Audi TT Coup'e 207 User Manual

Service.The Audi TT CoupéDesign and FunctionSelf-Study Programme 207For internal use only.

10BonnetTailgate The bonnet is made of aluminium to save weight.The tailgate can only be opened from the interior by means of the switch in the centra

11 TaillightsTo replace the filament lamps, the complete taillight unit is removed without needing any tools. Flaps are attached to the luggage com-par

12Dash panelWhen removing the cross-tube, please note that one of the faste-ning bolts is located on the outside in the plenum chamber. To remove this

13 To absorb the load resulting from a side impact, the body structure is extremely rigid even though the B-pillar is not continuous. An additional

14Vehicle safetyThe Audi TT Coupé has head-thorax side air-bags for the driver and front passenger.These side airbags are integrated in the seat backr

15 During a side impact, the vehicle occupant is inevitably subjected to a relative movement towards the force application point and away from the de

16Vehicle safetyTo minimise the risk of foot injuries in serious head-on collisions, the brake pedal is swung away from the foot area by means of a co

17The central locking control unit receives this signal simultaneously and unlocks the vehicle doors. The hazard warning lights are activated automati

18 Engine and gearbox combinationsMQ 350 5-speed quattro 02M.3Gearbox CodeMQ 250 5-speed front 02J.NMQ 350 6-speed quattro 02M.11.8-ltr. 5V turbochar

19 200180160140120100 80 60 40 20 01000400360320280240200160120 80 40 02000 3000 4000 5000 6000 7000SpecificationsEngine code: AJQType: 4-cyli

2Quality that is measurableThe plant – the plantsIngolstadt plantThe model series Audi A4 and Audi A3 are produced in Ingolstadt.A separate production

20System overview – 1.8-ltr. 132 kW 5V turbochargedDrive unitsHot-film air mass meter G70SensorsAuxiliary signals:Pressure switch for power steering F8

21EPCSSP207/46Fuel pump relay J17 and fuel pump G6ActuatorsInjection valves N30, N31, N32, N33Power output stage N122 and ignition coils N (1st cyl.),

22Turbocharged 1.8-ltr. 132 kW 5V engineMotronic ME 7.5ComponentsA BatteryE45 Switch for cruise control systemE227 Button for cruise control systemF B

301515 55 49 14 931N33FS+-AJ220G79N249CAN - BUS H3015BJ17Mλ30868785DA4E FN158 N163CAN - BUS LMQPQPQPQP+-GCSSSSG188G187G186G6G71+-N75F36E227E45N80G70G

245V TurboN249The turbocharging system comprises the follo-wing components:– Exhaust emission turbocharger– Charge air cooler– Charge pressu

255V TurboN249J220N75G70 G28 G69Charge pressure controlIf the control fails, the maximum charge pres-sure is limited to a basic charge pressure (mech

265V TurboN249When the throttle valve is closed, it produces a backpressure in the compressor circuit due to the charge pressure still present. This

27200180160140120100 80 60 40 20 01000400360320280240200160120 80 40 02000 3000 4000 5000 6000 7000Technical modifications:Basic 132 kW (180 b

28Extended system overview - 1.8-ltr. 165 kW 5V engineDrive unitsThe secondary air system in the 1.8-ltr. 5V engine developing 165 kW ensures that the

29MKHλG130 N112SSJ299 V101J173031Z29J220Extended function diagram - 1.8-ltr. 165 kW 5V engineLegendG130 Lambda probe downstream of catalytic converter

3Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 485-speed manual gearbox6-speed manual gearboxHaldex viscous coupling C

30On previous systems, it was not possible to initiate the first combustion cycle until a crank angle of approx. 600˚ - 900owas reached. The quick-star

31G71123G40J220The control unit compares the phase sensor signal with the reference mark signal and thus ascertains the working cycle currently taking

32Cooling circuitCoolant afterrun pumpDrive unitsThe coolant afterrun pump protects the coo-lant against overheating, e.g. after turning off a hot eng

33Function in vehicle with air conditioningThe pump starts via radiator fan control unit J293 when the ignition is turned “On“. A timer module integra

345V TurboSince the previous charge air cooler was no longer capable of effectively cooling down the increased air flow through the exhaust gas turboc

355V TurboG39 G62V101N122J299J220The vacuum box for the charge pressure con-trol valve is controlled in the cold start phase by the electro-pneumatic

