

Side reflector

Low-beam headlight / main-beam headlight

Daytime driving lights

Side light / sidemarking light (SAE)

Indicator

The following bulbs are used in the bi-xenon headlight or bi-xenon with AFS variant:

12 V bulb

Side light

Low beam headlight

Main-beam headlight

Indicator

Sidemarking lights (SAE)

H6W

D1S

D1S

H21W

WY5W

Type

6 watts

35 watts

35 watts

21 watts

5 watts

Rated power

382_023

Light bulb replacement

All light bulbs in the headlights can be replaced using the vehicle tool kit.

The headlights can be removed without taking off the bumper.

For information on light bulb replacement, refer to the Audi TT Coupé ´07 Owner's Manual.

Since gas discharge lamps are subject to special safety requirements, replacement of such lights should be referred to an authorised workshop.

Note

For instructions for removing the headlights and details of safety requirements for gas discharge lamps, please refer to the current service literature.

21

22


Fog light

Mounting bracket

Fastening bolts

Fog light

382_027

The fog lights on the Audi TT Coupé ´07 are located in the bumper. An H11 bulb with a rating of 55 watts is used as a lighting element.The bulb can be replaced with the vehicle tool kit.

For instructions for removing the fog lights, refer to the Audi TT Coupé ´07 Owner's Manual.

Sidelight

The sidelight uses LED technology and is housed in the door mirror housing. The sidelight is activated by the respective door control unit. The sidelight and the electrically adjustable outer mirror glass drive motor can be replaced individually by the service workshop.

Refer to the current Workshop Manual!

Sidelight

382_038

Rear outside light

The rear lights on the Audi TT Coupé ´07 are available in two variants:

– ECE variant for the European market

– SAE variant for the North American market

The differences between the two rear lights relate to the indicator and sidemarker lights:

– ECE variant: reflector in the area of the indicator in yellow-brown and rear lights without sidemarker light

– SAE variant: reflector in the area of indicators in red and rear lights with sidemarker light

Outer taillight and brake light Reflector

Sidemarker light (SAE only)

Side reflector

Outer indicator Inner indicator

Inner taillight, brake and parking light

Reversing light

382_025

The following lighting elements are used in the rear lights on the Audi TT Coupé ´07:

Type 12 V bulb

Taillight and brake light

Reversing light

Indicator

P21W

W16W

W16W

21 watts

16 watts

16 watts

Rated power

23

24


Third brake light

The third brake light is located in the bootlid under the rear spoiler.

It uses LED technology and can only be replaced as a complete assembly. Replacement of the third brake light should be referred to an authorised workshop.

Refer to the current Workshop Manual.

Third brake light

382_039

Rear fog light

The rear fog light in the Audi TT Coupé ´07 is fitted at the centre of the rear bumper. An H21W bulb with a rating of 21 watts is used as a lighting element.

The bulb can be replaced from below without taking off the bumper. The lamp socket is secured in the lamp housing by means of a bayonet fitting.

Rear fog light

382_037

Convenience system central control unit J393

Tasks of the convenience system central control unit J393

The convenience system central control unit J393 of the Audi TT Coupé ’07 is based on the convenience system control unit in the Audi A3 ’04.

Its range of functions has been extended to include an "electrically adjustable rear spoiler" function.

●

●

●

Convenience system central control unit J393 has the following tasks:

Central locking master

Anti-theft alarm system master

LIN master for communication with the components of the antitheft alarm system

●

●

●

● Control of the "electrically adjustable rear spoiler"

Activation of the luggage compartment lights

Read-in of the handbrake contact switch

Data exchange with other control units across the convenience CAN bus

● Self-diagnosis and diagnosis of connected components

In the Audi TT Coupé ´07, the convenience system central control unit J393 is located at the rear right on a control unit holder. It is located directly under the parking aid control unit J446, if installed in the vehicle.

382_003

382_001

25

26


Electrically adjustable rear spoiler

Introduction

The Audi TT Coupé ´07 has, as standard, an "electrically adjustable rear spoiler" function.

The extended rear spoiler provides additional driving stability when driving at high speeds.

Rear spoiler in lower end position (retracted)

382_011

Rear spoiler in upper end position (extended)

382_010

Function and operation

Automatic mode

The rear spoiler is extended automatically when a speed of 120 kph is exceeded. When the vehicle speed drops below the 80 kph speed threshold again, the rear spoiler is retracted automatically.

382_007

Manual mode

The rear spoiler can be extended up to a speed of 120 kph by flicking the adjustable rear spoiler switch E127.

The rear spoiler can also be retracted and extended within a road range between 20 kph and 120 kph by flicking the adjustable rear spoiler switch E127. The rear spoiler cannot be retracted at speeds of 120 kph or higher.

When driving at speeds of between 0 kph and 20 kph, the switch must be kept pressed while the rear spoiler is retracting. If the switch is released while the rear spoiler is retracting, the rear spoiler will stop in its momentary position. Actuating the switch again will cause the rear spoiler to extend again.

The adjustable rear spoiler warning lamp K242 integrated in switch E127 comes on whenever the rear spoiler is extended manually. As soon as the rear spoiler is retracted again or the system switches to Automatic mode because the vehicle is travelling faster than 120 kph, the warning lamp goes out again.

Note

When the Transport mode is activated, the Automatic mode is active and the "Manual mode" is deactivated.It is not possible to extend and retract the rear spoiler by actuating the adjustable rear spoiler switch when Transport mode is set.

27

28


System behaviour in case of malfunction

A detected system malfunction is indicated to the driver by activating a rear spoiler warning lamp in the rev counter. If no fault has occurred, this indicator lamp comes on for 3 seconds after turning on the ignition and goes out again.

In the case of the following faults, the rear spoiler is extended for safety reasons:

●

●

●

●

The convenience system central control unit J393 receives no road speed signal

The convenience system central control unit no longer receives any CAN messages

Implausible signals to rear spoiler adjustment limit switches 1 and 2 are detected

The convenience system central control unit is supplied with undervoltage (U < 10.5 V)

382_014

Note

If a fault is detected in the

"electrically adjustable rear spoiler" function, the ESP can no longer be switched off manually. If the ESP was switched off at this time, it is reactivated automatically.

Integration of the function into the vehicle

The "electrically adjustable rear spoiler" function is implemented in the convenience system central control unit J393. The control unit activates the adjustable rear spoiler motor V52 and reads in the two limit switches

F135 and F136, which are used to identify both limit positions of the rear spoiler.

The convenience system control unit J393 also reads in the adjustable rear spoiler switch E127 and activates the adjustable rear spoiler warning lamp K242 in the button according to the current status.


