Audi TT COUPE, Service

Page 1: ...Service The Audi TT Coupé Design and Function Self Study Programme 207 For internal use only ...

Page 2: ... 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...

Page 3: ...e 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 7...

Page 4: ...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 refle...

Page 5: ...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 ...

Page 6: ...1 mm Width 45 mm Height 69 mm Vehicle dimensions A brief introduction to the TT 4041 746 2419 quattro 2427 quattro 738 876 762 9 5 9 8 2 8 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 ...

Page 7: ...0 1 Audi AG A3 W A U Z Z Z 8 L Z X A 0 0 0 0 0 1 A4 W A U Z Z Z 8 D Z X A 0 0 0 0 0 1 A6 incl SKD Poland W A U Z Z Z 4 B Z X N X 0 0 0 0 0 1 A8 W A U Z Z Z 4 D Z X N 0 0 0 0 0 1 Cabrio W A U Z Z Z 8 G Z X K 0 0 0 0 0 1 Audi 100 C3 CKD W A U Z Z Z 4 4 Z X A 0 0 0 0 0 1 Vehicles to US specification USA Canada Saudi Arabia tourists On the VIN behind the windscreen the certification label and on official...

Page 8: ...ats 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 a...

Page 9: ...olts 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...

Page 10: ...itch 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 ...

Page 11: ...ally via a switch in the central console The fuel filler flap is attached from the exterior with three anti theft protected bolts plus four decorative bolts If the electrical system fails the fuel filler flap can be opened via an emergency release mechanism in the luggage compartment For this purpose it is necessary to open the flap in the side trim panel on the right hand side of the luggage compartme...

Page 12: ...d metal plates In the case of a side impact the strong cross members will also deform on the side of the body facing away from the impact to absorb some of the impact energy The body structure of the vehicle rear end area is designed in such a way that firstly the integrity of the fuel system remains largely intact and secondly the load on the occupants is kept to a minimum even in serious accident...

Page 13: ...ctively These include the side reinforcements made of high strength extruded aluminium sections in the doors The double rectangular section can absorb large mounts of energy During a side impact the forces acting on the vehicle are distributed via the side reinforce ments in the doors to the sill and the A and B pillars The strong sill also absorbs energy and simul taneously transmits this energy ...

Page 14: ... the belt tensioners can be fired independently of the airbags depen ding on how the trigger criteria are defined The Audi TT Coupé has a disable function for deactivating the front passenger airbag When using Reboard child seats on the front passenger seat the driver must disable the front passenger airbag with the vehicle key via the key switch located inside the glove box see Operating Manual Aud...

Page 15: ...oam protect the vehicle occupants in the pel vis and rib cage areas For protection of the head a padding is also integrated in the roof area An additional deformation element has been welded onto the A pillar These measures have enabled Audi to comply with the new US head impact laws for the first time SSP207 6 SSP207 7 Deformation element Roof padding The rear seat has been approved as a Group 3 c...

Page 16: ...dependent on operation of the brake pedal In the event of a frontal crash the foot con trols are displaced towards the central tube This causes the collapsing support to deflect and the piston rod to buckle The pedal footplate is swung up to 170 mm away from the foot area The buckling of the piston rod and the defor mation work resulting from this dampens the angular movement of the braking foot Th...

Page 17: ...own power The fuel tank is made of plastic and is housed in a protected position in front of the rear axle Airbag control unit Motronic control unit Fuel relay Door locking unit Hazard warning switch Interior lighting Central locking control unit and anti theft warning system Fuel pump Fuel cut off J234 J220 J17 J379 F220 223 E3 G6 The Audi TT Coupé is the first Audi to be equipped with a fuel cut ...

Page 18: ... quattro 02M 3 Gearbox Code MQ 250 5 speed front 02J N MQ 350 6 speed quattro 02M 1 1 8 ltr 5V turbocharged AJQ 132 kW 180 bhp 1 8 ltr 5V turbocharged APX 165 kW 225 bhp SSP207 33 SSP207 53 SSP207 14 SSP207 33 Drive units SSP207 13 Engine DZF DXW DQB ...

Page 19: ...rque 235 Nm at 1950 4700 rpm Rated output 132 kW 180 bhp at 5500 rpm Engine management ME 7 5 Fuel Premium unleaded 98 RON RON 95 can be used but reduces power output 1 8 ltr 5V turbocharged engine 132 kW AJQ Technical modifications Basic 110 kW 150 bhp EU II D3 electronic throttle control Tumble duct For details of the tumble duct in the intake system refer to SSP 198 Engine control unit character...

