TT Rs
TT Rs
Audi TT RS
with 2.5l R5 TFSI Engine
Audi
Service Training
451_067
In this Self-Study Programme you will learn the key distinctions • What changes have been made to the design, the body, the
between the Audi TT RS (Coupe and Roadster) and the production interior, the equipment, the power transmission system and the
model. The central feature of both models is the new 2.5l R5 TFSI suspension system?
engine. Once you have worked you way through this Self-Study • How is the new five-cylinder engine designed and configured?
Programme, you will be able to answer the following questions: • What do you have to pay attention to during servicing?
2
Downloaded from www.Manualslib.com manuals search engine
Contents
Introduction
Presentation ________________________________________________________________________________________________________________________________________ 4
Dimensions _________________________________________________________________________________________________________________________________________ 6
Body
Design _______________________________________________________________________________________________________________________________________________ 8
Technical features and occupant protection __________________________________________________________________________________________________ 10
Interior ____________________________________________________________________________________________________________________________________________ 11
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 Note
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 Reference
this Self-Study Programme.
3
Downloaded from www.Manualslib.com manuals search engine
Introduction
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.
4
Downloaded from www.Manualslib.com manuals search engine
Heated sports seats trimmed with leather /
Alcantara
451_008
5
Downloaded from www.Manualslib.com manuals search engine
Dimensions
Audi TT RS Coupe
451_009
1) max. headroom
6
Downloaded from www.Manualslib.com manuals search engine
Audi TT RS Roadster
451_010
Coupe Roadster
7
Downloaded from www.Manualslib.com manuals search engine
Body
From a purely visual standpoint, the Audi TT RS Coupe and the From the side, the 18-inch wheels, the large brakes and the flared
Roadster are both charismatic athletes. Even when stationary, they side skirts of the Audi TT RS instantly catch the eye. The door
seem to be straining at the leash. The muscular sheet-metal body mirror housings have a matt aluminium finish as standard and
and the tautly curved surfaces bounded by sharp lines give the are optionally available in the body colour or in carbon.
impression of a sculpture in motion. A series of design highlights The "Black Styling Package" featuring a black singleframe grille
impart the TT RS with that air of raw power which characterises a frame is optional.
top of the line model.
451_011
Front view
451_012
8
Downloaded from www.Manualslib.com manuals search engine
Headlight design
Together with the "wings" (dual plastic wings), the LEDs turn the
headlights into design objects in their own right.
451_013
451_014
Rear view
451_015
9
Downloaded from www.Manualslib.com manuals search engine
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.
Winner of the EuroCarBody AWARD 2006 for its innovative body concept
451_016
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".
10
Downloaded from www.Manualslib.com manuals search engine
Interior
The interior design of the Audi TT RS features a number of modifi- The entire interior is dressed in dynamic black.
cations.
RS-style door openers Rev counter featuring Driver information system "TT RS" welcome screen in the optional
with two narrow bars the "TT RS" logo with additional displays for: navigation system plus display
– Charge pressure
– Oil temperature
– Lap counter
451_018
Footrests and pedals in aluminium look Three-spoke multifunction sports steering Brushed aluminium inlays
wheel, flattened at the bottom and bound
in perforated leather with silver stitching
and a "TT RS" logo
451_019
11
Downloaded from www.Manualslib.com manuals search engine
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".
451_020
12
Downloaded from www.Manualslib.com manuals search engine
Synopsis of previously installed five-cylinder engines
1980 saw the launch of the Audi quattro unifying the two technol-
ogies of turbocharging and all-wheel drive. The turbocharged five-
Audi quattro, model year 1980 451_021
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.
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).
13
Downloaded from www.Manualslib.com manuals search engine
Specifications
Torque/power curve
Max. power in kW
Max. torque in Nm
451_005
Stroke in mm 92.8
Bore in mm 82.5
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
1)
premium unleaded petrol with a 95 RON rating can also be used, but results in a drop in power
14
Downloaded from www.Manualslib.com manuals search engine
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.
451_025
Competitive comparison
451_026
15
Downloaded from www.Manualslib.com manuals search engine
Material selection
The engine block is made from a high-tensile cast iron material, It is needed because the conrod bearings and main bearings have a
previously used by Audi in its V6 and V8 TDI engines. This is the relatively small width. Incidentally, this material was also used for
first time that it is used in a petrol engine. the cylinder blocks of naturally-aspirated racing engines during the
1990s.
