Self-Study Programme 391 Audi TT roadster.pdf

Service Training

Audi TT Roadster

Self-Study Programme 391

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 m 2

Developed area: 388,480 m 2

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

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 showc ases the brand's tremendous expertise in lightweight design.

391_026

Contents

Introduction

In brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine-gearbox combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Bodyshell

Technical proﬁles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Convertible top

Convertible top design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

Convenience electronics

Windbreak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Running gear

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Heating and air conditioning system

Heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Interior monitoring

Anti-theft alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Infotainment

Radios and radio navigation systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Sound system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Aerials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

The Self-Study Programme teaches the design and function of new vehicle models,

automotive components or technologies.

Reference

Note

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.