J393

V52

F135

Legend

E127 Adjustable rear spoiler switch

F135 Rear spoiler adjustment limit switch 1

F136 Rear spoiler adjustment limit switch 2

J393 Convenience system central control unit

K242 Adjustable rear spoiler warning lamp

V52 Adjustable rear spoiler motor

F136 E127 K242

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29


Design of the "electrically adjustable rear spoiler"

The "electrically adjustable rear spoiler" consists of two components which can be ordered separately:

●

● the rear spoiler module the spoiler wing

A DC motor mounted on the rear spoiler module transmits a rotary movement to the input shaft vi a gear and special joint (four-way joint). The shaft converts this movement to a lifting movement by means of left and right reversing mechanisms. The lifting movement moves the spoiler wing mounted on the rear spoiler module from the lower limit position to the upper limit position or vice versa, depending on momentary position of the rear spoiler.

Two limit switches for detecting the lower and upper limit positions are actuated by the four-way joint.

Complete rear spoiler module without mounted spoiler wing

Reversing mechanism Plate for mounting the spoiler wing

Reversing mechanism

30

Drive shaft

Adjustable rear spoiler drive unit

Four-way joint

Rear spoiler adjustment limit switch 1 F135

(the second limit switch F136 is not shown)

Gear

Drive unit

Drive shaft

DC motor

382_004

382_005

Diagnosis

The scope of diagnosis in the convenience system central control unit J393 has been extended to include the new function.Address word 46 is assigned to the convenience system central control unit in the diagnostic tester.

●

●

●

●

There is a new data block for the "electrically adjustable rear spoiler" function. It contains the following information:

Switch for detecting the end position "rear spoiler retracted" is actuated or not actuated

Switch for detecting the end position "rear spoiler extended" is actuated or not actuated

Adjustable rear spoiler switch E127 is actuated or not actuated

Warning lamp K242 in the adjustable rear spoiler switch E127 is on or off

There is adaption or final control diagnostics function for the electrically adjustable rear spoiler. It is not included in the coding either, but is standard equipment in the TT Coupé.

31


New features of the antitheft alarm system

In the Audi TT Coupé ´07 the interior monitor sender/receiver module 1 G303 and the antitheft/tilt system control unit J529 are combined as a unit - the antitheft alarm system sensor G578.

This means that the convenience system central control unit J393 in combination with the optional

"antitheft alarm system" two LIN users in the


The new antitheft alarm system sensor G578 is integrated in the overhead module of the


It has a 4-pin connector and is connected via a LIN bus line to the convenience system central control unit J393.


J393

Alarm horn

H12


G578

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Microphone

Ultrasonic sensor Anti-theft alarm system sensor G578 Ultrasonic sensor

Microphone

32

Interior light

Front passenger side

Overhead module connector

(interior light)

Connector of the antitheft alarm system sensor

Interior light driver side

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Parking aid control unit J446

Introduction

The Audi TT Coupé ´07 is equipped for the first time with an acoustic parking system with ultrasonic sensors as featured previously in other Audi models. A 4-channel rear acoustic parking system is available as optional equipment.

The term "4-channel rear acoustic parking system" means that 4 acoustic parking sensors which monitor the area behind the vehicle are integrated in the rear bumper cover.

Acoustic parking system control unit J446

The acoustic parking system control unit J446 is a carry-over part from the Audi A3 ‘04. Both the hardware and the software are identical.

The systems in the Audi TT Coupé ´07 and in the

Audi A3 ’04 (different installation positions of the acoustic parking sensor in the rear bumper) are differentiated by the software based on the control unit coding.

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In the Audi TT Coupé ´07, the acoustic parking system control unit is located at the rear right on a control unit holder. It is arranged above the convenience electronics central control unit J393.

382_000

33

34


Acoustic parking system adjustment options

In the Audi TT Coupé ´07, the volume and pitch (frequency) of the acoustic parking system can, for the first time, be adjusted via the "Extended convenience menu" in the control unit with display in dash panel insert.

Alternatively, these settings can be made at the service centre using the diagnostic tester. There are appropriate adaption channels in the acoustic parking system control unit for this purpose.

The relevant menu can be accessed as follows:

SET DISPLAY TYPE

>SET

QUERY

MENU OFF

HELP

WIPER

WINDOW

DOORS

>ACOUSTIC

PARKING SYSTEM

BACK

ACOUSTIC PARKING

SYSTEM

>REAR

BACK

REAR

VOLUME

1 2 3 4 5

PITCH

>1 2 3 4 5

BACK

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Acoustic parking sensor of the acoustic parking system

So-called fifth-generation acoustic parking sensors are used in the Audi TT Coupé ´07.This generation of sensors was used for the first time by Audi in the

Audi Q7. These sensors are much smaller than the fourth generation sensors and no longer have a fixed plastic housing which accommodates the oscillating membrane.

It has been replaced by an expandable decoupling ring, which is fitted on the ultrasonic sensor.

The decoupling ring must be removed to paint the acoustic parking sensor.

Decoupling ring

Oscillating membrane for transmitting and receiving ultrasound

3-pin connector

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System overview

The following lines lead to the acoustic parking system control unit:

●

●

●

●

2 lines from the convenience CAN bus

3 lines to the power supply

2 lines for the rear parking aid warning buzzer H15

3 lines to each of the 4 acoustic parking sensors (2 lines for power supply and one digital signal line for data exchange)

Rear parking aid warning buzzer

H15

Acoustic parking system control unit

J446

G203 G204 G205

Acoustic parking sensor in rear bumper cover

G206

382_006

35

Infotainment

Chorus, concert and symphony radios in 2-DIN housing

36

A new generation of radios is used in the Audi TT Coupé ‘07.

The main new features are an FM tuner with phase diversity as well as MP3 compatible CD drives in the concert and symphony radios.

382_058

Specifications - all radios

Tuner

RDS FM/AM radio

Display of stored station with RDS name display

FM tuner with phase diversity

Internal and external drives

Internal CD drive, CD text capable: information stored on the audio CD about the artist and title is shown on the display

The internal drive in the concert and symphony radios is MP3 compatible.

Control of an optional auxiliary 6-disc CD changer or an optional auxiliary iPod adaptor

Table cont'd

Telephone

Mute function for handsfree telephone: If the mobile phone adapter is factory-fitted, muting is via the infotainment CAN bus.A direct wiring plug contact is provided for retrofit solutions.

LF input for handsfree telephone: when the radio is switched on, the vehicle loudspeakers are used as loudspeakers for the handsfree telephone.

The handsfree telephone cannot be operated via the radio.

Control

Control via optional multifunction steering wheel

Display on the driver information display

Sound

Integrated 2 x 20 W amplifiers, connectivity for auxiliary amplifier

Speed-dependent volume control (GALA) via infotainment CAN bus

Sound coding according to body type (saloon/Avant/Cabrio), interior trim (fabric/leather) and engine type (petrol/diesel engine)..

Service

Comfort coding: after the power supply to the radio has been disconnected, it is not necessary to enter a PIN if the radio is restored to operation in the same vehicle.