Lower
timing case cover
451_037
Oil pan
The oil pan is of two-part construction. The upper part acts as a The front sides are sealed by the timing case cover on the gearbox
baffle plate and supports the oil pump. It is bolted together with side and by a sealing flange on the vibration damper side. Both
the crankcase. The oil pump is bolted to the cylinder block. seal off the crankshaft by means of a shaft oil seal.
The lower part of the oil pan is made from sheet steel and accom- The oil pans and the front-side covers are sealed against the cylin-
modates the oil level/oil temperature sender G266 and the oil der block by liquid sealant.
drain screw.
Note
! The liquid sealants differ and, therefore, have different part numbers. Refer to ETKA and the Workshop Manual for specifi-
cations.
16
Downloaded from www.Manualslib.com manuals search engine
Crankshaft drive
The steel crankshaft runs in six bearings. The main bearing is The torsion vibration damper is located at the front end and is
58 mm in diameter, while the conrod bearing is 47.8 mm in dia- configured as a viscodamper*.
meter.
Piston
Circlip
Gudgeon pin
Conrod bushing
Conrod
Crankshaft
451_027
Crankshaft bearings 6
17
Downloaded from www.Manualslib.com manuals search engine
Pistons and conrods
During the development of the box piston*, special emphasis was The conrod is manufactured as a forged crack conrod without a
given to low oil consumption and low weight. The box piston is deep bore. The pin on the small-end side of the conrod is
made of a highly heat-resistant alloy and has a cast-in ring land for 22 millimetres in diameter, and the bearing is made from lead-
the upper piston ring. Due to the high load to which it is sub- free materials.
jected, it has asymmetrical skirts and bevelled box walls on the
thrust and counter-thrust sides.
No deep bore
Reinforced threads
451_028
451_029
18
Downloaded from www.Manualslib.com manuals search engine
Cylinder head
The cylinder head is also a modified carry-over part sourced from • Different aluminium casting alloy
VW's 2.5l R5 MPI engine. To withstand the higher stresses which • Lower-set water jacket around the spark plug
occur in a turbocharged FSI engine, it was necessary to make the • Tempered exhaust valve seat rings
following modifications: • 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)
Rocker cover
Cylinder head
451_006
19
Downloaded from www.Manualslib.com manuals search engine
Chain drive
The timing gear of the five-cylinder TFSI engine is located on the A 3/8" gear chain is used in the primary drive train (for driving the
power output side. It is of two-stage construction and is driven by oil pump and the idler gear). It is similar in design to the chains in
two different chain types. 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.
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 The entire chain drive is lubricated by the oil returning from both
crankshaft also drives an idler gear, which has two tasks. Firstly, it camshaft phasers and by a bore in the high-pressure chamber of
drives both camshafts, and, secondly, it drives the vacuum pump. the "soft" chain tensioner in the secondary drive. There is no
Both drives have hydraulically damped chain tensioners. replacement interval for the chain drive.
Configuration
Chain tensioner
Tensioning rail
Primary drive
Tensioning rail
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.
20
Downloaded from www.Manualslib.com manuals search engine
Belt drive
For reasons of space, the belt drive for driving the refrigerant com- Both poly-vee belts have five ribs and a polyester cord as a tension
pressor, alternator and coolant pump is of two-stage construc- member. Both belt tensioners are friction-damped. The complete
tion. The torsion vibration damper on the crankshaft drives the belt drive is designed for lifetime operation.
refrigerant compressor via the first pinion gear. The refrigerant
compressor has twin belt pulleys. They transmit drive to the sec-
ond belt drive, which, in turn, drives the alternator with freewheel
and the coolant pump.
Configuration
Alternator (track 2)
Crankshaft (track 1)
451_033
Alternator (track 2)
Track 2
Track 1
451_065
21
Downloaded from www.Manualslib.com manuals search engine
Crankcase ventilation
The crankcase ventilation system is configured as a head ventila- The blow-by gases are pre-cleaned as they pass through the riser
tion system. The extraction point for the blow-by gases* is located channels.
in the cylinder block. The riser channels are protectively located in A windage tray is integrated in the upper part of the oil pan as pro-
the bearing saddle of main bearings two, three and four. The blow- tection for the oil pan. The returning oil is admitted into the oil pan
by gases are admitted directly into the rocker cover through the below the oil level.
cylinder head.
Overview
Non-return valve
451_031
Note
! The sectional view does not show the PCV combi valve and the second non-return valve.