36The combi-valveThe combi-valve is bolted to the secondary air duct of the cylinder head.The air path from the secondary air pump to the secondary du

37+G1301234J220Electrical circuitSSP207/101Subsystems of the MotronicCatalytic conversion diagnosisDuring the diagnosis, the engine control unit compa

38External and internal torque requests are co-ordinated by the engine control unit, making allowance for efficiency and implemented with the available

39In contrast to previously known systems, the ME 7.5 is not limited to the output of torque variables to the networked control units (ABS, automatic

4A brief introduction to the TTDesign needs no explanationThe name alone suggests that this is an Audi with a difference. The Audi TT was named after

40The accelerator position sender transmits the driver inputs to the Motronic.Subsystems of the MotronicThe accelerator position sender transmits to t

41With Motronic ME 7.5, there is no longer a mechanical throttle control cable between the accelerator pedal and throttle valve. This has been replace

42Fuel systemFuel tanks for vehicles with front-wheel drive and quattro power trainDifferent fuel tanks are used in the front-wheel drive and quattro

43The filler expansion chamber as well as the main expansion chamber are combined at the filler neck upper section and purged via the gravity float valve

44Fuel systemFuel tank for front-wheel drive versionWhen refuelling the fuel tank, the gas mixture is conveyed via the filler breather directly into th

45ComponentsG Fuel gauge senderG1 Fuel gaugeG6 Fuel pumpJ17 Fuel pump relayJ218 Combi processor in dash panel insertJ220 Motronic control unitS FuseTh

46Fuel systemLocated in the quattro fuel tank on the left-hand side is a suction jet pump which pumps the fuel from the left-hand fuel tank part upst-

47ComponentsG Fuel gauge senderG1 Fuel gaugeG6 Fuel pumpG169 Fuel gauge sender 2J17 Fuel pump relayJ218 Combi processor in dash panel insertJ220 Motro

48Power transmissionThree gearbox variants are used for power transmission:132 kW AJQ 5-speed front-wheel drive 2-shaft gearbox 02J.N5-speed quattro d

49The use of magnesium as a housing material results in a weight reduction of 30% due to its lower density (aluminium has a density of 2.695 g/cm3 and

5There is no doubt that the real highlight of the Audi TT is its emotive design, both on the exterior and in the interior. The engineers at Audi had

501st drive shaftGears 1-4SSP207/122Power transmission3-shaft gearbox MQ 350 in 6-speed versionThe spur gear is riveted to the differen-tial. If repai

51Notes

52Power transmissionThe transmitted torque is dependent on the speed difference between the front and rear axles.Also, the torque transmission paramet

53The housing is filled with oil and hermetically sealed against the atmosphere.The plate coupling which runs immersed in oil represents a closed syste

54Power transmissionMSafety valveIn the event of a breakdown, this means that the vehicle can be towed without the engine running and with the axle ra

55MBMAMdMAMAMAIf faulty signals are generated or if CAN mes-sages cannot be received, the vehicle switches to emergency mode.If speed signals are miss

56Running gearThe vibration-optimised attachment of the steering column to the dash panel cross-mem-ber keeps the steering wheel free of undesira-ble

57Electrical circuitSSP207/83F88J22012The pressure switch for power steering is located on the vane pump. It informs the engine control unit when the

58SSP207/3Running gearTo enhance track stability, newly developed cast steel-swivel bearing with modified track rod attachments as well as a new forged

5925°25°Rear axleFront-wheel driveTorsion beam axle with anti-roll barSSP207/115– Track width: 1507 mm– Modified axle plates for increased camber

6The “+ and –“ dimensions are refe-rence values compared to the Audi A3Length: –111 mmWidth: +45 mmHeight: –69 mmVehicle dimensionsA brief introducti

60SSP207/4Running gearRear axleQuattro driveDual link trailing arm axle (DLTA) with Haldex viscous coupling– The dual link trailing arm axle is fixe

61Brake systemSpinning wheels are braked automatically and the drive torque is diverted to the wheel which has traction.– The Traction Control Syst

62Anti-lock Braking SystemABS ITT/Mark 20 IEThe EBPD is entirely software-supported and does not require any hardware.The basis of the ABS system is a

63It utilises the sensors and actuators of the ABS system.ESBS is a software development in the ITT Mark 20 IE control unit.Electronic stability brake

64The vehicle electrical systemThe electrical/electronic connector stations as well as the necessary control units are decen-tralised to meet the requ

