Audi TT Coupe '07 380 Assembly instructions

380
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Technical specifications
subject to change without
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AUDI AG
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AUDI AG
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Technical status: 05/06
Printed in Germany
A06.5S00.25.20
Audi TT Coupé ‘07
Self-Study Programme 380
Vorsprung durch Technik www.audi.de Service Training

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
Self-study programmes on the TT Coupé
SSP 381 Audi TT Coupé ‘07 -
Suspension System
–Frontaxle
–Rearaxle
– Shock absorber system
– Brake system
Order number: A06.5S00.26.20
SSP 382 Audi TT Coupé ‘07 -
Electrical and Infotainment Systems
–Networking
–Bustopology
– Convenience electronics
– Infotainment
Order number: A06.5S00.27.20
380_043
SSP 380 Audi TT Coupé ‘07
–Body
– Occupant protection
–Engine
– Suspension system
– Electrical system
– Air conditioning
– Infotainment
Order number: A06.5S00.25.20
SSP 383 Audi TT Coupé ‘07 - Body
– Audi Space Frame
– Production processes and joining methods
–Surfacefinish
– Electromechanical rear spoiler
– Repair concept
– Passive safety concept
Order number: A06.5S00.28.20

NoteReference
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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.
Contents
Occupant protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Running gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Infotainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4
Overview
Dimensions of the Audi TT Coupé ‘07.
Introduction
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)
380_054

5
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
380_040

6
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 A8
Three-chamber extruded section
380_062
380_063
Sill section Audi TT Coupé ‘07
Four-chamber extruded section

7
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.
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.
Component parts overview
380_061

8
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:
–Airbagcontrolunit
– Dual-stage driver and front passenger airbags
–Frontsideairbags
– 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-onindicator
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)

9
380_005
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 -2-
N131 Front passenger side airbag igniter 1
N132 Front passenger side airbag igniter 2
N153 Driver seat belt tensioner igniter -1-
N154 Front passenger seat belt tensioner igniter -1-
N199 Side airbag igniter, driver side
N200 Side airbag igniter, front passenger side
N253 Battery isolation igniter
T16 16-pin connector, diagnosis connection

10
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)
–Activateseatbeltreminder
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.
380_008
Reference
For more information about the
airbag control unit J234, refer to Self-
Study Programmes 323 Audi A6 `05
and 361 Audi Q7.

11
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.
361_016
Time diagram for seat belt reminder
Visual and audio signals
- Delayed seat belt fastening
Termi n al 15
Road speed
Seat belt fastened
Seat belt warning system warning lamp
Audio signal
ON
OFF
V > 25 kph
v < 25 kph
yes
OFF
ON
OFF
No
ON
Time
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.
380_065

12
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.
380_003
Casing
Air outlet
Filter
Igniter I
Perforated tube
End cap
Ignition charge container Propellant charge II
Igniter II
Filter
Foil seal
Air outlet
Foil seal
Propellant charge I

13
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.
361_002
Igniter II
Pressurised gas bottle
Gas: approx. 98 % argon
approx. 2 % helium
Pressure: approx. 250 bar
Ignition charge I
Filter
Igniter I
Propellant charge I Coil spring
Ignition charge II Propellant charge II Coil spring Rupture disc
Reference
For more information about the
function of the front passenger front
airbag, refer to Self-Study Programme
361 Audi Q7.

14
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.
Occupant protection
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.
361_022
Air outlet
Air outlet
Metal filterIgnition charge
Propellant chargeDetonator
380_004

15
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.
Driver seat belt tensioner igniter -1- N153
Front passenger seat belt tensioner igniter -1- N154
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.
380_027
Metal band
Electrical connector
Seat belt retractor
shaft
Detonator
Metal band loop
380_030
Seat belt Inertia-reel seatbelt
Foil
Belt tensioner unit

16
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.
Occupant protection
380_028
Metal band
Electrical connector
Seat belt retractor
shaft
Detonator
Metal band loop
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.
380_026
Casing
Silicon layer
Casing cover
Metal band

17
Battery isolation igniter N253
The battery isolation igniter has the task of
disconnecting the starter and alternator leads from
the vehicle battery in the event of a crash.
Use is made of a pyrotechnic component which is
activated by the airbag control unit J234 whenever
the airbag is deployed.
During a rear collision, only the belt tensioner and
the battery isolation igniter are activated.
If the pyrotechnic propellant charge is ignited, the
resultant gas pressure displaces the pin on a piston
and disconnects the two terminals.
After deployment of the airbag, the battery isolation
igniter must be replaced.
Battery isolation igniter
332_030
Pin
Connecting
element with
terminals
Detonator
361_024
Reference
Further information on the function
of the battery isolation igniter, refer
to Self-Study Programme 361
Audi Q7.