Diagnosis via CAN bus (TT, A3 8P) or L-wire (A4 8E)

37

38

Infotainment

concert radio

The concert radio has all the features of the chorus radio. The single-CD drive is also MP3 compatible, i.e. MP3 CDs can be played.

The diagram shows the arrangement of the folders on the MP3 CD in the radio. Folders which do not contain MP3 files are not shown on the radio display. When selecting a folder, the previous folder, the folder currently selected and the next folder are shown on the display.

The first 16 letters of the CD folder name are shown on the radio display.

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In MP3 playback mode, the ID3 tag of the MP3 file can be viewed by pressing the INFO key. The Info key can be used to scroll from one display to another.

The file name, title, artist and album can be displayed.

Menu texts are displayed in English.

The display language of the radios cannot be changed.

File name

Title

Artist

Name of album

Folder

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Note

In the case of the concert and symphony radios, only the internal CD drive is MP3 compatible.

The optional auxiliary CD changer cannot play MP3 CDs. The CD changer featured in the Audi A3

8P and Audi A4 8E is fitted in the Audi TT Coupé ’07.

The amplifier in the concert radio is not used in the Audi TT Coupé ‘07. A 5-channel DSP amplifier is installed in combination with the concert radio as standard.An auxiliary BOSE sound amplifier is optional.

symphony radio

The symphony radio has all the features of the concert radio.

The symphony radio is additionally equipped with an internal MP3 compatible 6-disc CD changer.

In addition, the radio has the ability to record Traffic information Messages (TIM key = Traffic Information

Message). Traffic Information Messages stored by the radio can be played back by briefly pressing the TIM key. Holding the TIM key down activates a function which allows two time periods to be programmed during which Traffic Information Messages are recorded by the radio even when it is switched off.

Note

The radio has a higher power consumption in TIM record standby mode than when completely switched off. Please deactivate the TIM function to perform static current measurements on the vehicle.

Technical variants

In addition to the Audi TT Coupé ‘07, these radios will in future also be used in other Audi models equipped with the infotainment CAN bus. The necessary adjustments are basically the type of front trim panel and the diagnosis path (CAN, L-wire, etc.)

Country spec versions

The concert and symphony radios are modified for the North American market.

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The modifications are:

● different function key lettering and functions

– SAT: the radio can also be used to control the Sirius satellite tuner

– INFO: the Info key can be used to read information on the set radio station when the radio is in operation. In MP3 mode, the name of the album (ALBUM), the name the artist (ARTIST) and the CD title

(TITLE) are read off the ID3 tag of the MP3 file.

– MIX: the Mix key can be used to select a track mix from audio CDs or MP3 CDs.

● Optimisation of the FM/AM tuner for the North American market

– RDBS in lieu of RDS

– Station seek adapted to the frequency spacings of the radio stations

The concert radio will also be available in a variant for Japan at a later date.

39

40

Infotainment

Aerial system

Radios with phase diversity have two aerial inputs which can be diagnosed individually. The radios differ in this respect from the previous radios or the current radio navigation systems.

Radios with phase diversity do not have a separate diversity switch.The Diversity function is integrated in the radio. Only one aerial is connected to each of the two radio aerial inputs, thus simplifying diagnosis. Each aerial signal can be read out in a separate data block.

Although only two aerials are used, reception quality and interference immunity are better than those of the previous systems.

FM2 FM1 / AM

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Note

Different aerials are used by the new radios and navigation systems. For this reason, radios cannot be replaced with navigation systems in the unchanged FM aerial system. Reception is much poorer when the wrong aerial system is used.

Although different FM aerials are used, the radios and navigation systems have the same aerial connectors. The differences between the aerials are described on page 52.

MP3 basics - ID3 tag

The ID3 tag is a field containing additional information which can be attached to MP3 audio files. ID3 stands for "Identify an MP3".

MP3 files can, but need not necessarily, contain ID3 tags.

Left Outside alone

Summary

Feedback Options

Left Outside alone (4:17)

Anastacia

Anastacia

Lyrics Title name

Artist

Album

Type:

Size:

Bitrate:

Sampling rate:

Modified on:

Count:

Last played:

MPEG audio file

5.9 MB

187 Kbits/s (VBR)

44,100 kHz

25.04.2006 14:55

0

Not available

Type:

Channels:

ID3 tag:

Coded with:

MPEG-1, Layer 3

Stereo (Joint) v2.3

LAME3.96

ID3 tag version

Location: E:\MyMusic\Anastacia\Anastacia Storage location on PC

Back Next

An ID3 tag contains information on the selected

MP3 file. The main contents of the ID3 tag are the name of the artist, the name of the album as well as the name of the track. The ID3 tag is an integral part of the MP3 file. The ID3 tag can be used to call up details of the track title, even on compact MP3 player displays.

OK Cancel

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The ID3 tag can be generated and edited on the PC using standard MP3 converters and player software.

The ID3 tag version can be read out as illustrated, e.g. using Apple iTunes, the PC software for the

Apple iPod.

Note

There exist various versions of the ID3 tag. To find out which versions support the drive, please refer to the instruction manual for the Audi MP3 drive. Only then is it possible to show information on the system display.

41

Infotainment

Audi Navigation (BNS 5.0)

42

382_048

When model year 2007 is launched, the BNS 5.0 navigation system in the Audi A3, A4, TT will replace the current BNS 4.1 navigation system.

The system combines the concept of the Navigation System Plus (RNS-E) with the display of the MMI basic system. Unlike the Navigation plus system, the BNS 5.0 navigation system features CD navigation and a monochrome screen but no SD/MMC card reader.

For the first time, it is possible to navigate even with the navigation CD removed, which means that the drive can also be used to play audio CDs.

Specifications

Control

– 6 inch monochrome display with MMI basic display

– MMI operating logic as well as 6 function keys

– Control via optional integrated multifunction steering wheel

– Route indication by means of directional arrows on driver information display

– Display and voice output in 9 different languages

– The desired language (German, English, French, Italian, Dutch, Portuguese,

Swedish, Spanish and Czech) can be copied from the navigation CD to the system and converted, depending on the selection made in the language menu.

Navigation

– CD navigation with voice output and route display on the dash panel insert.

In total, 10 different navigation CDs are available for Europe.

The navigation CDs of the predecessor system cannot be used.

All CDs contain all major routes in Europe (Major Routes of Europe). The map data for the navigation CD is supplied by Teleatlas.

– Dynamic navigation with TMC

– The navigation CD can be removed after the route has been generated. This means that it is possible to navigate and simultaneously use the CD drive to play back audio CDs or MP3 CDs.

– Destination input by location, post code, POIs or longitude and latitude

– Routes with up to 6 waypoints can be generated

– Route memory

– Country CDs are available for the following countries (where digitised): Alps,

Benelux, Germany, France, United Kingdom/Ireland, Italy, Spain/Portugal,

Scandinavia/Finland.