22
Downloaded from www.Manualslib.com manuals search engine
Function (see also Fig. 451_040 on page 24)
At first, the gas and oil spray mixture admitted into the rocker In the extreme event of icing or malfunctioning, a pressure relief
cover flows into a relatively large hollow chamber, where the first valve in the rocker cover (PCV combi valve) prevents excessively
oil droplets deposit on the walls. The gas then passes through a high pressure from damaging the engine. To avoid drawing oil
fine oil separator. from the oil pan into the intake in such a condition, another non-
The fine oil separator operates on the centrifugal force principle return valve closes. This valve is integrated in the upper part of the
and employs a so-called axial cyclone (*Polyswirl TM ). oil pan.
The separator comprises four permanently open swirls and six
packs of up to nine swirls, which can be activated and deactivated The cleaned blow-by gas is now directed to the engine for combus-
according to the flow rate. tion. For this purpose, the gas passes through the single-stage
The six packs are activated and deactivated by locking springs with pressure-regulating valve. Depending upon the compression ratio
different spring characteristics. in the intake manifold, they then flow through the non-return
valves into the intake manifold downstream of the throttle valve
The fine oil separator is opened by the flow of blow-by gases or upstream of the exhaust turbocharger turbine.
(which is dependent on engine speed) and closed by the spring
force of the locking springs. The pressure-regulating valve is integrated in the rocker cover,
where there is sufficient space to allow a larger valve of single-
The separated oil coming from the rocker cover and the fine oil stage design. The non-return valves (to the intake manifold or to
separator is recirculated continuously into the oil pan below the the supercharger side) are optimised for pressure differential and,
engine oil level via the oil return line. together with the pressure-regulating valve, produce the required
partial vacuum in the crankcase.
Separated oil
451_035
23
Downloaded from www.Manualslib.com manuals search engine
Positive crankcase ventilation system
The engine has a PCV* system for purging the crankcase with fresh The fresh air for crankcase ventilation is extracted from the posi-
air at part throttle. This system helps to separate the fuel and tive crankcase ventilation line running to the exhaust turbo-
water which usually become entrained in the oil in the combustion charger.
process during engine operation. If fuel and water are allowed to The PCV valve, a combi valve, is integrated in the rocker cover.
remain in the oil sump, they can ice up at low ambient tempera- This valve has the following tasks:
tures and damage the ventilation system and the engine (e.g. loss • If a slight partial vacuum is present in the crankcase during
of oil pressure due to ice sludge clogging up the oil intake snorkel, normal operation, it opens in order to vent the crankcase. Fresh
oil leaks due to excess pressure in the engine). air flows from the line downstream of the air filter and into the
By admitting ambient air extracted downstream of the air filter, engine.
the fuel and water are channelled through the rocker cover and • If a pressure of over 100 millibars develops in the engine, the
into the cylinder head. The dry fresh air then flows through the excess pressure is relieved into the line, thereby protecting the
chain shaft and into the crankcase, absorbing moisture and fuel crankcase seals.
along the way, thereby "flushing" the engine dry. Furthermore, all Audi systems are still designed in such a way that
This useful life of the oil is greatly prolonged by this measure, as non-installation or faulty installation is diagnosable. If one of the
it slows down the ageing process. two crankcase ventilation lines is not installed, the unmetered air
is diagnosed via the lambda control system and indicated to the
driver by lighting-up of the MIL lamp.
Non-return valve
451_040
Note
! All components required for cleaning and ventilation are integrated in the rocker cover. If one of these components fails,
the complete rocker cover has to be replaced.
24
Downloaded from www.Manualslib.com manuals search engine
Oil supply Oil circulation system
Since high longitudinal and transverse acceleration forces are to be The oil pressure (raw oil) produced by the oil pump is initially circu-
expected in a sports engine of this kind, the oil supply has to lated through the oil filter module and then through the oil cooler.
function reliably even in extreme conditions. For this reason, the The clean oil now flows along oilways to the lubrication points
engine has a relatively high oil capacity (initial fill: 7 litres). (consumers). The oil filter and the oil cooler are component parts
Secondly, the oil pump intake line is fitted in such a way as to pro- of the plastic oil module. Non-return valves for the cylinder head
vide protection against air induction under high vehicle dynamics. and cylinder block, as well as a cooler bypass valve, are integrated
in the oil module.
