Audi TT 2016 Reference manual

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The 2016 Audi TT Introduction
eSelf Study Program 990153

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This eSSP contains video links which you
can use to access interactive media.
Audi of America, LLC
Service Training
Created in the U.S.A.
Created 5/2015
Course Number 990153
©2015 Audi of America, LLC
All rights reserved. Information contained in this manual is based on
the latest information available at the time of printing and is subject to
the copyright and other intellectual property rights of Audi of America,
LLC., its aliated companies and its licensors. All rights are reserved to
make changes at any time without notice. No part of this document
may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording
or otherwise, nor may these materials be modied or reposted to other
sites without the prior expressed written permission of the publisher.
All requests for permission to copy and redistribute 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.
Revision 2:8/2015

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This eSelf Study Program teaches a basic knowledge of the design and functions of new models,
new automotive components or technologies.
It is not a Repair Manual! All values given are intended as a guideline only.
For maintenance and repair work, always refer to the current technical literature.
Note
Reference
Introduction ..................................................................................... 1
Model history for the World-wide market ............................................................................................................. 2
Body .................................................................................................. 8
Joining technology ................................................................................................................................................. 10
Thermal "hot" and mechanical "cold" joining techniques .................................................................................. 12
Attachments .......................................................................................................................................................... 14
Passive safety .................................................................................. 16
Components ........................................................................................................................................................... 16
System overview .................................................................................................................................................... 17
Front Passenger Airbag -disabled- Indicator lamp ............................................................................................ 18
Engine.............................................................................................. 22
Engine transmission combination ....................................................................................................................... 23
Power transmission ......................................................................... 24
Overview ................................................................................................................................................................. 24
quattro drive ......................................................................................................................................................... 24
6-speed DSG transmission 0D9 - S tronic ........................................................................................................... 26
Chassis............................................................................................. 28
Overall concept ...................................................................................................................................................... 28
Axles and wheel alignment ................................................................................................................................... 29
Brake system .......................................................................................................................................................... 36
Electronic Stability Control (ESC) ......................................................................................................................... 39
Steering system ..................................................................................................................................................... 40
Wheels and tires .................................................................................................................................................... 43
Electrical system ............................................................................. 44
Installation locations of control units ................................................................................................................. 44
Topology ................................................................................................................................................................. 46
Audi virtual cockpit ................................................................................................................................................ 48
Audi drive select ..................................................................................................................................................... 50
Climate control................................................................................ 53
Introduction ........................................................................................................................................................... 53
A/C operating and display unit ............................................................................................................................. 54
Instrument Panel Temperature Sensor G56 ....................................................................................................... 56
Seat systems .......................................................................................................................................................... 58
Infotainment ................................................................................... 60
Overview of versions .............................................................................................................................................. 60
Service ............................................................................................. 61
Inspection and maintenance ................................................................................................................................ 61
Self-study programs ........................................................................ 62
Knowledge assessment ................................................................... 63

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1
The TT was a revolutionary car design when it was rst
unveiled in 1995. It’s strictly geometrical, formally coher-
ent design language made it an icon with huge charisma.
For the third TT generation, the Audi designers have
returned to many of these ideas and placed them in a new
context that is as dynamic as it is diverse.
The central motif was the circle – embodied in the curves of
the roof line, and the front and the rear overhangs with
their resolutely horizontal lines. From the side, many
details of the new Audi TT are reminiscent of the rst-
generation classic in many respects.
The third generation of the compact sports car again
commands attention with its emotional design and
dynamic attributes. Standout features of the new coupe
are its innovative driveline technology as well as its new
operating and display concept.
630_002
Introduction