Radio

– Dual FM tuner with switched diversity for optimum reception, as well as simultaneous dynamic station list updating and TMC reception

– AM tuner for medium wave and long wave

Internal and external drives

– Internal CD drive, MP3 compatible

– Control of an optional auxiliary 6-disc CD changer or an optional auxiliary iPod adaptor

– No connectivity for additional auxiliary source (AUX).

Note

In the case of the BNS 5.0 navigation system, only the internal CD drive is MP3 compatible.

The optional auxiliary CD changer cannot play MP3 CDs. Audi TT Coupé ’07 comes with the CD changer system previously featured in the Audi A3 8P and Audi A4 8E.

43

Infotainment

Telephone

– Operation of the optional factory-fitted mobile phone adapter with navigation system speller

– Mute function for handsfree telephone: If the mobile phone adapter is factory-fitted, muting is via the infotainment CAN bus. A direct wiring plug contact is provided for retrofit solutions. Retrofit solutions cannot be operated with the navigation system.

– LF input for handsfree telephone: when the radio is switched on, the vehicle loudspeakers are used as loudspeakers for the handsfree telephone.

Sound

– Integrated 2 x 20 W amplifier

– Auxiliary sound amplifier connected

– Connectivity for optional auxiliary BOSE sound amplifier

– Speed-dependent volume control (GALA) via infotainment CAN bus

– Basic sound setting via body version coding (A4 saloon/Avant/Cabrio, A3, TT).

Service

– Comfort coding: after the power supply to the radio has been disconnected, it is not necessary to enter the 4-digit PIN if the radio is restored to operation in the same vehicle.

– Diagnosis via CAN bus (TT, A3 8P) or L-wire (A4 8E). The scope of diagnosis

(data blocks, adaption, coding, etc.) is basically the same as for diagnosis of the Navigation plus system (RNS-E).

– The system software can be updated as required with a flash CD.

44

Technical variants

In addition to the Audi TT Coupé ‘07, the navigation system will in future also be used in other Audi models equipped with the infotainment CAN bus. The necessary adjustments are basically the shape of the front trim panel, the CAN communication and the diagnosis path (CAN, L-wire, etc.)

Simultaneous navigation and CD playback

With the BNS 5.0 navigation system, it is possible to navigate and listen to CDs simultaneously. For this purpose, the system is equipped with an internal memory into which the required map data can be loaded after entering the navigation destination.

After entering the route, the system first computes the distance to the route destination.

Load navigation CD

Enter navigation route

The map features of the route are then copied to a memory integrated in the system. If the CD is removed during the copy process, the system displays the following query

"Do you want to cancel loading the route features?"

to indicate that the corridor has not been loaded completely.

After completing the copy process, the navigation

CD can easily be removed.

The map data copied to the internal memory is also available for navigating to other route destinations within the copied area. This means that it is not necessary to load the navigation CD to navigate to each new navigation destination.

System copying corridor from CD

Remove navigation CD

Load audio CD

Play audio CD

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45

46

Infotainment

Behaviour of the internal map memory while driving

Route with corridor

Destination radius

Location radius

After entering the route destination a map section is copied to an internal memory. The map section consists of a location radius, a destination radius as well as a slightly narrower route corridor in between.

When the vehicle is driving towards the destination, the location of the vehicle changes. To make optimum use of internal memory, the position and size of the location radius are updated continuously by the system when the navigation CD is loaded.

Likewis, the size of the destination radius as well as the width of the corridor are updated continuously in the internal memory. In codedthe event that the navigation CD is removed, this ensures that the optimum map section is always stored in the system memory.

When the navigation CD is removed from the system, the map content stored at the time of removal of the CD remains stored in the system memory. The map content remains stored in the deactivated system for 72 hours.

This enables one to enter a route from town A to town B and to navigate between town A to town B over a lengthy period of time without having to reload the navigation CD.

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If the actual location and the destination are too far apart when the navigation CD is removed, the system may request that the navigation CD be reloaded while navigating to the destination.

The size of the corridor is defined by the size of the system memory. Due to the different density of the navigation data in towns and in sparsely populated areas, it is not possible to specify the size of the corridor area.

Note

When map data is stored in the system, the static current consumption of the system rises slightly. Map data can only be cleared prematurely by disconnecting the system from the power supply. Please bear this fact in mind when performing static current measurements on the vehicle.

Sound systems

Basic sound (standard equipment with chorus radio)

The Audi TT Coupé ’07 is equipped as standard with a two-way loudspeaker system.

The treble loudspeakers are installed in the dash panel, while the bass loudspeakers are installed the front doors. This variant is only available in combination with the standard chorus radio.

The 2 x 20 watt amplifier is also integrated in the chorus radio.

The loudspeakers are diagnosed via the radio, i.e. via address word 56.

R22

R23

R20

R21

382_050

R

R20

Legend

J525 Digital sound package control unit

R Radio

R14 Rear left treble loudspeaker

R16 Rear right treble loudspeaker

R20 Front left treble loudspeaker

R21 Bass loudspeaker, front left

R22 Front right left treble loudspeaker

R23 Bass loudspeaker, front right

R103 Front left mid-range loudspeaker

R21 R22 R23

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R104 Front right mid-range loudspeaker

R105 Rear left mid-range loudspeaker

R106 Rear right mid-range loudspeaker

R148 Centre loudspeaker (subwoofer)

R158 Mid-range/treble loudspeaker, centre

R159 Mid-range/treble loudspeaker, rear left

R160 Mid-range/treble loudspeaker, rear right

R164 Microphone unit in front roof module

47

48

Infotainment

Standard sound system

This sound system has an auxiliary 5-channel DSP amplifier, the digital sound package control unit J525 which is diagnosable via CAN. The amplifier supplies the front two-way systems, the rear two-way systems and the central loudspeakers integrated in the dash panel.

The standard sound system is standard equipment of the concert and symphony radios as well as the navigation systems with MMI operating logic. These radios or navigation systems do not use an internal amplifier.

All loudspeakers are diagnosed via the amplifier, i.e. via address word 47. Vehicle model, equipment, networking and type of driving noise compensation are also coded in the amplifier.

R22

R20

R158

R23

R160

R16

R21

R159

R14

R22 R23 R16 R160

J525

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J525

R158 R20 R21 R14 R159

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BOSE Surround Sound

In the Audi TT Coupé ’07, a BOSE surround sound system is optional in combination with the concert and symphony radios as well as Audi navigation systems. The sound system features BOSE 6000 amplifier technology with 8-channel DSP amplifier and Audio Pilot which set new standards for this automobile class.

The amplifier drives a total of 12 loudspeakers. It was adapted specially for use in the TT Coupé.

Compared with the standard sound system, a three-way system and an additional subwoofer are installed in the left-hand side trim of the rear seat bench. As with other current BOSE sound systems - a microphone is integrated in the overhead module to record background noise. The DSP amplifier utilises the background noise information picked up by the microphone to frequency-adjust the output signals to the loudspeakers, resulting in a well-balanced sound.