Page 20: ...gine speed sender G28 Hall sender G40 Lambda probe G39 Throttle valve control unit J338 with angle sender G187 for throttle valve gear G186 Intake air temperature sender G42 Coolant temperature sender G2 and G62 Knock sensor 1 cyl 1 2 G61 Knock sensor 2 cyl 3 4 G66 Accelerator pedal module with accele rator position sender G79 and G185 Brake light switch F and brake pedal switch F47 Clutch pedal s...

Page 21: ...8 3rd cyl and N163 4th cyl with integrated power output stage Solenoid valve for activated charcoal canister N80 Solenoid valve for charge pres sure limitation N75 Throttle valve control unit J338 with throttle valve gear G186 Air recirculation valve for turbo charger N249 Heater for lambda probe Z19 Auxiliary signals Fault lamp for electronic throttle control K132 ...

Page 22: ...l pump relay J220 Motronic control unit K132 Fault lamp for electronic throttle control M9 10 Stop lights N Ignition coil N30 33 Injection valves N75 Solenoid valve for charge pressure limitation N80 Solenoid valve for activated charcoal canister N128 Ignition coil 2 N158 Ignition coil 3 N163 Ignition coil 4 N249 Air recirculation valve for turbocharger P Spark plug socket S Fuse Q Spark plugs Z19...

Page 23: ... λ 30 86 87 85 D A 4 E F N158 N163 CAN BUS L M Q P Q P Q P Q P G C S S S S G188 G187 G186 G6 G71 N75 F36 E227 E45 N80 G70 G39 Z19 G40 G62 F88 G28 G61 G66 G42 K132 M9 10 S S S S N128 N N32 N31 N30 A 31 J220 P 23 SSP207 25 Dieses Dokument wurde erstellt mit FrameMaker 4 0 4 ...

Page 24: ...ler Since the density of the cooled air is higher the amount of fuel air mixture entering the engine is greater too The result is an increase in power output for the same displacement and engine speed In the case of the 1 8 ltr 5V turbocharged engine turbocharging is also used to provide high torque from the bottom end to the top end of the rev band Charge pressure increases in proportion to the t...

Page 25: ...ation regarding charge pressure control please refer to SSP 198 The engine control unit calculates the charge pressure setpoint from the engine torque request The engine control unit regulates the charge pressure as a function of the opening time of the solenoid valves for charge pressure limitation N75 For this purpose a control pressure is generated from the charge pressure in the com pressor ho...

Page 26: ...f the intake manifold pressure If the air recircu lation valve fails control takes place as a result of the engine vacuum downstream of the throttle valve As soon as the throttle valve is closed the air recirculation valve briefly closes the compres sor circuit The vacuum counteracts the spring in the valve The valve opens and the compressor and intake sides of the compressor circuit close for a sh...

Page 27: ...daptation Hot film air mass meter with reverse flow detector HFM5 integrated in the intake air filter upper section Single flow throttle valve unit integrated in the electronic throttle control positioner 1 8 ltr 5V 165 kW APX turbocharged engine SSP207 14 SSP207 63 Specifications Engine code APX Type 4 cylinder 5 valve four stroke petrol engine with exhaust gas turbocharger Valve timing Double overhea...

Page 28: ...probe will be installed downstream of the catalytic converter to meet the requirements stipulated in EU III SSP207 103 Lambda probe down stream of catalytic con verter G130 when EU III takes effect Motronic control unit J220 Secondary air pump motor V101 Secondary air pump relay J299 Secondary air injection valve N112 Heater for lambda probe down stream of catalytic converter Z29 when EU III takes...

Page 29: ...1 Secondary air pump motor Z29 Heater for lambda probe downstream of catalytic converter when EU III comes into effect H Air conditioning PWM signal K Fault lamp As of series production launch the 1 8 ltr 165 kW engine will be equipped with extended system components to ensure it complies with European exhaust emission standard EU II D3 The basic version is equivalent to the engine management syst...