2
Find out more about the model
history of the Audi TT.
Model history for the World-wide market
In 1995 Audi presented a pioneering study: the Audi TT. The Coupé (IAA Frank-
furt, 1995) and Roadster (Tokyo Motor Show, 1995) showcars were followed by
the production versions of the Audi TT Coupé in 1998 and Audi TT Roadster in
1999. When the rst-generation Audi TT came on the market in 1998 it was a
design revolution. Radical in design, but suitable for everyday use – that was the
motto for the rst Audi TT.
The third generation of this classic has adopted many of the design elements
that characterized the rst-generation TT – coupled with innovative technology.
Between the rst and third generation of the TT lie nearly 20 years of develop-
ment in technology and design. Here, in brief, are the key milestones in the
model history of the Audi TT.
1995
Presentation of the AudiTT study as a Coupé at the
IAA in Frankfurt.
1998
Start of production of the AudiTT Coupé in Ingolstadt
and Győr.
1999
Start of production of the AudiTT Roadster in Ingolstadt
and Győr.
2000 – 2003
The TT-R racing car prototype provided the basis for
the successful reentry of Audi into the German
Touring Car Championship (DTM).
2006
The second generation of the AudiTT (Type8J)
is rolled out featuring a new design and new
technology.
2007
A new edition of the Roadster also went into produc-
tion a year after the Coupé.

3
630_035
2008
Audi presents the AudiTT clubsport quattro study
with shorter windscreen and sporty attachments.
2012
Audi reveals the AudiTTRSplus, the most powerful
version of the sports car, powered by a 5-cylinder TFSI
engine.
2014
The allroadshootingbrake study provides a
glimpse into the design of the new AudiTT.
2014
The third generation of the AudiTT is released – rst as a Coupé and shortly afterwards as a TTS in Europe.
2010
The second generation of the TT makes a successful entry
into motor racing, in the Long Distance Championship.

4
The 2016 Audi TT has many technical highlights which are
explained in detail in this Self-Study Program. Here is a
quick summary:
Engine
4-cylinder engines with turbocharger :
• 2.0L TFSI
• Horsepower: 220 hp (162 kW)
@ 4500 - 6200 rpm
• Torque: 258 lb ft (350 Nm)
@ 1600 - 4400 rpm
Assistance systems
The following systems are optionally available:
• Audi side assist
• Park assist system with ambient display
Air conditioning
All control functions are integrated into the air vents. The automatic
air conditioning system has small displays which show the selected
setting.

5
630_007
Body
Audi Space Frame(ASF) body made from aluminum and steel with high-
strength and ultra-high-strength steel alloys, die-cast aluminum nodal
elements and side panels as well as a roof made of aluminum.
Suspension
Third-generation Audimagneticride adaptive damper control as
optional suspension version on the TTS. Audimagnetic ride is
adjustable in 3stages via Audidriveselect. Electro-mechanical pro-
gressive steering, where the steering ratio becomes more direct
with increasing steering input.
Displays and operation
Fully digital Audi virtual cockpit instrument cluster with dynamic animations
and graphics. New MMI control panel on the center tunnel console. On each
side of the central rotary pushbutton, there are two buttons together with a
main menu button and a back button. Touch-sensitive touch pad on the top
of the rotary pushbutton.
Power transmission
Full-time quattro drive – systematically developed and rened for the TT –
with electro-hydraulic multiplate clutch on the rear axle. It is possible to
customize the all-wheel drive characteristics by networking the quattro drive
with Audi drive select.

6
61.88 in (1572 mm) 61.10 in (1552 mm)
72.12 in (1832 mm)
37.51 in (953 mm)
39.09 in (993 mm)
3
33.77 in (858 mm)
30.62 in (788 mm)
98.62 in (2505 mm)
164.44 in (4177 mm)
34.80 in (884 mm)
32.00 in (813 mm)
53.26 in (1353 mm)
78.58 in (1966 mm)
630_005
630_003 630_004
Dimensions