Clean oil
Raw oil
451_032
25
Downloaded from www.Manualslib.com manuals search engine
Oil pump
The chain-driven oil pump is a gear pump configured as a fixed The control piston opens at pressures of up to 3.7 (+0.7) bar.
displacement pump. It integrates the cold start valve and the The cold start valve opens at pressures of up to 13 bar.
control piston.
451_066
Control piston Pump gear Intake from the oil pan Cold start valve
Oil pressure
Control piston
451_072 451_079
Reference
A self-regulating oil pump will be adopted from calendar week 36/2010. The design and function of a self-regulating oil
pump of this type are described in Self-Study Programme 436 " Modifications to the chain-driven 4-cylinder TFSI engine".
26
Downloaded from www.Manualslib.com manuals search engine
Cooling system
The cooling concept is based on longitudinal flow through cylin- To prevent the turbocharger from overheating when the engine
ders 1 to 5. The coolant pump is driven by the auxiliary drive by stops, the cooling system is equipped with a coolant run-on pump
means of a poly-vee belt and is designed to control the high ther- V51. When required, it is activated by the engine control unit (map)
mal load on the turbo engine. via the auxiliary coolant pump relay J496.
451_007
Legend:
27
Downloaded from www.Manualslib.com manuals search engine
Air supply
When designing the intake path, the main focus was on high effi- Air flow rates of up to 1000 kg/h are possible.
ciency and capacity. The cross-sections were optimally adapted to
the available space and the air flow was configured to be as direct
as possible.
451_034
Intercooler
451_069
28
Downloaded from www.Manualslib.com manuals search engine
Intake manifold with intake manifold flaps
The intake manifold is a two-part sand casting comprising the When the intake manifold flap valve N316 is not activated, no par-
intake plenum and the intake arm gallery. A pneumatically actu- tial vacuum is admitted and the intake manifold flaps are fully
ated system of flaps is integrated in the intake gallery. In conjunc- closed.
tion with the tumble intake port, this system produces the
turbulence necessary for optimal mixture homogenisation. The intake plenum, in combination with the rocker cover and the
The flap position requested by the engine control unit is measured small engine shroud, is the central component of the engine bay
by the intake manifold flap potentiometer G336 and monitored by design - a design which openly displays the technology behind this
the engine control unit. Audi RS model, too.
Positive crankcase ventilation system intake Intake manifold upper part Intake manifold lower part
Vacuum cell
Air recirculation
channel
451_038
Turbocharger divert air valve N249 Fuel rail Intake manifold flap
Intake manifold flap potentiometer G336 Injector (six-hole) Actuation of the intake manifold flap shaft
29
Downloaded from www.Manualslib.com manuals search engine
Exhaust end
The exhaust end consists of the following subassemblies: The exhaust turbocharger module is a derivative of the four-cylin-
• Manifold exhaust turbocharger (exhaust turbocharger) module der TFSI engine. The exhaust gases are admitted separately into
• Close-coupled pre-catalyst the turbine from the "additional" cylinder. The figure below shows
• Twin-flow headpipe with isolating elements the separate connection between the exhaust turbocharger and
• Two underbody catalytic converters with the following centre cylinder no. 3.
silencers The exhaust turbocharger module attachment system, like the
• Rear silencer with twin tailpipes modular design principle, derives from the four-cylinder engines.
The "clamping flange attachment system" is again used here (see
diagram 451_051). A modified screw attachment system will be
introduced at a later date.
451_036
Exhaust manifold
Clamping rail
451_051
30
Downloaded from www.Manualslib.com manuals search engine
Exhaust turbocharger
The exhaust turbocharger in use - a type K16 turbocharger by Borg It is also integrated in the cooling circuit. After an engine stop-
Warner Turbo Systems - is characterised by high efficiency over a page, the coolant run-on pump V51 dissipates the accumulated
wide operating range. heat.
A sensor-assisted exhaust gas temperature regulation system
It is large in size – its compressor wheel is 64 millimetres in diame- ensures that the maximum permissible exhaust temperature of
ter at the outlet end. At full throttle it can compress 290 litres of 980 °C is not exceeded in any operating conditions. For this pur-
air per second, and it produces relative charge pressures of up to pose, the exhaust gas temperature sender 1 G235 measures the
1.2 bar. Its housing has a separate oil supply. exhaust gas temperature in the exhaust turbocharger module
shortly before the turbine wheel (see diagram 451_036 on
page 30).
