Audi TT RS Manual

Audi Vorsprung durch Technik
Audi
Service Training
All rights reserved. Technical specifications
are subject to change without notice.
Copyright
AUDI AG
I/VK-35
[e-mail]
AUDI AG
D-85045 Ingolstadt
Technical status: 01/10
Printed in Germany
A10.5S00.67.20
Audi TT RS
with 2.5l R5 TFSI Engine
Self-Study Programme 451
451

2
The aims of this Self-Study Programme
In this Self-Study Programme you will learn the key distinctions
between the Audi TT RS (Coupe and Roadster) and the production
model. The central feature of both models is the new 2.5l R5 TFSI
engine. Once you have worked you way through this Self-Study
Programme, you will be able to answer the following questions:
The Audi TT RS developed by quattro GmbH breathes new life into
venerable old traditions. Thanks to a turbocharged 2.5-litre five-
cylinder inline engine, permanent all-wheel drive, a sporty yet
comfortable suspension and the design, both the Coupe and the
Roadster are uncompromising sports cars.
Turbocharged five-cylinder petrol engines already put the first
generation of the Audi quattro ahead of the competition.
The new engine generation combines turbocharging with petrol
direct injection. The TFSI engine develops 250 kW (340 hp) from
2480 cm³ of cubic displacement – that's an output of 137.1 hp per
litre. The Coupe weighs in at a mere 1450 kilograms and has a
power-to-weight ratio of only 4.3 kilograms per hp, while the
equivalent figure for the Roadster (1510 kilograms) is 4.4.
The TT RS Coupe's powerplant launches it from a standing start to
100 kph in 4.6 seconds, as against 4.7 seconds for the Roadster.
The top speed of both versions is electronically limited to 250 kph,
but can be delimited to 280 kph at the customer's option.
Peak torque is 450 Nm and is continuously available from
1600 rpm to 5300 rpm, giving the car formidable pulling power.
And yet, the TT RS Coupe gets by on only 9.2 litres of fuel per
100 km (Roadster: 9.5 litres per 100 km), making it another
example of how Audi blends dynamism and efficiency.
• What changes have been made to the design, the body, the
interior, the equipment, the power transmission system and the
suspension system?
• How is the new five-cylinder engine designed and configured?
• What do you have to pay attention to during servicing?
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3
Introduction
Presentation ________________________________________________________________________________________________________________________________________ 4
Dimensions _________________________________________________________________________________________________________________________________________6
Body
Design _______________________________________________________________________________________________________________________________________________ 8
Technical features and occupant protection __________________________________________________________________________________________________ 10
Interior ____________________________________________________________________________________________________________________________________________ 11
2.5l R5 TFSI engine
Introduction ______________________________________________________________________________________________________________________________________ 12
Specifications _____________________________________________________________________________________________________________________________________ 14
Cylinder block _____________________________________________________________________________________________________________________________________ 15
Crank train ________________________________________________________________________________________________________________________________________ 17
Cylinder head _____________________________________________________________________________________________________________________________________ 19
Chain drive ________________________________________________________________________________________________________________________________________ 20
Belt drive __________________________________________________________________________________________________________________________________________ 21
Positive crankcase ventilation ___________________________________________________________________________________________________________________ 22
Crankcase breather _______________________________________________________________________________________________________________________________ 24
Oil supply __________________________________________________________________________________________________________________________________________ 25
Cooling circuit ____________________________________________________________________________________________________________________________________ 27
Air supply __________________________________________________________________________________________________________________________________________ 28
Exhaust system ___________________________________________________________________________________________________________________________________ 32
Fuel system ________________________________________________________________________________________________________________________________________ 33
System overview __________________________________________________________________________________________________________________________________ 34
Engine management _____________________________________________________________________________________________________________________________ 36
Power transmission
Manual gearbox 0A6 _____________________________________________________________________________________________________________________________ 39
Drive concept _____________________________________________________________________________________________________________________________________ 41
Suspension system
Introduction ______________________________________________________________________________________________________________________________________ 43
Audi magnetic ride _______________________________________________________________________________________________________________________________ 44
Wheels and tyres _________________________________________________________________________________________________________________________________ 45
Brake system ______________________________________________________________________________________________________________________________________ 46
Service
Maintenance work ________________________________________________________________________________________________________________________________ 47
New special tools for the TT RS _________________________________________________________________________________________________________________ 47
Annex
Glossary ___________________________________________________________________________________________________________________________________________ 49
Test yourself_______________________________________________________________________________________________________________________________________ 50
Summary __________________________________________________________________________________________________________________________________________ 51
• This Self-Study Programme teaches the basics of the design and function of new models, automotive
components or technologies.
It is not a Repair Manual. The values specified are for illustrative purposes only and refer to the software
version valid at the time of preparation of the SSP.
For further information about maintenance and repair work, always refer to the current technical literature.
Terms which are indicated in italics and marked by an asterisk (*) are explained in the glossary at the back of
this Self-Study Programme.
Reference
Note
Contents