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53.62 in (1362 mm)1
57.04 in (1449 mm)2
630_006
1) Shoulder room width
2) Elbow room width
3) Maximum headroom
4) Excluding mirror
5) With 2.0l TFSI engine
6) With rear backrest folded down
All dimensions are given in inches and millimeters and refer to the unladen weight of the vehicle.
Exterior dimensions and weights
Length in (mm) 164.44 (4177)
Width in (mm) 72.12 (1832)4)
Height in (mm) 53.26 (1353)
Front track width in (mm) 61.88 (1572)
Rear track width in (mm) 61.10 (1552)
Wheelbase in (mm) 98.62 (2505)
Curb weight lb (kg) 3186 (1445)5)
Gross vehicle weight lb (kg) 4001 (1814)
Inner dimensions and other specications
Front cabin width in (mm) 57.04 (1449)2)
Front headroom in (mm) 39.09 (993)3)
Front shoulder width in (mm) 53.62 (1362)1)
Rear headroom in (mm) 33.77 (858)
Through-loading width in (mm) 39.36 (1000)
Load sill height in (mm) 32.00 (813)
Trunk capacity cu ft (liters) 10.77/25.14
(305/712) 6)
Drag coecient cw0.30
Capacity of fuel tank gal ( l ) 14.53 (55)
32.44 in
(824 mm)
39.36 in (1000 mm)

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Find out more about the bodyshell
of the Audi TT.
With its hybrid material concept, the bodyshell of the Audi
TT represents a new evolutionary stage of Audi Space
Frame technology (ASF). The bodyshell of the 3rd genera-
tion uses components of the Modular Transverse Platform
(MQB) At 98.62 in (2505 mm), the TT has the shortest
wheelbase of any vehicle in the MQB concept.
The substructure is formed from the cross members, sec-
tions of the A-pillars, the bulkhead, oor pan, rear wheel
arches and the rear tail panel. The hot-formed steel in the
sub-structure weighs 87.08 lb (39.5 kg) and accounts for
almost a quarter of the total structural weight.
Key:
Sheet aluminum
Die-cast aluminum
Aluminum section
Ultra-high strength steel (hot-formed)
Advanced high strength steel
High strength steel
Low strength steel
Prior to forming, the steel is heated to approximately 1832 °F
(1000 °C). It is then cooled immediately to about 392 °F
(200 °C) in a water cooled pressing tool during the forming
process. This drastic change in temperature produces an
extremely strong iron-carbon micro-structure. The form-hard-
ened steel has a relatively low wall thickness and is corre-
spondingly light.
Advanced high strength, cold-formed steel components
together with extruded aluminum sections for the outer
sills and aluminum panels for the rear wheel arches com-
plete the sub-structure of the Audi TT.
Body sub-structure
630_074
Sub-structure integrated into the MQB platform
Torsional rigidity
Compared to the predecessor model, the hybrid ASF of the
new TT has a 23% higher static torsional rigidity while
retaining a high level of dynamic rigidity.
Body

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The occupant cell, which weighs only 149.41 lb (68 kg), is
an aluminum lattice with four castings that form the nodal
elements of the body shell. Large nodal sections of the
A-pillars connect the side roof frame prole, sill, window
cross member and the upper longitudinal section at the
front end.
Two smaller cast nodal elements above the rear window
connect the roof arch to the at C-pillars and the rear roof
cross member.
The entire outer skin of the Audi TT is made from aluminum:
• Front fenders.
• Sidewalls.
• Roof.
• Attachments: hood, doors and trunk lid.
In total, the complete bodyshell with attachments weighs
approximately 608.47 lb (276 kg).
630_012

