Audi TT RS User Manual

Self-Study Program 990713

Audi TT RS with the 2.5L TFSI Engine

Audi of America, LLC
Service Training
Printed in U.S.A.
Printed 6/2011
Course Number 990713

©2011 Audi of America, LLC

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based on the latest information available at the time of printing
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information should be referred to Audi of America, LLC.

Always check Technical Bulletins and the latest electronic
service repair literature for information that may supersede any
information included in this booklet.

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Audi Space Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.5L TFSI Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Crankshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Crankshaft Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Intake Manifold with Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Exhaust System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Exhaust System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Engine Load Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Sport Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Manual Transmission 0A6 . . . . . . . . . . . . . . . . . . . . . . . . . .37

Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Drive Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Audi Magnetic Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Electronic Stabilization Program (ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

New Special Tools for the TT RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Self-Study Programs for the Audi TT . . . . . . . . . . . . . . . . .46

Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . .47

i

The Self-Study Program provides introductory information regarding the design
and function of new models, automotive components, or technologies.

The Self-Study Program is not a Repair Manual!
All values given are intended as a guideline only.

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

iiii

Reference Note

!

Introduction

The original Audi TT, named after the legendary
“Tourist Trophy” race in the United Kingdom,
was a milestone in automotive design. The
design followed pure geometry, with the central
theme being a circle refl ected in the wheel
arches, roofl ine arches, and both the front and
rear fascias of the vehicle.

TT_BodyShop_1

The Audi TT RS, developed by quattro GmbH,
breathes new life into old traditions. Thanks to
a turbocharged 2.5-liter fi ve cylinder engine,
permanent all-wheel drive, and a sporty yet
comfortable suspension and design, both the
RS Coupe and RS Roadster are uncompromising
sports cars.

The production of the Audi TT RS involves the
use of two factories. The Audi Space Frame (ASF)
body is constructed in Ingolstadt, Germany,
while fi nal assembly is completed in Györ,
Hungary.

TT_BodyShop_3

TT_BodyShop_2

1

The TT RS is clearly the fl agship of the TT
model series. The muscular sheet metal body,
tautly curved surfaces, and sharp lines give an
impression of sculpture in motion.

From the side, the 18-inch wheels, large brakes,
and fl ared wheel openings of the TT RS instantly
catch the eye. Matte aluminum door mirror
covers are standard.

The front of the TT RS features the Audi marque
single frame grille. The insert is shiny black
bounded with a matte aluminum fi nish. Large
side air intakes with fl ared edges draw air into
the engine compartment.

The left intake routes air to the transmission,
while the right intake routes air to an auxiliary
radiator. The turbocharger draws in air through
the upper section of the grille while the
intercooler sits behind the lower segment of the
grille.

The front valance has been designed as a
splitter, and when coupled with the rear spoiler,
provides perfect aerodynamic balance.

451_011a

451_012

2

The headlight design is a distinguishing Audi
characteristic. Xenon plus headlights, standard
on the TT RS, are accentuated by daytime
running lights comprised of 12 LEDs arranged in
a straight line.

451_013

Rear View

The rear bumper includes an integrated diffuser
insert that surrounds two large, oval tailpipes.

A wide, stationary spoiler increases downforce
on the rear axle, improving stability at high
speeds. The automatic spoiler featured on the
standard production TT is available on the TT RS
as an option.

451_014a

451_015

3

(10 mm lower than standard Audi TT)

2.5L TFSI engine with 335 hp
(250 kW) peak output

Sport suspension

ESP Sport Mode

Six-speed manual transmission

(0A6) with all-wheel drive

4

Xenon plus headlights

with LED DRLs

Heated sports seats trimmed

with leather / Alcantara

Optional rigid spoiler (adjustable

rear spoiler as found on the

standard TT is also available)

generation all-wheel drive clutch

Rear wheel drive via the 4th

451_008

18 inch alloy wheels

with 245/40 tires

5

Body

Dimensions

Audi TT RS Coupe

35.4 in (900 mm)

52.8 in (1342 mm)

61.2 in (1555 mm)

72.5 in (1842 mm)

35.8 in

(911 mm)

38.9 in

97.1 in (2468 mm)

165.2 in (4198 mm)

(990 mm)

60.8 in (1546 mm)

76.8 in (1952 mm)

32.6 in
(829 mm)

15.3 in

(390 mm)

32.4 in

(819 mm)

30.5 in
(777 mm)

32.1 in

60.3 in

(1532 mm)

6

47.4 in

(1532 mm)

(816 mm)

39.3 in
(1000 mm)

451_009

Audi TT RS Roadster

53.0 in
(1348 mm)

33.7 in

(856 mm)

61.2 in (1555 mm)

72.5 in (1842 mm)

35.8 in

(911 mm)

38.9 in
(990 mm)

97.1 in (2468 mm)

165.2 in (4198 mm)

60.8 in (1546 mm)

76.8 in (1952 mm)

9.6 in (245 mm)

32.2 in

(819 mm)

30.6 in
(778 mm)

53.2 in (1352 mm)

39.4 in

(1001 mm)

39.3 in
(1000 mm)

451_010

7

Coupe Roadster

Curb weight

Maximum gross weight

Luggage capacity (seats folded down)

Fuel tank capacity

Drag coeffi cient

3196.6 lb (1450 kg)

4034.4 lb (1830 kg)

10.2 cu ft / 24.7 cu ft
(290 liter / 700 liter)

15.8 gal (60 liter)

0.32

3328.9 lb (1510 kg)

4034.4 lb (1830 kg)

8.8 cu ft (250 liter)

15.8 gal (60 liter)

0.34

8

Notes

9

Audi Space Frame

Technical Design

The hybrid Audi Space Frame (ASF) fi rst used in
the 2008 TT is also used in the TT RS Coupe and
TT RS Roadster.

Sheet steel and aluminum sheet metal
components, aluminum castings, and aluminum
extruded sections form the TT RS body structure.

Vehicle weight distribution is optimized by
using sheet steel components in the rear facia,
improving driving dynamics and acceleration.

TT RS Coupe

Reference

For more information about the Audi Space Frame used in the Audi TT Coupe,
refer to Self-Study Program 994703, The 2008 Audi TT Body.

383_003

Aluminum castings

Sheet aluminum components

Aluminum extruded sections

Sheet steel components

10

This ASF hybrid design guarantees maximum
rigidity and a balanced distribution of axle loads.

The body shell of the Coupe weighs 454.1 lb
(206 kg), while the body of the Roadster weighs
in at 553.3 lb (251 kg). Roadster weight is slightly
higher due to extra reinforcement.

TT RS Roadster

Reference

For more information about the Audi Space Frame used in the Audi TT Roadster,
refer to Self-Study Program 995703, The 2008 Audi TT Roadster.

391_039

Aluminum castings

Sheet aluminum components

Aluminum extruded sections

Sheet steel components

11

2.5L TFSI Engine

Introduction

Audi’s fi ve-cylinder engines of the 1980s were
powerful, sporty engines that reinforced the
brand’s “Vorsprung durch Technik” commitment.

These fi ve-cylinder engines combined the
effi ciency of a four-cylinder with the power of
a six-cylinder, resulting in lighter and more
compact engine packages. A turbocharged
version was a sensation.

451_020

12