4
Introduction
Sports suspension with 10 millimetres lower
ride height and ESP Sport mode
2.5l R5 TFSI engine with 250 kW peak output
Xenon plus headlights with LED daytime
running lights
Six-speed manual gearbox 0A6 with all-
wheel drive
Presentation
The Audi TT RS is without doubt the flagship of the TT series. In
addition to the high-performance five-cylinder turbo engine, it has
a number of other technical highlights which you can read about
extensively in this self-study programme.

5
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Heated sports seats trimmed with leather /
Alcantara
Rear wheel drive with generation IV
all-wheel-drive clutch
Rigid rear spoiler (as an option, it can
be deselected for the adjustable rear
spoiler of the volume TT model)
18 inch alloy wheels with 245/40 tyres

6
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Dimensions
Audi TT RS Coupe
1) max. headroom
All dimensions are given in millimetres
Dimensions refer to the vehicle's kerb weight

7
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Audi TT RS Roadster
Coupe Roadster
Kerb weight in kg 1450 1510
Permissible gross weight in kg 1830 1830
Luggage capacity (seats folded down) in l 290/700 250/-
Fuel tank capacity in l 60 60
Drag coefficient cw0.32 0.34

8
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451_011
Body
Design
From a purely visual standpoint, the Audi TT RS Coupe and the
Roadster are both charismatic athletes. Even when stationary, they
seem to be straining at the leash. The muscular sheet-metal body
and the tautly curved surfaces bounded by sharp lines give the
impression of a sculpture in motion. A series of design highlights
impart the TT RS with that air of raw power which characterises a
top of the line model.
Front view
As always on an Audi, the front end is characterised by the single-
frame grille which is encircled by a frame with a matt aluminium
finish. The grille insert, which sports a TT RS badge, features a
shiny black rhombus design mirroring that of the big side air
intakes. Their flared edges draw air into the engine compartment:
the left intake directs the air to the gearbox; the right intake
routes air to an additional water cooler. The turbocharger takes in
air through the upper section of the single-frame grille, while the
intercooler sits behind the lower segment of the grille.
The front skirt has been redesigned. Its splitter and the rear
spoiler collectively provide perfect aerodynamic balance.
Audi offers the splitter, the moulded lip of the diffuser insert and
the mounting for the rear spoiler in aluminium look as an option.
Side view
From the side, the 18-inch wheels, the large brakes and the flared
side skirts of the Audi TT RS instantly catch the eye. The door
mirror housings have a matt aluminium finish as standard and
are optionally available in the body colour or in carbon.
The "Black Styling Package" featuring a black singleframe grille
frame is optional.

