Audi TT Coupe 207 Assembly instructions

Service.

The Audi TT Coupé

Design and Function

Self-Study Programme 207

For internal use only.

Quality that is measurable

The plant – the plants

Ingolstadt plant

The model series Audi A4 and Audi A3 are produced in Ingolstadt.

A separate production line has been set up for the body in white of

the Audi TT Coupé.

The head ofﬁce of Technical Development is also located in Ingol-

stadt.

Special trucks were developed for transferring the body-

shells to Györ for ﬁnal assembly.

High-tech from Györ

Qualiﬁed specialists and a good infrastructure are key factors for the

Audi production shop in Györ.

Audi has been manufacturing four-cylinder 5V, V6 and V8 engines

here since 1997. Final assembly of the TT has also been taking place

here since 1998.

Axle and steering geometry measurement

Watertightness test

Electrical function test

Roller dynamometer

Exhaust emission test and optimal setup

Acoustic test bench

100% reliability is ensured through a series of systema-

tic checks integrated in the production process.

Functional tests are an integral part of the production

process

Mounted parts are tested for accuracy of ﬁt, build quality

and functionality after each stage of assembly.

After ﬁnal assembly, extensive tests and adjustments

are carried out on every single Audi.

Power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5-speed manual gearbox

6-speed manual gearbox

Haldex viscous coupling

Contents

A brief introduction to the TT . . . . . . . . . . . . . . . . . . . . 4

Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Special features

Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Steering

Front axle

Rear axle

Brake system

Design needs no explanation

Vehicle dimensions

Vehicle identiﬁcation

Environmentally-friendly production

The Self-Study Programme is not a Workshop Manual.

The Self-Study Programme provides you with information

regarding design and function.

New. Important.

Note.

Vehicle safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Occupant protection

Fuel cut-off

Drive units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Engine and gearbox combinations

1.8-ltr. 132 kW 5V turbocharged engine AJQ

1.8-ltr. 165 kW 5V turbocharged engine APX

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Vehicle electrical system

Interior monitoring

Immobiliser

Sound system

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Flexible service interval indicator

Oil level sensor

Speciﬁcations

Special tools

Heating/air conditioning system . . . . . . . . . . . . . . . . 76

Page

Please refer to the Service Literature for all the relevant

maintenance and repair instructions.

Overview

Expansion valve

Subsystems of the Motronic . . . . . . . . . . . . . . . . . . . 37

Lambda control in the EUIII

Torque-oriented engine management

Accelerator position sender

Electrically-activated throttle valve

A brief introduction to the TT

Design needs no explanation

The name alone suggests that this is an Audi

with a difference. The Audi TT was named

after the legendary Tourist Trophy race on the

Isle of Man - the only one of its kind in the

world.

The Audi TT is equally as unique as its legen-

dary namesake.

Engines

As beﬁts a sports car, the Audi TT is

turbocharged engine developing

180 bhp with a sports gearbox in

the front-wheel drive and quattro

versions. A four-cylinder 5-valve

turbocharged engine

developing 225 bhp is

available for the

quattro version.

Running gear

The running gear also underscores Audi’s

total commitment to the sports car concept.

The front axle kinematics were revised with

regard to steering quality and response.

This, in combination with the Audi TT’s sporty,

stiff suspension tuning, ensures excellent

handling and a high standard of driving safety.

The interior styling matches the exterior per-

fectly - a fact reﬂected in the features of the

dash panel, the styling of the instruments, the

air nozzles and controls.

The styling of some parts has also been inﬂu-

enced by the use of aluminium.

The basic version is equipped with 16-inch

wheels shod with size 205/55 R 16 tyres.

A 17-inch suspension is standard with the

quattro and available as optional equipment

for all other engine variants.

There is no doubt that the real highlight of the

Audi TT is its emotive design, both on the

exterior and in the interior. The engineers at

Audi had an ambitious development goal: to

meet all functional and quality standards as

well as the latest statutory requirements and

Audi’s high standards of safety without com-

promising the design concept and while retai-

ning the car’s full viability for everyday use.

Design

We at Audi ﬁrmly believe that the most

important thing about designing is that

actions speak louder than words. Sufﬁce to

say, a good design speaks for itself.

The TT has a “wheel-hugging” design, that is

to say the entire body is styled around the

wheels. That also goes for the front and rear

bulges as well as the roof and window lines

and the low-slung passenger cabin.

Quattro power train

The TT will feature a new generation of Audi

technology and the new Haldex viscous cou-

pling, further emphasising the vehicle’s sporty

character.

Safety

Safety is paramount:

That’s why the TT is equipped with front air-

bags for the driver and front passenger.

