Audi TT 30 User Manual

Service Training

Audi TT Coupé ‘07

Self-Study Programme 380

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

Excellence in design & performance

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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.

NoteReference

Introduction

Overview

Dimensions of the Audi TT Coupé ‘07.

Audi TT Coupé ‘07 2.0l HS 2.0l s-tronic 3.2l HS qu 3.2l s-tronic qu

Permissible gross weight in kg 1660 1680 1810 1830

Kerb weight without driver in kg 1260 1280 1410 1430

Drag coefficient Cw 0.30 0.30 0.31

Fuel tank capacity in litres 55 60

Body type Audi Space Frame (ASF)

Height of loading sill in mm 790

Luggage compartment volume in l 290 (700l with rear-seat back folded forward)

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4

Body / dimensions

Length in mm 4178 + 137

Width in mm 1842 + 78

Height in mm 1352 + 6

Wheelbase in mm 2468 + 46

Front track width in mm 1572 + 26

Rear track width in mm 1558 + 30

Number of seats 2 + 2

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5

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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6

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.

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)

8

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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 -2­N131 Front passenger side airbag igniter 1
N132 Front passenger side airbag igniter 2
N153 Driver seat belt tensioner igniter -1­N154 Front passenger seat belt tensioner igniter -1­N199 Side airbag igniter, driver side
N200 Side airbag igniter, front passenger side
N253 Battery isolation igniter

T16 16-pin connector, diagnosis connection

9

Occupant protection

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

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

10

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

Term i n a l 1 5

Road speed

Seat belt fastened

Seat belt warning system warning lamp

Audio signal

ON

OFF
V > 25 kph

v < 25 kph
yes

No
ON

OFF
ON

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

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Occupant protection

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.

Perf ora ted tu be

Casing

Foil seal

Air outlet

Filter

Igniter I

12

Ignition charge container Propellant charge II

Propellant charge I

Igniter II

End cap

Foil seal

Air outlet

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.

Igniter I

Igniter II

Ignition charge I

Ignition charge II Propellant charge II Coil spring Rupture disc

Propellant charge I Coil spring

Filter

Pressurised gas bottle

Gas: approx. 98 % argon

approx. 2 % helium

Pressure: approx. 250 bar

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Reference

For more information about the
function of the front passenger front
airbag, refer to Self-Study Programme
361 Audi Q7.

13

Occupant protection

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.

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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.

Metal filterIgnition charge

Propell ant chargeDetonator

Air outlet

Air outlet

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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.

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.

Seat belt Inertia-reel seatbelt

Foil

Belt tensioner unit

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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

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15

Occupant protection

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

Seat belt retractor
shaft

Electrical connector

Detonator

Metal band loop

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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

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