451_064
31
Downloaded from www.Manualslib.com manuals search engine
Exhaust system
When the car is accelerated at full throttle, the typical sound of The two underbody catalytic converters are positioned further
the five-cylinder engine is delightfully resonant in the intake and down the exhaust system, which has a twin-flow configuration
exhaust system. And yet the sound is unobtrusive when driving at a after the pre-catalyst. Both catalytic converters are of metal con-
constant speed and under moderate acceleration. struction.
To ensure compliance with the EU-5 exhaust emission standard, it
was necessary to position the pre-catalyst as close as possible to A further focal point in the development of the exhaust system
the turbine outlet. The catalytic converter is made of a ceramic was minimising exhaust gas backpressure. Hence, the exhaust
material. The continuous-duty oxygen sensor, which is integrated pipes are very large and, in part, have a twin-flow configuration.
directly in the exhaust turbocharger module, is also positioned at A sport exhaust system with black tailpipe trims is available as an
the turbine outlet. The post-cat oxygen sensor is located directly option, in addition to the basic exhaust system. It has an even
downstream of the pre-catalyst and has a non-linear characteristic. more distinctive soundscape.
451_052
Underbody catalytic converters Centre silencer Tailpipe trims
Exhaust flap
The exhaust gases are admitted into the large rear silencer behind Vacuum cell
the two centre silencers. The rear silencer, in turn, has twin tail-
pipes.
The left tailpipe is fitted with an exhaust flap. When this flap
opens, the sound becomes even more sporty. The exhaust flap is
opened and closed by a vacuum cell. For this purpose, the exhaust
flap 1 valve 1 N321 is activated by the engine control unit.
If the Sport button is pressed at idle and when the vehicle is at a
standstill, the exhaust flap opens, thus allowing the system to be
checked quickly and easily. The opening and closing of the exhaust
flap are otherwise computed by a map in the engine control unit.
If the exhaust flap 1 valve 1 N321 fails or if a leakage occurs in the
hose system, the exhaust flap stays continuously open.
451_071
32
Downloaded from www.Manualslib.com manuals search engine
Fuel system
The fuel system is demand-controlled on the high and low-pres- The central element of the fuel system is a demand-controlled
sure sides. On the low-pressure side, the engine control unit regu- single-piston high-pressure pump. This generation III fuel pump
lates the fuel pump control unit J538 and with it the delivery rate by Hitachi is driven by a three-lobe cam seated on the exhaust
of the fuel pump in the fuel tank. camshaft.
On the high pressure side, the engine control unit regulates the The system with a maximum pressure of 120 bar.
fuel metering valve N290 directly at the high-pressure pump. The pressure-limiting valve in the pump opens at a pressure of
To monitor the pressure levels in the system, two fuel pressure approx. 145 bar.
senders send their respective signals to the engine control unit.
System overview
Injectors 1 – 5
N30 – 33 and N83
to engine 451_003
control unit
Fuel metering valve Battery
N290 (positive)
Note
! Caution: danger of injury. The system operates at very high pressures. To open the high-pressure side, always follow the
instructions given in the Workshop Manual.
Reference
To learn more about the functional principle and control concept of the high-pressure fuel pump, refer to Self-Study
Programme 432 "Audi 1.4l TFSI engine".
33
Downloaded from www.Manualslib.com manuals search engine
System overview
Sensors
Auxiliary signals:
J393 Door contact signal
E45 Cruise control system (ON/OFF)
34
Downloaded from www.Manualslib.com manuals search engine
Actuators
Diagnostic
port
Coolant circuit solenoid valve N492
451_004
35
Downloaded from www.Manualslib.com manuals search engine
Engine management Operating modes
The Bosch MED 9.1.2 measures load by means of the intake mani- The following operating modes are possible:
fold pressure sender G71 and the engine speed sender G28. • High-pressure stratified starting down to an ambient tempera-
The target for emission classification was compliance with exhaust ture of -26 °C
emission limits EU 5. This was achieved by using the following • Catalyst heating and engine warm-up with twin injection
subassemblies in combination with special injection and catalyst • When the engine is warm and running at low rpm, the amount
heating strategies: of residual gas in the cylinders is minimised by high scavenging
• Intake manifold with intake manifold flaps rates, achieved by adjustment of the intake and exhaust cam-
• Multi-port injectors in combination with flat pistons shaft phasings and by adaptation of the valve timings and event
• Close-coupled pre-catalyst duration*.
