Audi TT 59 User Manual
Service Training
Audi TT Coupé ´07 - Suspension System
Self-Study Programme 381
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
381_064
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Contents
Axles
Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake system
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ESP
System components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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
System components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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
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 preparation of the SSP.
For maintenance and repair work, always refer to the current technical literature.
NoteReference
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
Damper
Swivel bearing
Coupling rod
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.
Spring
Ball joint
Anti-roll bar
Wishbone
Subframe
Wheel bearing
381_001
4
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
Swivel bearing
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.
Brackets
Wishbone
Self-aligning support
Subframe
381_002
5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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
Swivel bearing
Note
Note: Special tool 3424 must always be used to
widen the clamp when installing and removing
the damper!
Wheel bearing
381_003
*: The Cobapress process is a casting process in which the component subsequently undergoes a forging
process. The result is high strength and toughness.
6
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
Retaining element
Wishbone
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
Subframe
Wishbone
Ball joint
Bracket
381_004
381_005
Note
Note: after undoing the threaded connection
between the ball joint and wishbone, always
replace the retaining element.
7
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
= 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
8
Anti-roll bar
381_007
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
Rear axle for front-wheel drive
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 quattro models
381_008
381_009
9
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Axles
System components
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.
Wheel carrier
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
381_010
Ribbed washers
381_011
Note
Note: Always replace the ribbed washers during
removal and installation of parts in the service
workshop.
10
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
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.
Tra c k ro d
Wishbone
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.
Guide bearing
381_012
Rear axle
The camber and toe can be adjusted at the rear
axle.The adjustment procedure is the same as for
the Audi A3.
Camber adjustment
Toe adjustment
381_013
11
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Brake system
Overview
optional Tyre Pressure Monitor
TEVES Mk60E1 with
Front axle brake caliper:
16" for all four-cylinder models
17" for all six-cylinder models
ESP:
10", 11", 7/8", with contactless brake
without dual rate characteristic
12
Brake servo:
light switch
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Rear axle brake caliper:
16" for all four-cylinder models
17" for all six-cylinder models
381_014
13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Brake system
Front axle
Engine R4-4V 2.0l TFSI VR6 3.2l MPI
Minimum wheel size 16" 17"
Brake type FN3 FNR-G
Number of pistons 1 1
Piston diameter (mm) 54 57
Brake disc diameter (mm) 312 340
Rear axle
Engine R4-4V 2.0l TFSI VR6 3.2l MPI
Minimum wheel size 16" 17"
Brake type CII 38 CII 41
Number of pistons 1 1
Piston diameter (mm) 38 41
Brake disc diameter (mm) 286 310
14
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
System components
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.
381_015
16" wheel brake
17" wheel brake
381_016
15
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