9
Headlight design
The headlight design is a distinguishing feature of all current
Audi models. Xenon plus headlights are standard on the TT RS.
They are accentuated by daytime running lights whose 12 LEDs are
arranged in a straight line.
Together with the "wings" (dual plastic wings), the LEDs turn the
headlights into design objects in their own right.
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Rear view
The rear bumper includes an integrated diffuser insert that sur-
rounds the two large, oval tailpipes. A "TT RS" logo also adorns the
rear of the car.
The TT RS comes as standard with a wide, stationary spoiler that
increases the downforce on the rear axle and thus improves stabil-
ity at high speeds. The spoiler of the volume model is available as
an alternative; it automatically extends at 120 kph and retracts
again at 80 kph.

10
Reference
The body construction is described in Self-Study Programme 383 "Audi TT Coupe ’07 – Body".
The occupant protection systems are described in Self-Study Programme 380 "Audi TT Coupe ’07".
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Technical features and occupant protection
Like on the "normal" Audi TT, the body is noted for its low weight
thanks to an innovative hybrid body construction developed by
Audi. Up front the body is made of lightweight aluminium compo-
nents assembled using Audi Space Frame ASF technology; steel is
used at the rear.
This solution guarantees maximum rigidity and a balanced distri-
bution of axle loads. The bodyshell of the Coupe weighs
206 kilograms, while the body of the TTS Roadster weighs in at
251 kilograms Roadster owing to the special reinforcements.
Audi won the EuroCarBody AWARD 2006 for the innovative body
concept of the Audi TT and Audi TT RS.
Other body and occupant protection features:
• Enlarged front air intakes, striking rear diffuser insert
• Stationary rear spoiler
• Dual-stage driver and front passenger front airbags
• Driver and front passenger belt tensioners and belt force limiters
• In a rear-end collision, head restraints support the back of the
head
• Head/thorax side airbags for protection in the event of a side
impact
Winner of the EuroCarBody AWARD 2006 for its innovative body concept

11
Interior
The interior design of the Audi TT RS features a number of modifi-
cations.
The entire interior is dressed in dynamic black.
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451_019
Seats
The front occupants are welcomed by deep-set sports seats which
trimmed in a mixture of leather and Alcantara. They have a wide
range of adjustability. The upholstery leather has a special "TT RS"
grained texture.
The front seat backs can be released for folding down by pressing
either of the 2 handles in the slots in the backrest.
"TT RS" welcome screen in the optional
navigation system plus display
Driver information system
with additional displays for:
– Charge pressure
– Oil temperature
– Lap counter
Rev counter featuring
the "TT RS" logo
RS-style door openers
with two narrow bars
Footrests and pedals in aluminium look
Seat back release handles
Brushed aluminium inlaysThree-spoke multifunction sports steering
wheel, flattened at the bottom and bound
in perforated leather with silver stitching
and a "TT RS" logo

12
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2.5l R5 TFSI engine
Introduction
Audi was the brand most noted for its five-cylinder engines in the
1980s. The powerful engines sharpened the new, sporty profile
and reinforced Audi's proverbial "Vorsprung durch Technik".
The five-cylinder engines combined the efficiency of a four-cylin-
der with the cultivation of a six-cylinder at a lower weight and in a
compact size. A turbocharged version was later launched. It was
the first engine concept to embrace the principle of downsizing*
and it caused a sensation when it was first unveiled 30 years ago.