The TT already complies with the new Euro-

pean safety laws which will come into effect in

the year 2003 as well as the tougher require-

ments according to the US Head Impact Pro-

tection Act.

SSP207/1

The “+ and –“ dimensions are refe-

rence values compared to the Audi A3

Length: –111 mm

Width: +45 mm

Height: –69 mm

Vehicle dimensions

A brief introduction to the TT

4041 7462419 (quattro 2427) (quattro 738)

876

762

959

828

1525

1764

1354

1507 (quattro 1503)

1856

1412

1209

900

1221

950

Track width

Front: +12 mm

Rear: +12 mm

+ 8 mm quattro

Wheelbase: –93 mm

–85 mm quattro

Vehicle identiﬁcation

Key of manufacturing

plants within the Group

in digit position 11:

World manu-

facturing code

Part describing vehicle Part identifying vehicle

A Ingolstadt

N Neckarsulm

1 Györ

X Poznan

K Karmann/Rheine

Filler

constant = Z

Model year, alphanumeric as prescri-

bed by law

Digits 1 + 2 vehicle

class. acc. to struc-

ture table

Manufacturing plant within

the Group (as at 04/94)

Serial No. beginning

with:

1234567891011121314151617

Audi Hungaria Motor Kft:

TT/TTS *TRUZZZ8NZX 1 000001

Audi AG:

A3 *WAUZZZ8LZX A 000001

A4 *WAUZZZ8DZX A 000001

A6 (incl. SKD Poland) * W A U Z Z Z 4 B Z X N/X 000001

A8 *WAUZZZ4DZX N 000001

Cabrio *WAUZZZ8GZX K 000001

Audi 100 (C3, CKD) * W A U Z Z Z 4 4 Z X A 000001

* Vehicles to US speciﬁcation

(USA, Canada, Saudi Arabia, tourists)

On the VIN (behind the windscreen), the certiﬁcation label and on ofﬁcial documents, the ﬁllers (Z) are repla-

ced by a vehicle code (digits 4-8) or by a test mark (digit 9). This (18-digit) number is the ofﬁcial vehicle identi-

ﬁcation No. (VIN) in the countries listed above.

*TRUZZZ8NZX1000301*

AUDI HUNGARIA MOTOR KFT

TRUZZZ8NZX1000301

1765 kg

1 - 1015 kg

2 - 850 kg

1000

2111008

Typ 8N

Environmentally-friendly

production

Environmental protection is ﬁrmly rooted in

Audi’s corporate strategy. During the vehicle

development process, all environmental crite-

ria are incorporated into the product and pro-

duction concept from the outset. Economic

goals and ecological needs are balanced so

that no conﬂicts of aims arise.

Waste avoidance and reduction

From 1998 onwards, Audi will use only water-

soluble paints in a effort to make its produc-

tion process more environmentally-friendly.

This step will see a dramatic reduction in sol-

vent emissions. Today’s ﬁllers and base coats,

for example, contain up to 45% solvent. By

comparison, the solvent content in water-solu-

ble systems is only about 6%.

A brief introduction to the TT

Produce locally - think global:

Audi lays great store by waste avoidance,

reduction and recycling.

– Almost all production resources and

supplied parts are delivered in re-usable

packaging.

– Most sheet-metal blanks are designed so

as to minimise cutting waste after

pressing.

Recycling

The recycling rate at Audi is now about 94%

by weight. Metal cuttings from the press plant

are used to manufacture small parts as far as

possible. The resulting scrap is returned to the

steelworks, where steel and zinc are separated

from one another.

Other waste materials such as paper, card-

board, timber, polystyrene, etc. are collected

separately and fully recycled .

The 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 guide proﬁles attached to the left and

right wings ensure an even gap all round.

A zero joint is created by attaching the bum-

per to the wing by means of threaded bolts as

well as nut and washer combinations.

The rear cover is available in two versions

depending on engine variant (TT has one

tailpipe, the TTS two). A seamless transition to

the body side section (zero joint) is produced

by means of 2 bolts on each body side section.

Body

The front bumper comprises two parts: the

cover panel and a decorative grille. The bum-

per carrier is made of aluminium and bolted to

the side members by impact absorbing ele-

ments.

SSP207/74

SSP207/75

Special features

Front bumper

Rear bumper

Bonnet

Tailgate

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 central

console or by radio-wave remote control. The

tailgate does not have a lock cylinder or a

handle.

The tailgate has a single-joint hinge.

Body

SSP207/78

SSP207/76

If the electrical system fails, the tail-

gate can be released in an emergency

by means of the cable pull located

below the rear central console cover.

SSP207/77

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