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Joining technology
The key to optimizing the body structure is using "the right
materials in the right place". The resulting challenge for
the joining technology was to develop universal and reliable
solutions for the large variance in material/thickness com-
binations in the body. On the TT, Audi uses "cold" joining
techniques such as riveting, ow-drill screwing and clinch-
ing to create the aluminum/steel hybrid structure.
Adhesive is also used to strengthen the connection and to
prevent contact corrosion of the aluminum/steel joint.
The body is constructed using the following types of joining
methods:
• 3020 spot welds.
• 1113 punch rivets.
• 44 solid punch rivets.
• 128 ow-drill screws.
• 199 clinching points.
• 6.23 ft (1.9 m) of MIG/MAGwelds
(metal inert gas/metal active gas).
• 16.07 ft (4.9 m) of laser-welded seams.
• 249.34 ft (76 m) of adhesive.
Joining methods used on the Audi TT
Laser welding
Bonding
Resistance spot welding
Semi-tubular punch riveting

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Safety precautions against contact corrosion
Aluminum has a naturally occurring (passivating) surface
oxide layer that protects the underlying material from
corrosion. This is why an unpainted aluminum component
does not normally corrode.
However, if aluminum comes into contact with a metal
which has a positive electrical potential relative to alu-
minum and is in an electrolyte, such as salt water, contact
corrosion will occur.
The greater the dierence in electrical potential, the
greater the corrosion will be. Since aluminum is usually the
less noble metal, it is degraded.
Contact corrosion can also occur if unsuitable connecting
elements (screws, nuts, washers, etc.) are used. Therefore,
a number of precautions must be taken in order to prevent
this process from occurring during body production and
repair work. Audi uses only connecting elements with a
special surface coating for the aluminum/steel hybrid
construction used in the TT. In addition, all rubber and
plastic parts and all adhesives are made of non-conductive
materials. As a further precaution, all hybrid metal connec-
tions are sealed with polyvinyl chloride (PVC) or with wax
after cataphoretic dip primer coating. The cataphoretic
coating (sometimes referred to as E-coat) is an electrically
induced surface treatment that provides resistance to
corrosion and oxidation. See the complete denition on the
following page.
630_075
MIG/MAG welding
Solid punch riveting
Flow-drill screwing
Clinching

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Thermal "hot" and mechanical "cold" joining techniques
The choice of the right joining technique in modern body
construction is material-dependent. Welding similar mate-
rials is still the most frequently used joining technique.
These welding and soldering techniques are called "hot"
joining techniques and have a large variety of applications.
However, the heat input causes high internal stresses in the
component, which often can only be compensated through
time-consuming re-work.
The mechanical "cold" joining technique has the decisive
advantage over the thermal joining technique in that hybrid
joints can be reliably produced between dierent types of
materials. The positive properties of the material are not
adversely aected by thermal inuences.
The following "cold" joining techniques are used:
• Punch riveting.
• Clinching.
It makes good sense to combine the mechanical spot
joining techniques with bonding methods. First, it increases
the strength of the joint and, second, the adhesive also acts
as insulation in the case of hybrid aluminum/steel joints.
This, in combination with seam sealing, prevents direct
contact between the metals and ensures that corrosion
cannot occur. In addition, a carefully selected adhesive
concept also helps to absorb the diering degrees of
thermal expansion of the individual materials. Cataphoresis
is a fully automated process of painting by immersion,
which is based on the movement of charged particles in an
electric eld (paint) towards an oppositely charged pole
(metallic surface to be painted). The main objective of the
coating process is to protect the surfaces from corrosion,
and its properties make it the ideal treatment for this
purpose. This technique also allows areas which are hard to
reach, such as recessed areas, piping etc to be painted.
"Hot" joining technique in the Audi TT
MIG/MAG welding
With the MIG/MAG (MIG = metal insert gas, MAG = metal
active gas) welding technique, an electric arc forms
between the automatically fed welding wire (electrode) and
the workpiece. A shielding gas protects the electric arc and
the welded surface against the ingress of ambient air. The
inert gas and welding wire have to be adapted to the basic
material.
Advantages:
• Versatility in use.
• High weld seam strength.
• Outstanding thin panel properties.
630_076
Resistance spot welding
In the case of resistance spot welding, panels are welded
together using opposed electrodes under the application of
force, pressure and electrical current.
Advantages:
• No additional connecting element.
• No heat inuence zone.
• Short welding time.
Laser welding
With laser welding, the focused laser beam serves as an
energy source. In the welding head, the laser beam is
focused by a lens and reected back onto the workpiece by
mirrors. At the point of contact, the laser beam melts the
workpiece. Welding can be performed both with and
without welding ller material.
Advantages:
• Less inuence of heat.
• Less thermal distortion.
• Less time spent on re-work.
630_077
630_065
• Flow-drill screwing.
• Seaming.
• Bonding.