65Micro-ZESSP207/112Fuse carrierTelephone operating electronics control unit J412Control unit for headlight range control J431Control unit for navigat

66Interior monitoringThe vehicle interior is monitored by an ultra-sonic monitoring system.It gives the alarm audibly via the horn of the anti-theft w

67Self-diagnosisAddress word for self-diagnosis: 45 The interior monitoring sensor unit only has diagnostic capability when deactivated.For more detai

68The components of the immobiliser are as fol-lows:– The immobiliser control unit is integrated in the dash panel insert.– The warning lamp in

69The engine control unit has a set of equations. It is also stored in the immobiliser control unit, according to which the variable code is con-verte

7Vehicle identificationKey of manufacturing plants within the Group in digit position 11:World manu-facturing codePart describing vehicle Part identif

70STARTElectricsPower supplyIgnition OnTransponder (key )Immobiliser control unitCommunicationvia single linesIf fixed code is OKGenerate variable code

71Notes

72ElectricsSound systemCar phone or provisionBose subwoofer 9RadioCentral loudspeaker(left-hand defrost outlet)Navigationsystem receiverCar phone aeri

73The door loudspeakers of the audio system are also used by the navigation system and the hands-free car phone.When the car phone is used (prepared f

74In connection with the navigation system, the door loudspeakers on the front left and right are used.Car phone announcements are played back via the

75Concert with Bose amplifier audio system and optional equipmentDoor, front lefttweeter/subwooferWindowaerialamplifierRadioDoor, front righttweeter/sub

76OverviewOperating and indicator unitPress the “Defroster“ button, and the air recir-culation mode will be disabled automatically.The fully automatic

77This overview shows the component parts of the heater:G89 Fresh air intake duct temp. sensorG192 Footwell vent temp. senderJ126 Fresh air blower con

78OTUAOFFECONOTUAOFFECONDash panel temperature sensor G56with blower fortemperature sensor V42not replaceableSensorsPhotosensor for sun G107Ambient te

79SSP207/35Solenoid coupling N25Radiator fan V7Radiator fan control unit J293Control motorfor central flap V70with potentiometer G112Control motor fort

8Environmentally-friendlyproductionEnvironmental protection is firmly rooted in Audi’s corporate strategy. During the vehicle development process, all

80Heating/air conditioning systemAir distributionDash panel outletsleft - right - centreFresh airAir recirculationDefrostFootwellSSP207/39

81Air recirculation modePress the air recirculation button and the air recirculation flap is closed by the positioning motor.When the air recirculation

82The expansion valve is thermostatically regu-lated. It has a control unit with a thermostatic valve element and a ball valve.The thermostatic valve

83The pulse duty factor of the valve openings is dependent on the temperature at the evapora-tor outlet (low pressure). Pressure equalisa-tion is regu

84Flexible service interval indicatorThe service interval indicator informs the driver when a service is due.If the remaining distance until the next

85Oil level The oil level in mm can be calculated from the cooling-down period during the cooling-down phase by means of a sensor equation. Accu-racy

86Specifications of the Audi TT1.8 T(132 kW)1.8 T quattro(165 kW)Engine/electricsEngine code AJQ (EU II + 3D standard) APX (EU 3D standard)Engine typec

871.8 T(132 kW)1.8 T quattro(165 kW)SteeringPower-assisted, maintenance-free rack and pinion steering system, track-stabilising kingpin offsetNo. of s

88Service1.8 T(132 kW)1.8 T quattro(165 kW)Length of luggage com-partment with rear seat folded downmm 1397 1360Height of luggage comp.mm 764 660Lugga

89PinOrder No. T10027Special toolsWheel bearing puller for quattro rear axlecomprises:Order No.Sleeve T10030/1Tube T10030/2Spindle T10030/3Thrust piec

9The rear bumper comprises a total of 4 parts: the bumper panel, the rear cover, the alumi-nium cross-member and the central locating element.The guid

90ServiceSocketOrder No. T10035Attachment for SW 3300A(front-wheel drive vehicles only)Order No. T10036Spring retainer(in preparation)+ Gear wneelSSP2

91Dear readers,By reading this Self-Study Programme, you will have now familiarised yourself with the technical innovations of the new Audi TT.The app

207All rights reserved.AUDI AGDepartment I/VK-5D-85045 IngolstadtFax +49 841/89-6367840.2810.26.20Technical Status 06/98Printed in Germany