Audi TT Roadster Manual

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391

Service Training

speciﬁcations subject to

change without notice.

AUDI AG

I/VK-35

Service.tr[email protected]

Fax +49-841/89-36367

AUDI AG

D-85045 Ingolstadt

Technical status: 12/06

Printed in Germany

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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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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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

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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.

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.

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.

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.

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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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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with respect to the correctness of information in this document. Copyright by AUDI AG.

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

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