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"Cold" joining technique in the Audi TT
Punch riveting
Punch welding is a method where pieces that have not been
pre-punched are joined together by inserting a rivet
(semi-tubular rivet or solid punch rivet) into two or more
layers of the workpiece, the rivet piercing the upper work-
piece layers and then expanding in the lower workpiece
layer.
Advantages:
• No pre-punching needed.
• High dynamic strength.
• Form-tting and non-positive connection.
• Ideal for hybrid joining.
Clinching
With clinching, panels or sections are joined together by
cold-forming the materials to produce a form-tting and
non-positive connection without the need for an auxiliary
joining element such as a rivet. In this case, the connec-
tions can have two or more layers.
Advantages:
• No additional connecting element.
• Protects the surfaces of coated workpieces.
Flow-drill screwing
A special, coated screw is inserted through partially non-
pre-punched workpieces by applying high contact pressure.
Due to the high pressure and high RPM, the screw forms a
thermoow hole without producing a burr. The screw
penetrates the material and, in the process, cuts its own
thread.
Advantages:
• High strength through thermo-ow process.
• Ideal for applications in which the material is accessi-
ble on one side only.
• Easy to disconnect.
Bonding
In addition to punch riveting, clinching, solid punch rivet-
ing, ow-drill screwing and resistance spot welding, addi-
tional adhesive bonds are used in certain areas. These
bonds increase the strength of the connection. Adhesive is
also used in seamed connections, as is the case at the rear
wheel arch. In other areas of the bodyshell, use is made of
adhesive beads to provide sealing and insulation between
aluminum and steel, as well as for noise reduction.
Advantages:
• Large area connections are possible.
• Unchanged surface and micro-structure.
• Suitable for connecting dierent materials.
• Sealing connection.
630_061
630_063
630_064
630_078
Semi-tubular punch rivet
Solid punch rivet
630_062

14
Attachments
Hood lock with integrated catch hook
A new hood release mechanism is being introduced with on
the 2016 TT. This design will be used on other vehicles of
the Modular Transverse Platform in the future. The advan-
tage of this system is its improved ease of use for the
customer.
As in the predecessor model, the two hood locks are
released by pulling the lever at the left side lower ‘A’ pillar.
Next, the two catch hooks at the sides of the hood are
released via an additional Bowden cable that is actuated by
a release lever on the lock mount.
Filler ap module
The new TT is the rst Audi model to eliminate the fuel
ller cap. The fuel lling nozzle slots directly into the ller
neck. Two aps are pushed to the side when the nozzle
enters the ller neck and seal the neck after refueling has
been completed.
The fuel ller ap is opened by lightly tapping on the
embossed TT logo. The ap is locked and unlocked auto-
matically when the central locking system is actuated.
630_079
630_080
Hood lock, right
Hood lock, left
Release element in lock
mounting
Catch hook, left
Catch hook, right