Page 30: ...l is attached to the camshaft It supplies a signal which enables the engine control unit to determine the posi tion of the camshaft relative to the crankshaft more quickly and in combination with the signal which the engine speed sender supp lies to start the engine more quickly Drive units The quick start sender wheel comprises a twin track sender wheel and a Hall sensor The sender wheel is desig...

Page 31: ...al Compression cycle High phase signal Exhaust cycle SSP207 85 SSP207 86 SSP207 87 Electrical circuit The Hall sender G40 is connected to the sen sor earth terminal of the engine control unit The signal which the engine speed sender G28 supplies enables the injection cycle to be initiated after a crank angle of approx 440o Even if the Hall sender fails it is still possible to start the engine ...

Page 32: ...er G2 G62 Exh gas turbocharger Cylinder head Oil cooler Cooler Coolant afterrun pump V51 Coolant regulator Thermoswitch for radiator fan F18 F54 SSP207 37 The exhaust gas turbocharger is water cooled and integrated in the cooling circuit When the coolant regulator is open the coo lant flows back to the cooler or coolant pump via cylinder head exhaust gas turbocharger and coolant afterrun pump among...

Page 33: ...runs on for approx 10 min after the ignition has been switched off In vehicles without air conditioning these functions are implemented by means of a timer relay Coolant afterrun pump V51 To counteract the thermal loads and in parti cular at the exhaust gas turbocharger the pump V51 starts up when the ignition is tur ned On SSP207 38 The coolant afterrun pump V51 is atta ched to the radiator fan h...

Page 34: ...r cooler on the left hand side of the vehicle Charging Drive units SSP207 24 To increase the power output and torque of the 1 8 ltr 5V engine to 165 kW it was neces sary to make various design modifications to the basic engine of the Audi TT Coupé developing 132 kW A characteristic feature of the engine is its higher air demand making it necessary to enlarge the diameter of the intake port and exha...

Page 35: ...erature during the cold start phase To improve the exhaust gas composition these constituents must be reduced The secondary air system is responsible for this task The system injects air upstream of the outlet valves during this phase thus enriching the exhaust gases with oxygen This causes post combustion of the uncombusted hydrocar bons contained in the exhaust gases The catalytic converter reac...

Page 36: ...secondary air injection valve releases atmospheric pressure Secondary air pump V101 The secondary air pump relay J299 which the Motronic control unit drives switches the elec tric current for the secondary air pump motor V101 The fresh air which is mixed with the exhaust gases is drawn out of the air filter housing by the secondary air pump and released by the combi valve This valve also prevents h...

Page 37: ...applicable limit values for hydrocarbon content in the exhaust gases are exceeded by a factor of 1 5 in the course of a statutory exhaust emission test this must be identified via the fault memory SSP207 100 Lambda control in the EU III An additional lambda probe G130 which is located downstream of the catalytic converter was integrated in the system to comply with EU III Its purpose is to test the...

Page 38: ...n makes this possible Internal torque requests External torque requests Start Idling control Catalytic converter heating Power output limitation Driving comfort Component protection Engine speed limitation Driver input Throttle valve angle Charge pressure Ignition angle Cylinder suppres sion Injection time Torque influencing manipula ted variables Driving dynamics Driving comfort Cruise control sys...

Page 39: ...e for consumption and emission data so as to ensure optimal torque control External and internal tor que requests Calculation of efficiency and tor que reference variables Charge path prio ritisation Prioritisation of crankshaft syn chronous path Conversion of torque into charge Throttle valve angle Charge pressure control Calculation of crankshaft synchronous initiations Throttle position calculat...

Page 40: ...ion and plausibility of the two senders G79 and G185 If a sender fails the other sender acts as a back up Resistance in Ω Accelerator pedal travel G79 G185 LHD SSP207 98 SSP207 102 The electronic throttle control function is used to reduce and increase torque without adver sely affecting the exhaust emission values Accelerator position senders G79 and G185 Traction control Engine speed limitation ...

Page 41: ...ottle valve control unit Accelerator position sender Safety module Throttle valve control unit J338 The engine control unit positions the throttle valve via an electric motor The engine control unit is provided with continuous feedback on the throttle valve position Extensive safety measures have been imple mented in the hardware and software For example dual senders a safety module and a self mon...

Page 42: ... line connected to the air vent valve while the vehicle is being refuelled The filler neck cannot be separa ted from the fuel tank Air vent valve for vehicles with front wheel drive and quattro power train Bypass duct Activated by unleaded fuel valve Air vent valve Filler expansion tank Main expansion chamber Filler neck Housing for gra vity float valve When refuelling the vehicle the unleaded fuel ...