All loudspeakers are diagnosed via the amplifier, i.e. via address word 47. Vehicle model, equipment, networking and type of driving noise compensation are also coded in the amplifier.

R20

R158

R164 R22 R104

R23

R160

R16

R103

R21

R164

R158 R22

R159

R14

R104

R148

R23

J525

382_052

R160 R16

J525

R148 R20 R103 R21 R159 R14

382_055

49

50

Infotainment

Apple iPod adaptor

The iPod by Apple is a very popular and versatile

MP3 player. Various versions of the Apple iPod are currently available on the market. The iPod has up to

60 GB (gigabytes) of memory. This is enough to store about 15,000 songs on the device.

The Apple iPod adaptor can be ordered with the new vehicle or purchased as an OEM accessory.

Music

Playlists

Artists

Albums

Titles

Clock

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Radio or navigation

Apple iPod

Dock Connector

Adaptor (interface)

Radio connecting cable

382_032

The Audi iPod adaptor can be used to connect the Apple iPod to radios with communication CAN bus. The adaptor converts the CD changer messages from the radio for the iPod. It can be connected as an alternative to the CD changer. Simultaneous operation of the CD changer and iPod adaptor is not possible, because both devices use the same port on the radio. All iPods with

Dock Connector, a 30-pin blade terminal, can be connected to the adaptor iPod. Models without a Dock

Connector, e.g. with USB port only, cannot be connected to the iPod adaptor.

The iPod adaptor allows the iPod to be operated using the CD changer control functions. The displays on radios or navigation systems support only CD changers with max. 6 discs and max. 99 tracks per CD. For this reason, they cannot display folders, artists and tracks like the iPod display.

To overcome this system limitation of the CD changer interface, an operating concept adapted to the interface has been developed.

382_033

The Apple iPod and the associated PC software

(iTunes) have a function for programming playlists.

A playlist can have a freely selectable name and contain any number of songs in a fixed sequence.

This feature has been utilised.

The iPod adaptor loads the first 5 playlists in alphabetical order. The corresponding CD number is assigned to each playlist. The first alphabetical playlist appears on the radio as CD 1, the second playlist as CD 2, and so on. All tracks are loaded in alphabetical order of artist as CD 6.

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To program special playlists for use of the iPod in the car, it is recommended to place a number in front of the playlist name.

When playlists are sorted in alphabetical order, a number always takes precedence over the letter "A".

The playlists "1_Mozart", "2_Beethoven", "3_ Chopin", etc. are loaded by the adaptor based on the preceding number in the order CD1 = 1_Mozart, CD2 = 2_Beethoven, CD3 = 3_ Chopin.

The songs are displayed as Track 01, Track 02, etc. like on the CD changer. The numbering on the radio display goes up to Track 99. All tracks in a playlist can be played. If more than 99 tracks are stored in a playlist, only the last two digits of the track number are displayed for tracks 100 and upwards. Track 00 is displayed for track 200 and Track 37 for track 1037.

When the radio is on, the rechargeable battery of the iPod is charged using the iPod adaptor.

To disconnect the iPod from the adaptor, switch the radio off.

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Note

For further information on the adaptor function and handling the iPod on the adaptor, please refer the relevant Audi instruction manual.

51

Infotainment

Aerials

In the Audi TT Coupé ‘07, most aerials are integrated in the rear window. Only the navigation aerial (GPS), the telephone and digital satellite radio (North

America only) aerials are integrated in the roof aerial.

The amplifiers for the various systems are fitted at the top left and right, as well as the bottom right of the rear window. The bottom right aerial module is available in variants for phase diversity and switched diversity.

Various FM aerial systems are installed in the vehicle to serve the various radio tuner systems.

Radios with phase diversity for FM reception

(= chorus, concert or symphony radios) have a different FM aerial system to radios with switched diversity (= Navigation plus (RNS-E) or Navigation

(BNS 5.0))

Aerial system with phase diversity

DAB / TV4

R52

Telephone

SDARS SAT

R113

SDARS Terr.

TV3 Radio FM1 / AM

R24

Central locking

52

Note

Only the aerial modules required for the existing equipment are fitted in the vehicle.

TV2

TV1

R111

Radio FM 2

382_029

Aerial system with switched diversity

DAB / TV4

SDARS SAT

SDARS Terr.

R113

TV3

R52

Telephone

Navigation

FM1 / AM

R24

Central locking

TV2

TV1

R111

Radio IF

Radio HF

Aerial Function

Aerial amplifier R24 Analogue radio aerial amplifier (FM1, AM)

Central locking aerial amplifier

Radio/telephone/navigation aerial R52 Telephone aerial, navigation aerial

Digital satellite radio aerial (SDARS, North America only)

Aerial amplifier 2 R111 Analogue radio aerial amplifier (FM2)

TV aerial amplifier -1-


Aerial amplifier 4 with switched diversity only:

Analogue radio aerial amplifier (FM3, FM4, Diversity)

R113 TV aerial amplifier -3-


Digital terrestrial radio aerial amplifier (DAB)

382_026

53

54

Notes

Innovations in the electronics, electrical and infotainment systems in the Audi TT Coupé ‘07

Self-Study Programme 382 describes the new features of the convenience electronics in the

Audi TT Coupé ‘07. The proven electronic technology of the Audi A3 ‘04 has been adopted for the TT Coupé. The most striking new feature is the automatic extending rear spoiler activated by the convenience system central control unit.

In the TT Coupé, the driver information system (DIS) in the centre display of the dash panel insert has an extended settings and query menu.

The customer can use the settings menu to configure functions and make adjustments. This was previously possible only in vehicles with MMI.

382_014

The Audi TT Coupé ‘07 offers the customer a multitude of functions and equipment options, with the result that the number of control units has increased considerably compared to the predecessor model.

To ensure smooth interaction between control units, the control units communicate with one another across various bus systems.

The networking structure is largely identical to that of the Audi A3 `04. In this self-study programme you will be informed about the network topology of the

TT Coupé and about the installation locations of the various control units as well as their functions.

382_044

The Audi TT Coupé ‘07 comes with new generation

2plus radios. The radios feature a new reception concept as well as

MP3 compatible CD drives.

The TT Coupé, as do the Audi A3 and A4, comes with a BNS 5.0 radio navigation system with MMI user interface and CD navigation.

The BOSE Surround Sound system, which includes

12 loudspeakers driven by a 255 watt amplifier, sets new standards in this vehicle class.

382_032




– Body


– Engine




– Infotainment




– Front axle

– Rear axle


– Brake system




– Networking

– Bus topology


– Infotainment





– Surface finish


– Repair concept




Service Training

Audi TT Coupé ‘07 -





Copyright

AUDI AG

I/VK-35


Fax +49-841/89-36367

AUDI AG




A06.5S00.27.20


Service Training

Audi TT Coupé ´07 - Body


All rights reserved. Technical specifications subject to change without notice.