13
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451_022
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451_024
Synopsis of previously installed five-cylinder engines
The first five-cylinder engine debuted in the spring of 1977 in the
Audi 100 5 E. It had a capacity of 2.1 l and developed 100 kW
(136 hp). A five-cylinder normally aspirated diesel with a displace-
ment of two litres and producing 51 kW (70 hp) was released in
the autumn of 1978. The first turbocharged, five-cylinder petrol
engine was added to the product line-up in 1979. With an output
of 125 kW (170 hp) and 265 Nm of torque, the Audi 200 5 T was
the new flagship model and one of the fastest saloons of its day.
1980 saw the launch of the Audi quattro unifying the two technol-
ogies of turbocharging and all-wheel drive. The turbocharged five-
cylinder produced 147 kW (200 hp) when it first went on sale. In
the 1984 Sport quattro, a direct motorsports derivative, it devel-
oped 225 kW (306 hp) - and was, therefore, one the most power-
ful production engines of the 1980s.
The 1989 Audi 100 TDI, a 2.5-litre model developing 88 kW
(120 hp) and 261 Nm of torque, marked a milestone in automo-
tive history.
In the mid 1990s, the five-cylinder engines were gradually replaced
by the new V6 units, but not without one last hurrah: the 1994
RS 2 produced 232 kW (315 hp).
As a practical Avant with the power of a sports car, it established
an entirely new class of automobile.
Five-cylinder engines in motorsport
The strength and ruggedness of the Audi design was proved in the
competition cars for the World Rally Championship,where the
supercharged five-cylinder pumped out a good 350 kW (476 hp).
The high point in the motorsports career of the five-cylinder was
marked by two all-out racing cars. The Audi Sport quattro S1, with
which Walter Röhrl won the Pikes Peak Hill Climb in the US state of
Colorado in 1987, produced around 440 kW (approx. 600 hp).
IMSA-GTO, a touring car based on the Audi 90, dominated the US
racing scene with 530 kW (approx. 720 hp) from only 2.2 litres of
displacement.
Audi quattro, model year 1980
Audi RS2, model year 1994
Audi Sport quattro S1
Audi IMSA-GTO

14
451_005
Torque/power curve
Max. power in kW
Max. torque in Nm
Engine speed [rpm]
Specifications
Engine code CEPA
Engine type Five-cylinder inline engine
Displacement in cm32480
Stroke in mm 92.8
Bore in mm 82.5
Valves per cylinder 4
Firing order 1-2-4-5-3
Compression ratio 10:1
Output in kW at rpm 250/5400 – 6500
Torque in kW at rpm 450/1600 – 5300
Fuel grade 98 RON 1)
Engine weight in kg 183
Engine management Bosch MED 9.1.2
Exhaust emission standard EU 5
Carburetion FSI (homogeneous) direct injection with demand-based high and low fuel pressure
regulation
Engine management with p/n control and without air mass meter
Exhaust gas aftertreatment Continuous lambda control, with sensors upstream and downstream of the catalytic
converter
CO2emissions in g/km 214
1) premium unleaded petrol with a 95 RON rating can also be used, but results in a drop in power

15
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451_026
Cylinder block
The cylinder block, with its extremely short dimensions, originates
from the 2.5l R5 MPI naturally aspirated engine which VW has
been fitting on Bora and Jetta models for the North American
market since 2004.
It lends itself very well to transverse mounting due to its very
short overall length, and is the shortest and most powerful engine
in its class (see figure below).
The piston cooling spray nozzles are mounted in the crankcase.
Competitive comparison

16
It is needed because the conrod bearings and main bearings have a
relatively small width. Incidentally, this material was also used for
the cylinder blocks of naturally-aspirated racing engines during the
1990s.
Material selection
The engine block is made from a high-tensile cast iron material,
previously used by Audi in its V6 and V8 TDI engines. This is the
first time that it is used in a petrol engine.
Note
The liquid sealants differ and, therefore, have different part numbers. Refer to ETKA and the Workshop Manual for specifi-
cations.
!
451_037
Oil pan
The oil pan is of two-part construction. The upper part acts as a
baffle plate and supports the oil pump. It is bolted together with
the crankcase. The oil pump is bolted to the cylinder block.
The lower part of the oil pan is made from sheet steel and accom-
modates the oil level/oil temperature sender G266 and the oil
drain screw.
The front sides are sealed by the timing case cover on the gearbox
side and by a sealing flange on the vibration damper side. Both
seal off the crankshaft by means of a shaft oil seal.
The oil pans and the front-side covers are sealed against the cylin-
der block by liquid sealant.
Oil pan upper part
Non-return valve of the oil
return line in the positive
crankcase ventilation system
Lower
timing case cover
Cylinder block
Oil level/oil temperature
sender G266
Front sealing flange
Oil pan lower part
Oil drain screw