Page 43: ...via the gravity float valve by the ACF system The gravity float valve prevents fuel from entering into the ACF system when cornering at high speed or if the vehicle rolls over Filler expansion cham ber Main expansion chamber to ACF system Gravity float valves for vehicles with front wheel drive and quattro power train SSP207 117 ...

Page 44: ...d fuel vapours are channelled through the operating vent and collected in the main expansion chamber at the filler neck upper section Gravity float valve Filler neck Air vent valve Filler expansion chamber Main expan sion chamber to activated charcoal filter Main breather Filler breather The vapours are conveyed to the activated charcoal filter via the closed filler neck the bypass at the air breather ...

Page 45: ...use The fuel is transferred to the engine by a high performance fuel pump with a pressure increase from 3 to 4 bar In the event of a crash the fuel pump is swit ched off by the fuel pump relay A single stage fuel pump is used in vehicles with front wheel drive Electrical circuit SSP207 55 M 30 15 X 31 J220 30 15 X 31 G6 G1 J218 J17 S 31 31 G SSP207 119 ...

Page 46: ...t hand fuel tank part upst ream of the baffle housing of the fuel delivery unit Fuel tank for quattro vehicles The breather system is designed in the same way as for front wheel drive vehicles Gravity float valve Air vent valve Filler neck Filler expansion chamber Main breather Filler breather Main expansion chamber SSP207 120 ...

Page 47: ...tructions given in the Work shop Manual The tank senders are connected in series R1 R2 Rtotal Signals are evaluated in the dash panel insert microprocessor Electrical circuit SSP207 121 The fuel lines and left hand tank sender are connected to the baffle housing in the tank The suction jet pump is driven by the two stage fuel pump The suction jet pump can only be removed after de taching the fuel l...

Page 48: ...rential with flange shaft adaptation and triple roller joint shaft The gearbox was modified in the selector shaft area standardised gear change linkages used and the gear lever of the sporty version of the TT has been adapted Technical features of the gearboxes The 5 speed and 6 speed quattro gearboxes are identical as regards their design whereby the change gear for 6th gear in the 5 speed gearbox ...

Page 49: ...38 g cm3 6 speed manual gearbox 3 shafts The triple shaft design permits a space saving and highly compact design A distinction is made between two gearbox variants the variant for vehicles with front wheel drive and the variant for vehicles with four wheel drive quattro Both variants differ from one another as regards their attachment points and oil penetration points SSP207 54 ...

Page 50: ...t gearbox MQ 350 in 6 speed version The spur gear is riveted to the differen tial If repair work is necessary the spur gear must be bolts Reverse gear 2nd drive shaft Gears 5 6 Engine drive For more detailed information on the manual gear boxes see SSP 205 Spur gear ...

Page 51: ...51 Notes ...

Page 52: ... the engine out put directly to the front axle and simultane ously via an angle gear and the propshaft to the Haldex viscous coupling flanged to the rear axle drive The rear axle drive is composed of the Haldex viscous coupling the axle drive and the diffe rential Acceleration with high directional stability Handling is neutral with a slight tendency to understeer No restrictions on towing when the...

Page 53: ...oupling is accommoda ted in a closed housing and mounted in front of the rear axle drive The input shaft and the output shaft are sepa rate These shafts are connected via a plate cou pling running in oil The coupling package comprises inner and outer plates which are connected to the input shaft and output shaft respectively Arranged around the shaft at the coupling input end are a working piston ...

Page 54: ...om being damaged The hydraulics Torque is transmitted to the rear axle drive by means of the plate coupling The necessary coupling pressure is generated via the two annular piston pumps The annu lar piston also known as axial piston is driven by an axial piston pump The speed at which this pump rotates is the difference between coupling input and output speeds An even pressure curve is ensured by ...

Page 55: ...e control system can recognise corners manoeuvring mode acceleration phase and different wheel circumferences The stiffness of the Haldex viscous coupling is adjusted according to the recognised driving conditi ons The control system Legend ABS EDL sensor line ABS EDL control line Brake line pressurised Brake line depressurised MA Drive torque per wheel MB Brake torque per wheel Md Engine torque A...