Copyright

AUDI AG

I/VK-35


Fax +49-841/89-36367

AUDI AG




A06.5S00.28.20

Audi-Space-Frame ASF ® of the Audi TT Coupé

The development targets for the bodyshell of the Audi TT

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 milestone in the development of modern Audi bodyshells.

Crash safety of the bodyshell is enhanced by means of load-bearing structures at the front end, sides and rear end, with a heavy emphasis on pedestrian safety.

To ensure efficient volume bodyshell production, various new joining and production techniques are employed.

The repair concept is based heavily on the well-known aluminium repair concept. However, of course, the materials combination of aluminium and steel necessitated that new approaches be taken.

383_001

Contents

Audi Space Frame of the Audi TT

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technological concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Combination of steel and aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Comparison of ASF concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Joining techniques and production processes

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Punch riveting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Clinching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

MIG welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Resistance spot welding and MAG welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Structural bonding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

New joining technique: solid punch riveting (Kerb-Konus riveting) . . . . . . . . . . 16

New joining technique: Flow Drill screwing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

New joining technique: aluminium laser welding . . . . . . . . . . . . . . . . . . . . . . . . . 18

Repair concept

Aluminium repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Steel repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Aluminium-steel repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Workshop equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Qualification of aluminium. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Bodyshell safety concept

Head-on collision, side impact and rear collision . . . . . . . . . . . . . . . . . . . . . . . . . 26

Pedestrian safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electromechanical rear spoiler

The self-study programme teaches the design and function of new vehicle models, new automotive parts or new technologies.


All values given are intended as a guideline only and refer to the software version valid at the time of preparation of the SSP.


Reference Note


Dimensions

4

Audi TT Coupé ’ 07

Transmission

Kerb weight without driver in kg

Max. perm. gross weight in kg cw (rear spoiler extended)

Boot capacity in l

Max. power output in kW vmax in kph

Acceleration 0-100 kph in s

Fuel consumption in l/100 km

* with the rear-seat back folded forward

2,0

Manual gearbox

1260

1660

0.3

290 (700*)

S tronic

1280

1680

147 (200 bhp)

240

6.6

7.7

6.4

7.7

383_002

3,2 quattro

Manual gearbox S tronic

1410

1810

0.3

1430

1830

0.31

5.9

10.3

290 (700*)

184 (250 bhp)

250

5.7

9.4

Technological concept

Sheet-steel parts are used for the first time in the

ASF of the new Audi TT in addition to aluminium castings, aluminium extruded sections and aluminium sheet-metal parts. Collectively, they make up the body structure. Vehicle weight distribution has been optimised by using sheet-steel parts in the rear body section. This has a direct bearing on sporting characteristics, such as driving dynamics and acceleration as well as safety characteristics, such as stopping distance and driving stability

In spite of the partial use of sheet-steel parts, the total body weight of 277 kg, including attachments such as doors and lids, is considerably less than that of a comparable all-steel body.

Although the new TT has grown in size, the gross weight of the vehicle has been reduced through the use of the aluminium-steel bodyshell.

The body structure of the new Audi TT has higher strength and 50 % higher torsional rigidity than its predecessor.

Aluminium extruded sections

Sheet-aluminium parts

Aluminium castings

Sheet-steel parts

383_003

5


Contact corrosion

Aluminium has a passivating oxide surface layer which protects the material underneath from corrosion. This is why an unpainted aluminium part normally does not corrode.

However, if there is contact between aluminium and a metal higher up in the electrochemical series than aluminium and if an electrolyte, such as salt water, is present in this region, contact corrosion will occur.

The greater the difference in potential, the greater the contact corrosion. As aluminium is normally the lesser noble metal, it degrades.

Contact corrosion

6

383_005

Schematic of contact corrosion with example

383_004

Contact corrosion can only be prevented by taking measures to stop the flow of electrical current induced by the potential difference between the two metals. This is best achieved by painting the surfaces. However, the risk of corrosion is high even if a tiny amount of paint damage occurs.

In the case of the Audi TT, the following anti-corrosion measures have been taken:

– coating of all steel screws and fasteners such as self-piercing rivets

– Galvanising of all sheet-metal parts (zinc and aluminium have a smaller potential difference than steel and aluminium)

– Insulation by means of adhesive

– Sealing of aluminium-steel joints

Reference

For detailed information on contact corrosion, please refer to Self-Study Programme 239 "Audi

A2 - Body" .

Joining steel and aluminium

One of the challenges for the development of the

Audi TT bodyshell was the attachment of the sheetsteel rear-end parts to the aluminium body assemblies.

Thermal joining processes such as MIG welding can be ruled out because it is not possible by these means to make a joint which has the requisite structural and dynamic strength and will not result in contact corrosion.

Steel

Aluminium

383_011

Aluminium-steel connections

383_006

7


Special requirements are made with regard to the strength and corrosion protection of the joints between aluminium body parts and steel parts.

This is ensured by non-thermal joining of parts using coated self-piercing rivets and special screws in combination with bonding.

Adhesive

Adhesive

8

383_012

Aluminium and steel joints with faulty corrosion protection can exhibit much higher corrosion rates than all-aluminium joints or all-steel joints.When making aluminium-steel joints, therefore, highest standards of quality must be maintained at all times during the production process and in the service workshop.

Adhesive bonding is the basis for the corrosion protection of corrosion-susceptible aluminium/galvanised steel joints in the bodyshell of the Audi TT.In this way, the mating materials are superficially insulated, thus suppressing corrosion processes at the point of contact. As a further measure, all composite joints either sealed with PVC or coated with wax preservative after the cataphoretic dip coating (KTL) process.

This illustration shows clearly what effects contact corrosion can have if adequate corrosion protection is not provided. A this joint, the flange was sealed in the bodyshell without using adhesive.

The aluminium sheet shown here exhibits severe contact corrosion, which has resulted in mechanical failure of the punch riveted joint.

Seal

Seal

383_007

By way of a comparison, this illustration shows the same flange with an adhesive bond and sealing.

In this case, the aluminium sheet showed no damage due to contact corrosion after exposure to identical environmental conditions.

Seal

Adhesive

Seal

383_008

9


Comparison of ASF concepts

Audi A8 (2003 ➔ )


Sheet aluminium parts


383_013

10

Sill section Audi A8

Three-chamber extruded section

383_014

A-post, Audi A8

Single-chamber extruded section

383_017

Audi TT (2006 ➔ )


Sheet aluminium parts


Sheet-steel parts

383_009

Sill section, Audi TT

Four-chamber extruded section

383_016 383_015

A-post, Audi TT

Sheet-aluminium sections (interior/exterior)

11


Overview

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.