In the upper rpm band, the entire system is optimised for high
A secondary air injection system was not needed. flow rates. In this regard, it is essential that the intake, pressure
and exhaust lines be carefully matched and optimised for pres-
sure losses.
Combustion process
The basis for the development of the combustion process was the By optimising the spray parameters in combination with a flat pis-
Audi 2.0 litre TFSI engine. Like this engine, the 2.5 litre TFSI unit ton crown shape, it was possible to improve carburetion compared
benefits from the acknowledged advantages of multiport valve to the 2.0 litre TFSI engine, despite the approx. 25 % increase in
technology, as shown in diagram 451_053. the flow rate of the high-pressure injectors.
Flat-crown piston
451_053
36
Downloaded from www.Manualslib.com manuals search engine
Engine load sensing
The load on the 2.5l R5 TFSI engine is determined via the engine
speed and the air mass. Since no air mass meter is installed, two
identical combined temperature/pressure sensors are used for air
mass metering:
Two sensors are used because the throttle valve must be regarded
as a source of interference - very different pressures can simulta-
neously exist upstream and downstream of the throttle valve.
Another reason is the use of the cast aluminium intake manifold.
This manifold accumulates heat and could, therefore, potentially
falsify the temperature signal generated by the temperature sen-
sor (G71/G42). The temperature signal generated by the sensor
upstream of the throttle valve (G31/G299) is utilised for this pur-
pose.
451_078
This sensor is the charge pressure sensor, upon whose signal the
charge pressure is controlled. Since the throttle valve will be oper-
ating wide open as much as possible, there is no need for this valve
because charge pressure equals intake manifold pressure.
To achieve better response, however, the charge pressure control
unit runs before the throttle valve is wide open. In principle, there-
fore, it works against the throttle valve.
Second sensor:
Task: measurement of pressure and temperature in the intake
manifold
Designation: Intake manifold pressure sender G71 and intake air
temperature sensor G42
This identical combined sensor is the so-called main charge sen-
sor, which replaces the hot-film air mass meter. The air mass flow-
ing through the engine is determined at every operating point
from the pressure and temperature signals generated by this sen-
sor. For this purpose, a corresponding quantity of fuel is injected.
37
Downloaded from www.Manualslib.com manuals search engine
Sport mode
451_045
Function diagram
451_039
Legend:
E461 Operating unit in front of centre console J623 Engine control unit
E541 Sport program button K91 Sport program indicator lamp
G76 Rear left vehicle level sender L156 Switch illumination bulb
G77 Rear right vehicle level sender N321 Exhaust flap 1 valve 1
G78 Front left vehicle level sender N336 Shock absorber damping adjustment valve, front left
G79 Accelerator pedal position sender N337 Shock absorber damping adjustment valve, front right
G185 Accelerator pedal position sender 2 N338 Shock absorber damping adjustment valve, rear left
G289 Front right vehicle level sender N339 Shock absorber damping adjustment valve, rear right
J250 ECD control unit (electronically controlled damping) S Fuses in relay plate fuse box
38
Downloaded from www.Manualslib.com manuals search engine
Power transmission
451_070
Specifications
Note
! Please refer to the Electronic Parts Catalogue (ETKA) for the following details.
• Assignments of the individual gear wheels
• Gear oil specification
• Bevel box assignments
• Propshaft flange assignments
• Clutch assignments
• Rear-axle drive assignments
39
Downloaded from www.Manualslib.com manuals search engine
Configuration
Selector shaft
Angle drive
Output flange to
prop shaft
451_062
Output shaft – 3rd – 6th gear Front axle drive gear wheel
Reverse gear
A special feature of the gearbox is that the direction of rotation is The change gear of the first gear is itself driven by the input shaft.
reversed for reverse gear. The change gear of the reverse gear When frictional engagement is established between the change
slides into mesh with an idler gear which is fixedly connected to gear and the reverse gear output shaft by synchronisation of the
the change gear of the first gear. reverse gear, the reverse gear output shaft transmits the engine
torque to the front axle drive gear.
40
Downloaded from www.Manualslib.com manuals search engine
Drive concept
The permanent quattro four-wheel drive in the version for trans-
verse-mounted engines is standard equipment in the Audi TT RS.
The permanent quattro four-wheel drive system also imparts to
the Audi TT RS the superior capabilities that have long since been
a characteristic trait of Audi models, e.g. extra grip, reduced slip
under acceleration, driving dynamics, driving safety and direc-
tional stability.