Page 56: ... rake and reach as standard The maintenance free rack and pinion steering gear is power assisted The steering gear stroke is transmitted directly to the swivel bea ring due to the fact that the track rods are opti mally attached to the steering arm Consequently the steering is direct A steering damper reduces the influence of impacts and vibrations which are transmitted from the wheels to the steer...

Page 57: ...e control unit to recognise engine loading in time and to regulate engine torque at idling speed The ME 7 5 determines itself how engine tor que is to be increased at idling speed in order to counteract the load e g ignition angle cor rection towards retard Pressure switch for power steering This is how it works As steering forces increase the pressure switch closes and sends a signal to the engin...

Page 58: ...sverse anti roll bar the McPherson strut axle is designed as a sports suspension Track rod joint Subframe Steering gear Coupling link bet ween suspension strut anti roll bar Ball joint The features of the front axle are Track rod joints larger diffraction angle Ball joint is reinforced by thicker journals The subframe is rigidly bolted to the aluminium bush The suspension strut attachment to the a...

Page 59: ...hich occur when cornering are transmitted favourably to the bearing and from the bea ring to the body Wheel housing support Wheel bearing Double ball bearing requiring no adjustment Positioning inclined 25o The shock absorbers are supported in the wheel housing and the coil springs are sup ported below the side member The axle is stabilised by a tubular anti roll bar Due to the separate layout of ...

Page 60: ...bframe 4 point attachment and each of the track correcting wishbones attached to the trailing link For stabilisation purposes a transverse anti roll bar is located on the axle subframe Fitting position of damper approx 45o Damper Anti roll bar Rubber bea ring Trailing arm Trailing link Haldex viscous coupling Subframe New tool for mounting rear wheel bea rings ...

Page 61: ...n EBFD regulates the brake pressure acting on the rear wheels via the ABS control unit so that they cannot be overbraked The EBFD control is suppressed when the ABS control takes effect The electronic differential lock EDL provides assistance with driving away on slippery surfaces SSP207 42 132 kW Diagonal split dual circuit brake system Anti lock Braking System ABS with elec tronic brake force di...

Page 62: ...t front right and rear left wheels A separate brake line running from the 4 chan nel system of the hydraulic unit is assigned to each wheel K14 33 K47 G44 G46 G45 G47 J104 F V64 N55 For a brief description of the components please refer to function diagram Brake circuit Brake circuit Output signals Input signals SSP207 31 Fault recognition in the ABS system is via warning lamps visual contact and ...

Page 63: ...e vehicle stabilises itself and follows the direction in which the vehicle is steered Oversteer If the vehicle oversteers during a braking ope ration this means that the maximum corne ring grip of the rear wheel has been exceeded The vehicle breaks away towards the outside of the corner over the rear axle The ABS control unit recognises this situation from the reduced circumferential speed of the ...

Page 64: ...ra tion Electrics Airbag control unit J234 Radiator fan control unit J293 Fuse box battery ABS EDL control unit J104 Engine control unit J220 Combi processor in the dash panel insert J218 Immobiliser control unit J362 Navigation operating elec tronics control unit J402 Connector point A pillar Socket power windows radio CLS ATA light mirror adjustment Lateral acceleration sen sor passenger s side ...

Page 65: ...412 Control unit for headlight range control J431 Control unit for navigation system and CD J401 Central locking control unit J429 Coupling point A pillar Lateral acceleration sen sor driver s side Mini electrics Socket power windows loudspeaker radio central locking anti theft alarm ...

Page 66: ...against false alarms e g knocking on the roof of the vehicle or against the window air movement caused by wind or passing vehicles temperature changes e g due to the interior of the vehicle heating up as a result of exposure to strong sunlight any kind of noise horns sirens bells The system communicates with the anti theft warning system regarding activation deactiva tion as well as tripping of th...

Page 67: ...n the vehicle headliner In its activated state the transmitter module sends out sound waves at a frequency of 40 kHz imperceptible to the human ear and receives the echo a short time later via the receiver module The evaluation electronics detects irregularities in the ultrasonic field and sends an alarm signal to the central locking control unit The anti theft warning system LED indicates that the...

Page 68: ...ol unit actively into evaluation and monitoring processes Electrics SSP207 88 The 3rd generation immobiliser differs from the previous immobiliser in the following respects Variable code evaluation in the engine control unit and immobiliser control unit The engine control unit has an equation which calculates the generated variable code in the same way as in the immobiliser control unit Always use...