Riveted joint

383_018

383_019

Flow-Drill screw connection

12

Technology

Mechanical joining techniques

Thermal joining techniques

Bonding technology

Machining technology

Clean Laser

Process

Punch riveting

Flow Drill screwing

Solid punch riveting (Kerb-Konus)

Clinching

MIG welding

Laser welding

Resistance spot welding

MAG welding

Stud welding

Bonding

Milling

Drilling

Thread cutting

Brushing

Roll seaming

Clean lasering

Quantity per vehicle

1615 pce.

229 pce.

96 pce.

164 pce.

21462 mm

5309 mm

1287 spots

809 mm

234 pce.

97156 mm

188 mm

16 pce.

8 pce.

2300 mm

26737 mm

4000 mm

383_020

Punch riveting

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

The process has been in use since launch of the Audi A2. Self piercing rivets with two different diameters and lengths are used in the Audi TT.

Punch riveting process

383_032

Applications of punch riveting

383_051

Clinching

With clinching, the metal sheets to be joined are clamped between a die and a blankholder. The sheets are then pushed down into the die by a punch to form an interlocking joint. However, joints produced in this way is not as strong as joints produced by punch riveting, for example.

In the Audi TT, this technology is used on attachments such as doors and lids. Several clinched joints are also located in the area of the B-post and rear wheel arch. In this area, aluminium sheets as well as steel and aluminium sheets are clinched together.

Clinching process

383_052

Applications of clinching

383_053

13


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.

This joining technique is notable for producing high-strength joints, but it introduces a great deal of heat into the joint and has a relatively slow process speed.

MIG welding process

383_054

Applications of MIG welding

383_055

Resistance spot welding and MAG welding

The usual techniques of resistance spot welding and, to a lesser extent, metal active gas welding (MAG welding) are used for joining sheet steel body parts in steel body manufacturing.

Resistance spot welding process

383_056

14

Applications of MAG welding

Applications of resistance spot welding

383_057

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.

Structural bonding process in production

383_058

Applications of structural adhesive

383_059

15


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. This is the case with the joint between the body side section and the drip moulding. However, the strength of solid punch riveted joints is inferior to that of punch riveted joints.

Solid punch riveting process

383_060

Solid punch riveting process in production

383_061

Micrograph of a solid punch riveted joint

383_073

Information on the repair concept

Aluminium solid punch rivets are used in the C-post drip moulding area, while coated stainless steel solid punch rivets are used in the region of the roof frame. Stainless steel rivets must not be drilled out or ground, due to the risk of corrosion.

16

Applications of solid punch riveting

383_048

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. The lower part is not predrilled. The pressure and rotational speed soften the material and allow the screw to be inserted.

383_062

Flow Drill screwing process

Flow Drill

Screw

Screwing process in production

383_063 383_074

Micrograph of a Flow Drill screw connection

Information on the repair concept

Flow Drill screws can be removed in the service workshop and replaced with new screws. In case of thread damage, screws are also available in oversize (M6 instead of M5) . For use in new parts, it may be necessary to predrill the material.

Applications of Flow Drill screwing

383_064

17


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.

Laser-induced plasma

Liquid melt zone

Solid melt zone

Laser beam

Evaporating metal vapour

Welding wire

Vapour / plasma / channel

Direction of welding

383_065

383_066

Laser welding process in production

383_025

Micrograph of the roof frame and roof panel joint

18

Applications of laser beam welding

Invisible roof seam

Applications of laser beam welding

383_067

To ensure consistent laser welding of aluminium parts, the parts to be welded must have a perfectly clean surface. 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. Parts cleaned using this method can be directly laser-welded.

383_069

Laser Clean process in production

383_068 383_075

Micrograph of a laser-welded seam with

Laser Clean (above) and without cleaning (below)

The joint between the roof frame and roof panel is reworked and surface finished automatically in the production line by means of a brushing process.

Brushing process in production

383_070

383_071

Laser weld seam before (above) and after the brushing process (below)

383_072

19

Repair concept

Aluminium repair

The repair concept for the all-aluminium body parts is similar to that for the repair of previous Audi aluminium-bodied vehicles.

If the vehicle structure is damaged, beam 1 can also be replaced by undoing the screw connection. All further damage to the vehicle front end can only be repaired by welding suitable genuine parts into place.

The front end of the vehicle is designed in such a way that the bumper beams and bolted crash boxes can be replaced after minor collisions up to approx.

15 kph.

Crash box

Bumper beam 1

Bumper beam Screw connections

Bumper beam 2

383_023

20

Joint between beam 1 and beam 2

383_024

The four-chamber extruded section is located beneath the sill moulding.A special repair method was developed for damaged outer chambers. When repair work is needed, the extruded section is split vertically so that the two rear chambers including the centre ridge of the four-chamber profile remain.

A dual-chamber genuine part developed specially for this repair solution is welded to the remainder of the sill profile using a continuous MIG weld seam at the top and bottom. In addition, the U-shaped channel in the genuine part is filled with an adhesive bead which provides additional strength and eliminates noise transmission between the two sills.

New part

Adhesive bead

MIG weld seam

383_039

21

Repair concept

Steel repairs

The rear end of the Audi TT is only area where it is possible to carry out repair work involving only steel parts and where the aluminium-steel joint is fully intact.

This repair work can be carried out on the

– rear end section

– rear side member (body side section undamaged)

– rear floorpan

Basically, the repair procedure is the same as for allsteel-bodied vehicles. Due to the danger of contact corrosion in aluminium body parts, however, special safety precautions must be taken. Grinding dust of steel parts, particularly flying sparks caused by cutting or welding work, must not be allowed to drop onto the aluminium parts.

This also applies to painted aluminium parts! Red hot steel parts can damage the paintwork and steel particles can come into contact with the aluminium body parts, leading to contact corrosion on the undamaged aluminium body.

Therefore, the complete bodyshell must be protected carefully when carrying out steel repairs. This is done by using suitable protective covers and by masking the body with masking tape. Furthermore, cutting work may only be performed using a body saw. If grinding work is needed, this must be done using grinding discs which produce little or no flying sparks. The spot welding machine should be used for welding work where possible, because it produces less weld spatter during the welding process.

22 body parts which must be covered when carrying out steel repairs

Damage to be repaired

383_040

Aluminium-steel repairs

In the case of body side or rear-end damage, both aluminium and steel body parts may become damaged. This is the case, for example, when the body side section (aluminium) and rear wheel arch (steel) are damaged. After removing the damaged parts, the new genuine parts are installed in accordance with the repair procedures described in the previous sections. Joining of steel and aluminium parts must be carried out with the greatest care in order to eliminate the possibility of future contact corrosion.

Two-component car body adhesive DA 001 730 A1 and rivets or screws are used for joining. As in series production, an insulating layer is placed between the two materials to prevent contact corrosion. When welding steel body parts, the aluminium parts must be carefully covered and masked!

Reference

All body repair work must be performed in accordance with the guidelines set out in the current workshop literature!

23

Repair concept

Workshop equipment

A special tool is required for repair work on aluminium-bodied vehicles. The basis is work scope 2010.