17
Crankshaft drive
The steel crankshaft runs in six bearings. The main bearing is
58 mm in diameter, while the conrod bearing is 47.8 mm in dia-
meter.
The torsion vibration damper is located at the front end and is
configured as a viscodamper*.
451_027
Crankshaft
Conrod
Circlip
Gudgeon pin
Conrod bearing cap
Piston
Conrod bushing
Conrod bearing shell
Cylinder included angle in mm 88
Block height in mm 220
Conrod length in mm 144
Crankshaft bearings 6
Main bearing diameter in mm 58
Conrod bearing diameter in mm 47.8
Specifications of the cylinder block

18
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451_028
Pistons and conrods
During the development of the box piston*, special emphasis was
given to low oil consumption and low weight. The box piston is
made of a highly heat-resistant alloy and has a cast-in ring land for
the upper piston ring. Due to the high load to which it is sub-
jected, it has asymmetrical skirts and bevelled box walls on the
thrust and counter-thrust sides.
The conrod is manufactured as a forged crack conrod without a
deep bore. The pin on the small-end side of the conrod is
22 millimetres in diameter, and the bearing is made from lead-
free materials.
Enlargement of the gudgeon pin diameter to 22 millimetres
Widening of the small-end eye
Optimised skirt geometry with noticeably enlarged cross-section
Use of M9 conrod bolts
Reinforced threads
No deep bore
Mini headland rings
N1 – asymmetrical and spherical, steel nitrided + PVD*
N2 – taper-face piston ring
N3 – DSF ring* with tapered lands

19
Cylinder head
The cylinder head is also a modified carry-over part sourced from
VW's 2.5l R5 M I engine. To withstand the higher stresses which
occur in a turbocharged FSI engine, it was necessary to make the
following modifications:
• Different aluminium casting alloy
• Lower-set water jacket around the spark plug
• Tempered exhaust valve seat rings
• Attachment of the high-pressure pump to the ladder frame
• Optimised exhaust cam contour
• Additional exhaust cam phaser
• The exhaust valves are sodium-filled for cooling
• Turbo-specfic intake port (to produce the required tumble air
flow in the combustion chamber)
451_006
Cylinder head gasket
Cylinder head
Upper timing case cover
Rocker cover
High-pressure fuel pump
Intake valve diameter in mm 33.85
Exhaust valve diameter in mm 28
Intake valve lift in mm 10.7
Exhaust valve lift in mm 10
Intake camshaft adjustment range in ° crank angle 42
Exhaust camshaft adjustment range in ° crank angle 22

20
Chain drive
The timing gear of the five-cylinder TFSI engine is located on the
power output side. It is of two-stage construction and is driven by
two different chain types.
In the first stage of the chain drive, the oil pump and an idler gear
are driven by the crankshaft. The oil pump has a low ratio. The
crankshaft also drives an idler gear, which has two tasks. Firstly, it
drives both camshafts, and, secondly, it drives the vacuum pump.
Both drives have hydraulically damped chain tensioners.
A 3/8" gear chain is used in the primary drive train (for driving the
oil pump and the idler gear). It is similar in design to the chains in
the 1.8l R4 TFSI engine and offers acoustic advantages over a
roller chain. A 3/8" roller chain is used in the secondary drive.
The entire chain drive is lubricated by the oil returning from both
camshaft phasers and by a bore in the high-pressure chamber of
the "soft" chain tensioner in the secondary drive. There is no
replacement interval for the chain drive.
451_030
Note
After assembly work on the chain drive, all seals must be replaced on each of the timing case covers. Refer to the Workshop
Manual for specifications.
!
Exhaust camshaft phaser
Intake camshaft phaser
Secondary drive train
Idler gear - vacuum pump drive
Primary drive
Oil pump sprocket
Configuration
Chain tensioner
Tensioning rail
Tensioning rail