15
Rear spoiler
The Audi TT has an electrically retractable rear spoiler as
standard. There is a choice of 2 operating modes for
extending and retracting the rear spoiler.
Design
The operating module is bolted to the rear trunk lid. The
spoiler blade is mounted to the operating module. The
operating module consists of the drive unit, drive shaft and
pivot mechanism (hinge) and the self-adjusters.
630_081
Note
The spoiler mechanism components cannot be repaired/replaced individually. In the event of damage, the operating module
must be replaced as a unit. The spoiler blade, however, can be replaced if damaged.
Driving stability is increased signicantly at high speeds
when the rear spoiler is extended.
Operating mode Function
Automatic mode Automatic extension and retraction: The rear spioler is automatically extended when a speed of
approximately 75 mph (120 km/h) is exceeded and retracted again at about 50 mph (80 km/h).
Manual mode Manual extension: The rear spoiler can be extended fully with a short touch of the rear spoiler button in
the center console.
Manual retraction:
• At a speed of up to about 12 mph (20 km/h), the rear spoiler can be retracted by holding the button
down.
• At a speed of between 12 mph (20 km/h) and 75 mph (120 km/h), the rear spoiler can be retracted
fully by touching the button.
Sheet-metal spoiler blade
Drive unit with drive shaft and
pivot mechanism (hinge)
Trunk lid

16
Components
Depending on country version and trim level, the passive
occupant protection system in the Audi TT may have the
following components and systems:
• Airbag Control Module.
• Driver airbag.
• Front passenger airbag.
• Front side airbags.
• Head airbags.
• Knee airbag, driver and front passenger sides.
• Front airbag crash sensors (acceleration sensors).
• Front crash sensors for side crash detection
(pressure sensors).
• Rear crash sensor for side crash detection
(acceleration sensor).
• Front inertia-reel seat belts with pyrotechnic belt ten-
sioners.
Key to illustration on page 17:
E24 Driver Seat Belt Switch
E25 Front Passenger Seat Belt Switch
E258 Driver Side Rear Seat Belt Switch
E259 Passenger Side Rear Seat Belt Switch
G128 Front Passenger Occupant Detection Sensor
G179 Driver Side Airbag Crash Sensor
G180 Front Passenger Side Airbag Crash Sensor
G256 Driver Side Rear Side Airbag Crash Sensor
G283 Driver Front Airbag Crash Sensor
G284 Passenger Side Front Airbag Crash Sensor
G551 Driver Belt Force Limiter
G552 Front Passenger Belt Force Limiter
G553 Driver Seat Position Sensor
G554 Front Passenger Seat Position Sensor
J234 Airbag Control Module
J285 Instrument Cluster Control Module
J533 Data Bus On Board Diagnostic Interface (Gateway)
J706 Passenger Occupant Detection System Control Module
• Inertia-reel safety belts with active belt force limiters.
• Rear inertia-reel safety belts with pyrotechnic belt ten-
sioners, driver and front passenger sides.
• Safety belt warning for all seats.
• Safety belt switches on all seats in the safety belt
buckles.
• Seat occupancy sensor in front passenger seat.
• Airbag disabling switch, front passenger side.
• Front passenger airbag OFF and ON warning lamps.
• Driver and front passenger seat position sensors.
• Battery disconnect.
K19 Seat Belt Indicator Lamp
K75 Airbag Indicator Lamp
K145 Front Passenger Airbag -disabled- Indicator Lamp
(ON and OFF status of front passenger airbag is indicated)
N95 Driver Airbag Igniter
N131 Front Passenger Airbag Igniter 1
N132 Front Passenger Airbag Igniter 2
N153 Driver Seat Belt Tensioner Igniter 1
N154 Front Passenger Seat Belt Tensioner Igniter 1
N196 Driver Side Rear Seat Belt Tensioner Igniter
N197 Passenger Side Rear Seat Belt Tensioner Igniter
N199 Driver Thorax Airbag Igniter
N200 Front Passenger Thorax Airbag Igniter
N251 Driver Head Curtain Airbag Igniter
N252 Passenger Head Curtain Airbag Igniter
N253 Battery Interrupt Igniter
N295 Driver Knee Airbag Igniter
N296 Front Passenger Knee Airbag Igniter
N490 Driver Airbag Release Valve Igniter
N491 Front Passenger Airbag Release Valve Igniter
T16 Data Link Connector
Passive safety