18
Occupant protection
Additional functions and components of the occupant
protection system for the North American market
The additional functions and components of the occupant protection system for the North American market
are described on the following pages.
The occupant protection system is equipped with additional functions and components,
e.g. second crash sensor for front airbag, so that the Audi TT Coupé ‘07 meets the statutory and market-
specific requirements for the US market.
Seat occupied detection, front passenger side
The front passenger side seat occupied recognition system was largely adopted from the Audi Q7.
The system basically comprises the following components:
– Seat squab
– Sensor mat for seat occupied recognition
– Pressure sensor for seat occupied recognition G452
– Seat occupied recognition control unit J706
– Front passenger side belt switch E25
– Seat belt force sensor for seat occupied recognition G453
– Front passenger side airbag deactivated warning lamp
K145 (PASSENGER AIRBAG OFF)
–AirbagcontrolunitJ234
These components form a single
unit and must not be separated
from each other.
Driver side belt switch E24
Front passenger side belt switch E25
The Audi TT Coupé ‘07 for the North American
market is equipped with seat belt switches for belt-
fastened recognition on the driver and front
passenger sides.
Seat belt switches E24 and E25 are integrated in the
belt buckles on the front seats So-called "reed
switches" are used. The reed switch remains open
until the occupants have fastened their seat belts.
The airbag control unit J234 performs a resistance
measurement from which it can determine whether
the occupants have fastened their seat belts or not.
Depending on the position of the reed switch, the
measurement is made using one or both resistors.
361_029
Reference
For further information about the
seat occupied recognition system
and the seat belt switch, refer to Self-
Study Programme 361 Audi Q7.

19
Knee airbag igniter, driver side N295
Knee airbag igniter, front passenger side N296
The Audi TT Coupé ‘07 for the North American market is equipped with knee airbags for the driver and front
passenger sides.
Ignited knee airbags allow the occupants to participate earlier in the vehicle deceleration process. The airbag
system of driver and front passenger front airbags in combination with knee airbags reduces the injury risk
for the occupants.
On the driver side, the knee airbag is located in the footwell trim panel below the dash panel.On the front
passenger side, the knee airbag is located behind the glove box lid.
Hybrid gas generators have the task of inflating the airbags with gas.
The airbag control unit J234 activates the igniter in the gas generator. The resultant pulsation wave is directed
to the rupture disc. The rupture disc breaks and the helium from the pressurised gas bottle flows into the
airbag.
After the airbags are activated, the airbag unfolds
between the dash panel and the occupants' legs.
View inside the dash panel
Gas generator
Airbag
380_006
380_009
Detonator
Filter Air outlet
Filter Air outlet Rupture disc Pressurised gas bottle
Gas: Helium
Pressure: approx. 600 bar

20
Occupant protection
The front inertia-reel seatbelts have a two-stage belt
force limiter. In the event of a collision, the belt
tensioners (band tensioners) are ignited first. The
inertia-reel seatbelt blocks the seat belt retractor
shaft and prevents the seat belt from unreeling,
which would occur due to the forwards movement
of the occupants. The seat belt retractor shaft is
designed as a torsion shaft. To limit the load which
the seat belt places on the occupants, two torsion
shafts allow controlled unreeling of the seat belt;
belt force limiter.
After a defined interval, the airbag control unit
activates the belt force limiter igniter.
The second torsion shaft is decoupled. The seat belt
retractor shaft now counteracts the force which the
seat belt exerts.
To ensure that the occupants are afforded a good
level of protection, the belt tensioning function, the
belt force limiting function and the front airbags are
coordinated with each other.
Gears I and II are permanently connected to the seat
belt retractor shaft and the second torsion shaft
respectively.
In the initial state, both gears are in mesh with one
another.
Belt force limiter, driver side G551
Belt force limiter, front passenger side G552
380_013
Detonator
Spline end
Gear II
Gear I
Torsion shaft II
Seat belt
retractor shaft
380_012
Seat belt retractor shaft
Gear I
Torsio n sha ft II
Spline end
Gear II