Page 69: ...ontrol unit This code is sent to the transpon der A secret arithmetic process is started in the transponder and in the control unit according to a set of equations The result of the compu ting process is evaluated in the control unit If the results tally the vehicle key is acknow ledged as correct The engine control unit then sends a variable code to the immobiliser con trol unit Self diagnosis Th...

Page 70: ...ponder key Engine control unit Variable code STOP Calculate according to equation set B Calculate according to equation set A Fixed code Communication 30 20 10 40 50 60 0 P ABS AIR BAG 90 C 50 70 10 30 50 70 100 140 180 220 260 20 40 60 80 160 200 240 120 1 2 1 1 0 130 Immobiliser III Same fixed code storage locations as in immobiliser II Generate variable code Communication via CAN W VIN Personal ...

Page 71: ...71 Notes ...

Page 72: ...tailgate 6 disc CD changer Telephone operating electronics control unit J412 on the rear floorpan assembly Tweeter Subwoofer in left hand door Loudspeaker rear Bose Fitting locations for radio Bose amplifier 6 disc CD changer loudspeaker aerial and car phone system SSP207 105 Rear loudspea ker Bose Tweeter Subwoofer in right hand door Tweeters and subwoofer are fitted in the Chorus and Concert Audio ...

Page 73: ...udspea kers as well as a 250 W power amplifier The reception of the rear window aerial is boosted by an aerial accommodated in the tailgate When the Bose sound system is in use the FADER function is deactivated volume dis tribution between front rear left right loud speakers in order to safeguard sound quality in the vehicle interior In this case the separate amplifier module located in the rear end...

Page 74: ... front left door loudspeaker Electrics Chorus Concert and Concert audio systems with optional equipment Door front left tweeter subwoofer Door front right tweeter subwoofer Rear left tweeter subwoofer Rear right Tweeter subwoofer CD player Car phone Navigation Active Passive Window aerial amplifier Radio Optional equipment Car phone Navigation Legend ...

Page 75: ...oofer Window aerial amplifier Radio Door front right tweeter subwoofer Rear right subwoofer Rear left subwoofer Car phone Navigation 6 disc CD changer Bose amplifier Optional equipment Central loudspeaker FAD BAL RD MODE CPS RDS AM TP FM TRE BASS AS Scan 3 6 2 5 1 4 Audi concert Optional equipment ...

Page 76: ...g system ON OFF switch pull press and temperature control rotary switch warmer colder Rotary switch Blower motor speed control air flow rate control Button defroster for windscreen and side window Display panel for operating conditions blower settings desired interior temperature Temperature sensor G56 Dash panel with blower V42 for temperature sensor Economy mode The compressor is switched off But...

Page 77: ...l unit V2 Fresh air blower V68 Temperature flap actuating motor V70 Central flap control motor V71 Air flow flap control motor V85 Footwell defrost flap positioning motor SSP207 34 V85 V71 V2 J126 V70 G192 G89 V68 The air conditioner may only be remo ved after evacuating the coolant cir cuit properly Air flow flap Fresh air air recirculation flap Air conditioner ...

Page 78: ...empe rature sensor G89 Footwell vent temp sender G192 Pressure sensor for air conditioning system G65 Thermoswitch for air conditioning system switch off F14 Thermoswitch for radiator fan F18 F54 Auxiliary signals Stationary period signal Road speed signal Engine speed signal Engine temperature engine hot LED Heating air conditioning system Diagnosis plug connection T16 Operating unit for air cond...

Page 79: ...eter G112 Control motor for temperature flap V68 with potentiometer G92 Positioning motor for air flow flap V71 with potentiometer G113 Fresh air blower V2 with blower control unit J126 Auxiliary signals Engine control unit Ambient temperature display Actuators Actuating motor for defroster flap in footwell V85 with potentiometer G114 ...

Page 80: ...80 Heating air conditioning system Air distribution Dash panel outlets left right centre Fresh air Air recirculation Defrost Footwell SSP207 39 ...

Page 81: ...7 41 Ventilation control In fresh air mode the air flow flap is closed depending on the selected fresh air blower motor speed and vehicle road speed Fresh air ventilation produced at high engine speeds is kept at an almost constant value by controlling the closing of the air flow flap The fresh air supply is not interrupted entirely In Off mode the air flow flap is closed and the air recirculation flap i...