In addition to the special equipment and machines for stud welding, dent removal, bonding and riveting, the aluminium welding technology is of special importance.

383_026

Aluminium body dent removal tools VAS 5196 and VAS 6049

383_076

Cordless punch riveter VAS 5279A

24

Aluminium inert gas welder V.A.G 2001B

383_028 383_029

Aluminium inert gas welder VAS 6388

Reference

For further information on the workshop equipment for Audi aluminium-bodied vehicles, refer to the workshop literature and the Audi Service

Net.

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, produce perfect aluminium welded joints which have optimum strength.

Qualification of aluminium

A special knowledge and special skills are required to repair aluminium bodyshells. A prerequisite for successful body repairs is participation in the relevant training courses.

Particularly for welding work, certification of employees according to international standard DIN

EN ISO 9606-2 is important.

EX 351

Welding

Aluminium Certificate

Repeat exam

AB 352

Aluminium technology

EX 353

Audi TT


BT 350

Welding


Welding Certificate

BT 351

Basics

Body

BT 352

Basics

Vehicle electrical systems for car body technology

BS 301 Occupant protection, airbags and belt tensioners

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.

25

26

Car body safety concept

Head-on collision, side impact and rear collision

Likewise, in terms of crash safety, the new TT makes no compromises. The front beams consist of aluminium extruded sections and aluminium castings.

In combination with the front beams and a subframe, they reduce and distribute the forces which act on the car body during a head-on collision.

Large-sized beams in the rear end protect the occupant cell.High-strength aluminium beams in the doors provide side impact protection. The aluminium bonnet is designed to all requirements for pedestrian safety.

The simulation provides information on the collision behaviour of the body structure at a very early stage in the development process. For this purpose, calculations are done on the basis of the available car body data using the Finite Elements Method. The results are incorporated into the ongoing design process, thus allowing the body structure design to be optimised in respect of the relevant crash loads.

Simulation Euro NCAP head-on collision

383_031

To check the theoretical results and to meet statutory requirements, actual tests are conducted.

Various test conditions are simulated on the basis of the applicable standard.

Euro NCAP head-on collision (64 kph with partial overlap)

383_041

Euro NCAP side impact (50 kph)

383_042

ECE and Japan rear collision (50 kph)

383_043

27

Car body safety concept

Pedestrian safety

Pedestrian safety is an increasingly important factor. Various measures were implemented in the new

Audi TT in order to meet the safety requirements.

When designing the bonnet, importance was attached to a stable design which yields to absorb head impacts. This is achieved by the honeycomblike structure of the car body inner panelling.

28

383_034

The overall concept provides for deformation zones between the bonnet and the units or car body structural parts.

To reduce leg impact force at the front end, the bumper cover has been decoupled and an impactabsorbing foam part has been integrated between the bumper beam and bumper cover.

383_044

The development tools "Simulation" and "Testing" were used for design.

Headform

(head impact)

Lower legform

(leg impact)

Head impact

To test the head impact a hemisphere which represents the head is catapulted onto the bonnet.

The relevant physical variables are determined, on the basis of which conclusions are drawn regarding impact loads.

Leg impact

Leg impact is simulated by means of a test configuration in which a test body similar to the actual body part impacts the vehicle bumper.

383_035

383_036

383_037

29

Electromechanical rear spoiler

The new Audi TT has as standard an electrically extendable rear spoiler. The extended rear spoiler significantly increases driving stability at high speeds. The spoiler extends automatically at a speed of 120 kph and retracts at a speed of 80 kph.

At speeds of less then 120 kph, the rear spoiler can be actuated manually with a switch in the centre console.

The unit consisting of the rear spoiler module and the spoiler wing is integrated in the boot lid of the

Audi TT. The rear spoiler module with drive unit, input shaft and reversing mechanism (hinge) is bolted with self-adjusting elements to the sheetsteel spoiler wing painted in the body colour.

383_038

30

Reference

For further information on operation, function and diagnosis, refer to Self-study

Programme 382 "Audi TT Coupé ‘07 -

Electrical and Infotainment Systems“.

383_045

When repair work is needed, the spoiler wing can be replaced separately. The rear spoiler module is replaced completely in case of damage.


– Body


– Engine




– Infotainment


SSP 381 Audi TT Coupé ‘07 - Suspension System

– Front axle

– Rear axle


– Brake system




– Networking

– Bus topology


– Infotainment



– Audi Space Frame of the Audi TT

– Joining techniques and production processes

– Repair concept

– Car body safety concept




Service Training

Audi TT Coupé ´07 - Body


All rights reserved. Technical specifications subject to change without notice.

Copyright

AUDI AG

I/VK-35


Fax +49-841/89-36367

AUDI AG




A06.5S00.28.20

Audi TT 2006 Workshop Manual

Audi TT Coupé ‘07

Introduction

Overview

Audi Space Frame ASF of the Audi TT Coupé ´07

The development targets for the bodyshell of the Audi TT Coupé ‘07

Technological concept

Occupant protection system in the Audi TT Coupé ‘07

Airbag control unit J234

Belt-on warning

Driver side belt switch E24

Airbag

Driver airbag

Front passenger airbag

Side airbags

Driver seat belt tensioner igniter -1- N153

Front passenger seat belt tensioner igniter -1- N154

Battery isolation igniter N253

Additional functions and components of the occupant protection system for the North American market

Seat occupied detection, front passenger side

Driver side belt switch E24

Front passenger side belt switch E25

Knee airbag igniter, driver side N295

Knee airbag igniter, front passenger side N296

Belt force limiter, driver side G551

Belt force limiter, front passenger side G552

Engine-gearbox combination

2.0l TFSI

Technical features

3.2l VR6 MPI

Technical features

Fuel supply

Pressure regulation

Fuel tank breather system, ROW spec (2.0l and 3.2l engines)

Fuel tank breather system, US spec (2.0l and 3.2l engines)

Soundpipe

Function

Suspension system

Overview

Front axle

Rear axle

Brake system

Overview

Steering system

Audi magnetic ride

Wheels and SST tyres (self supporting tires)

Low tyre pressure indicator

Topology and networking

Installation overview - control units

Overview

Air conditioner in Audi TT Coupé ‘07

Climatronic control unit J255

Components of the air conditioning system in the Audi TT Coupé ‘07

Air conditioner compressor

Ambient temperature sensor G17

Dash panel temperature sensor G56

Outlet temperature sensor

Combined filter in the Audi TT Coupé ‘07

Function diagram of the automatic air conditioning system

(lefthand-drive vehicles only)

(right-hand drive vehicles only)

Radio navigation systems at a glance

Radio systems at a glance

Introduction

Audi TT Coupé ‘07

Vorsprung durch Technik www.audi.de

Service Training

Audi TT Coupé ´07 - Suspension System

Self-Study Programme 381

Axles

Brake system

ESP

Steering system

Audi magnetic ride

Wheels/tyres

Front axle

Rear axle

Overview

System components

System components