Audi TT Roadster Manual

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391
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AUDI AG
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Technical status: 12/06
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A07.5S00.33.20
Audi TT Roadster
Self-Study Programme 391
Vorsprung durch Technik www.audi.co.uk

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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.
Audi Hungaria Motor Kft.
The engine plant at Györ, Hungary, was
inaugurated in October 1994.
The plant is not only central to the international
competitiveness of company, it also creates in
Hungary a solid strategic base that continues
to grow in importance.
Virtually the entire Audi range of engines is
now assembled in Györ.
Volume production of TT models commenced
in April 1998.
By the end of 2005, 265,241 Audi TT Coupés
and TT Roadsters as well as 36,458 Audi A3
and S3 models had rolled off the Györ assembly
lines.
The plant
Location: Györ, Hungary
Company formation: February 1993
Land purchase and construction of the building
carcass in April 1993
Site area: 1,659,163 m2
Developed area: 388,480 m2
Logistic links to road and rail infrastructure
Workforce: 5,022 (as at 31.12.05)
Production of engines and engine components
as well as vehicle assembly
Engine development centre with flanking
development activities during series
production
Production planning
Tool making

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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.
391_026
The new Audi TT Roadster
Unfiltered sportiness, a truly authentic driving experience plus high power reserves – cue the new TT Roadster from
Audi. The open-top sports car has taken all the design cues from its tremendously successful predecessor, but instils
them with even greater emotion, performance and dynamics.
With its rigorous geometry and clarity, the design of the first TT Roadster elevated it to the status of a cult classic.
In designing the new TT Roadster Audi has preserved this charismatic stylistic idiom and carefully honed it for the
new model.
Whereas the tail end and the roof section seem to flow into one another at the rear of the TT Coupé, the convertible
top of the TT Roadster forms a clear contrast that gives the overall design a more geometric look.
This impression is underscored by the athletic curves of the vehicle's flanks just as much as by the rising dynamic line
above the sill area and the taut, muscular shoulder line.
The TT Roadster has a lightweight fabric convertible top which fits in perfectly with the philosophy of puristic open-top
motoring and also offers a number of benefits over a folding steel hard top. It is very light and takes up only a small
amount of space when folded down. The roof is manually operated or electro-hydraulically powered.
Like the TT Coupé, the body of the TT Roadster is also built on the principles of Audi Space Frame ASF®technology,
featuring a pioneering hybrid construction that showcases the brand's tremendous expertise in lightweight design.

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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
Bodyshell
Convertible top
Convertible top design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Technical profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Introduction
In brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine-gearbox combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical convertible top control system
Installation locations of the system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Automatic convertible top operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emergency operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Components of the convertible top control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Topology and networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Data exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CAN data bus interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Function diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hydraulics
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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.
The Self-Study Programme teaches the design and function of new vehicle models,
automotive components or technologies.
The Self-Study Programme is not a Repair Manual!
The 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
Heating and air conditioning system
Interior monitoring
Heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Infotainment
Radios and radio navigation systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Sound system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Aerials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Running gear
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Convenience electronics
Windbreak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

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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.
6
391_031
Introduction
Overview

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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.
7
391_091
391_090
391_095
391_096
Reference
For further information on engines and
fuel supply systems, refer to Self-Study
Programme 380.
Reference
For information on the design and function
of the S tronic gearbox, refer to Self-Study
Programme 386 "Six-speed Twin Clutch
Gearbox 02E".
2.0l TFSI engine
Engine-gearbox combination
3.2l V6 MPI engine
Direct manual gearbox 02E front-wheel drive
Six-speed manual gearbox 02Q front-wheel drive
Direct manual gearbox 02E four-wheel drive
Six-speed manual gearbox 02Q four-wheel drive

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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.
8
391_039
Bodyshell
Technical profiles
The Audi Space Frame ASF®with its innovative
material mix of aluminium (58 %) and steel (42 %)
is the ideal solution to the severe demands on the
bodyshell of a roadster.
A balanced weight distribution was achieved by
using aluminium in the forward section of the body
and steel in the rear section and in the roll cage
stiffening frame.
The roll bars integrated in the body structure create
a survival space for the occupants in the event of a
roll-over.
In order to brace the windscreen frame, a high-
strength steel tube has been integrated.
A very high level of passive safety has been achieved
as a result of these modifications.
With a special hybrid construction that makes
intelligent use of aluminium and steel, the new
Audi TT Roadster scores top marks for high strength
and rigidity.
Thus, the TT Roadster has all the credentials for
dynamic handling, high roll and vibration comfort
as well as excellent occupant protection.
The intelligent use of steel and aluminium results in a well-balanced weight distribution as well as
outstanding strength and rigidity.
Extruded
aluminium section
Aluminium panel Aluminium
die castings
Sheet steel

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with respect to the correctness of information in this document. Copyright by AUDI AG.
9
391_025
391_033
The extruded aluminium sills significantly increase
the rigidity of the bodyshell.
The much higher rigidity is achieved thanks to a
modified inner geometry.
The result is best-in-class static torsional rigidity.
These impressive results are basically
attributable to three factors:
– selective use of materials according to their
function
– the special bodyshell construction
– Audi's cutting-edge expertise in the
use of aluminium as a body material, and in
particular the Audi Space Frame ASF®design
concept
Reinforced A-post with reinforced windscreen frame and door sills
Rigidity has been further enhanced by extensive modifications to the sill architecture.
Extruded section sill

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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.
10
Convertible top
Front roof cross member
Roof cross member 1 Roof cross member 2
Roof linkage 1
Roof linkage 2
Tensioning cable for
convertible top cover
Main linkage
Roof cross member 3
Convertible top design
Fabric convertible top with space-saving
folding system
A special new feature of the new Audi TT Roadster
is the Z-fold system of the fabric convertible top, as
a result of which the convertible top takes up only a
small amount of space when folded down.
With this space-saving folding system, the front
section of the roof lies on top of the cloth like a
cover and locks into place to lie flush with the body.
The side openings for the drive motor of the
convertible top mechanism are covered by
convertible top flaps. As a result, there is no need
for a tonneau. The linkage for both the fully
automatic and manual convertible tops is made
from a combination of steel and aluminium
components and, as a result, is exceptionally light.
Main bearing