Page 82: ...vated by a push rod Expansion valve The expansion valve is located directly in front of the evaporator between the high pres sure and low pressure sides of the refrigerant circuit to compressor Pressure equalisation bores Control unit Gas filled thermostatic valve element from evaporator Diaphragm to evaporator Push rod Ball valve from condenser SSP207 44 Heating air conditioning system Lack of the...

Page 83: ...section of the ball valve is reduced SSP207 49 SSP207 50 SSP207 51 SSP207 52 The temperature at the evaporator outlet is higher due to the cooling load increase Pressure rise Pa of the gas filling in the thermostatic valve element The cross section of the ball valve is enlarged via the diaphragms and push rod Refrigerant flows to the evaporator and absorbs heat at the transition from high pressure t...

Page 84: ...ce intervals the flexible service interval indicator will enable the performance margins of the engine oil to be utilised to full capacity A new type of sen sor for oil level and oil temperature recogni tion has been developed for this purpose Oil level sensor SSP207 91 30 20 10 40 50 60 0 70 10 30 50 70 100 140 180 220 260 20 40 60 80 160 200 240 120 1 2 1 1 0 90 C 50 130 AIR BAG ABS Level sensor ...

Page 85: ...r cooling down phase The influencing criteria for the flexible service interval indicator are oil level oil tempera ture fuel consumption in l h per cylinder and distance covered High Low Cooling down phase 200 1 000 ms Heating phase Oil temperature evaluation 25 85 ms In the combi instrument the condition of the oil in the vehicle determined by evaluating these influencing variables and the upper li...

Page 86: ...l filter Battery A Ah Manual 220 A 44 Ah Automatic 280 A 60 Ah Manual 220 A 44 Ah Automatic 280 A 60 Ah Alternator A max 90 A 90 A Power transmission Drive Front wheel drive Traction Control System TCS EDL Four wheel drive Electronic differential lock EDL Clutch Hydraulically activated single dry plate clutch with asbestos free linings two mass flywheel Gearbox type 5 speed manual gearbox fully sync...

Page 87: ...r Brake disc diameter front rear mm front 312 x 25 fwd rear 232 x 9 quattro rear 239 x 9 front 312 x 25 rear 256 x 22 Wheels 7J x 16 7 1 2J x 17 Offset depth of rims mm 31 32 Tire size 205 55 R16 225 45 R17 Body dimensions Body type self supporting fully galvanised steel aluminium bonnet front rear crumple zones side protection Number of doors seats 2 2 Frontal area A m2 1 99 Drag coefficient cd 0 ...

Page 88: ... Capacities Cooling system capacity l 7 Engine oil capacity l 4 ltr and 4 5 ltr without and with filter change respectively Gearbox oil capacity l fwd 2 3 quattro 2 6 Tank capacity l 55 62 Windscreen washer fluid tank l 4 l 3 74 ltr usable water volume Performance consumption acoustics Max speed kph 228 243 at engine speed rpm 6430 6281 Acceleration 0 80 kph s 5 5 4 3 0 100 kph s 7 4 6 4 Elasticity ...

Page 89: ...s Wheel bearing puller for quattro rear axle comprises Order No Sleeve T10030 1 Tube T10030 2 Spindle T10030 3 Thrust piece T10030 4 Cross piece T10030 5 Tube T10030 6 Adapter Order No T10031 SSP207 127 SSP207 128 SSP207 134 1 2 4 5 3 6 ...

Page 90: ...Order No T10035 Attachment for SW 3300A front wheel drive vehicles only Order No T10036 Spring retainer in preparation Gear wneel SSP207 130 SSP207 131 SSP207 132 Additinal tool for set V A G 1459B Thrust piece VAS 5146 ...

Page 91: ...he CI for Audi s own Self Study Programmes The section on Service provided you with information regarding new special tools and service highlights among other things We would be pleased to receive any suggestions for improvement of the Self Study Programmes If you have any queries please do not hesitate to contact us under Fax No 49 841 89 637 With kind regards Technical Service Training Team ...

Page 92: ...207 All rights reserved AUDI AG Department I VK 5 D 85045 Ingolstadt Fax 49 841 89 6367 840 2810 26 20 Technical Status 06 98 Printed in Germany ...