Audi TT Coupe 207 Assembly instructions

Service.
The Audi TT Coupé
Design and Function
Self-Study Programme 207
For internal use only.

2
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.

3
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

4
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
powered by a four-cylinder 5-valve
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.

5
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.
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6
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

7
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
kg
1 - 1015 kg
2 - 850 kg
1
1000
2111008
Typ 8N

8
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 .

9
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.
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SSP207/75
Special features
Front bumper
Rear bumper

10
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