An Audi TT RS handles dynamically and is extremely stable at any
speed and in all weather conditions.
Gearbox
Engine
Bevel box
Prop shaft
Rear-axle drive
451_001
41
Downloaded from www.Manualslib.com manuals search engine
Multi-plate clutch
At the heart of the system is a multi-plate clutch, which is control- Thanks to a high-performance pressure reservoir, all of this hap-
led electronically and actuated hydraulically. The clutch control pens within a matter of milliseconds.
unit permanently analyses the driving conditions. If slip occurs at To make the already good axle load distribution even better, the
the front wheels, an electrically driven annular piston pump clutch is now mounted on the end of the prop shaft in front of the
almost instantaneously generates the oil pressure needed by the rear axle differential. This clutch is likewise a recently developed,
clutch to divert the drive torque almost entirely from the front to highly compact component, and it designed to withstand the rig-
the rear wheels. ours of heavy use.
451_063
Reference
The design and function of the generation IV all-wheel-drive clutch are described in Self-Study Programme 414 "4MOTION
with generation IV all-wheel-drive clutch".
42
Downloaded from www.Manualslib.com manuals search engine
Running gear
Introduction
The suspension system of the Audi TT RS makes use of the excel-
lent qualities that have become a hallmark of the basic Audi TT
design.
451_048
The front wheel suspension system, with a track width of The four-link rear axle (track width: 1546 millimetres) is able to
1555 millimetres, adheres to a proven formula: a McPherson absorb longitudinal and lateral forces separately thanks to its
structure with triangular lower wishbones. The pivot bearings, the sophisticated design. The longitudinal links absorb the driveline
subframe and the wishbones are made from aluminum. and braking forces, and their relatively soft mounts permit good
To increase rigidity, the subframe is bolted to the body at six ride comfort. On the other hand, the three wishbones per wheel –
points. the spring link, the upper wishbone and the tie rod – are attached
very rigidly to the subframe to enhance handling dynamics.
Steering
The elastokinematic behavior of the rear control arms (all of which
The rack-and-pinion steering system comes with variable servo are made from high-strength steel grades) has been slightly modi-
assistance; its characteristics have been adapted to the dynamic fied compared with the basic technical configuration. Separate coil
character of the TT RS. Because the electromechanical system does springs and newly developed dampers provide vertical support.
not use up energy when the car is driving in a straight line, it is The body of the TT RS has been lowered 10 millimetres compared
highly efficient and saves about 0.2 litres of fuel per 100 km. to the volume TT model. Audi's designers have tuned the set-up to
The ratio of 16.9:1 is sporty and direct. perfection in the course of exhaustive testing, including endless
high-speed laps of the Nürburgring North Loop.
43
Downloaded from www.Manualslib.com manuals search engine
Audi magnetic ride
As an option, the customer can order the Audi TT RS with Audi
magnetic ride. This system is already available in the volume TT
model.
Functional principle
Circulating inside its damper pistons is a synthetic hydrocarbon They cluster transversely to the direction of flow of the fluid, thus
fluid containing minute magnetic particles between three and ten inhibiting its flow through the piston channels. This alters the
micrometers in size.When voltage is applied to a coil, a magnetic damping characteristic within a matter of milliseconds.
field is created in which the orientation of the particles changes.
Piston orifices
451_049
Operating principle
The system's control unit constantly monitors the driver's style and In Sport mode, when flow is inhibited, the suspension is uncom-
the condition of the road, adjusting its response accordingly. promisingly firm and the car hugs the road without so much as a
The driver can change between the Normal and Sport modes at the hint of body roll. The specific stabilisation of each wheel gives even
touch of a button. In Normal mode, when the fluid has a high vis- more neutral self-steering behaviour and steering response
cosity, the suspension of the Audi TT RS offers a well-balanced, becomes more precise.
comfortable ride.
Reference
You will find a detailed description of the design and function of the systems in Self-Study Programme 381 "Audi TT ’07 –
Suspension System".
44
Downloaded from www.Manualslib.com manuals search engine
Wheels and tyres
The TT RS comes as standard with large cast aluminium wheels
featuring a five double spoke design. They are 9J x 18 in size and
shod with 245/40 tyres.
Overview
18" basic wheel 19" optional wheel 19" optional wheel 20" optional wheel
Cast aluminium wheel Cast aluminium wheel Cast aluminium wheel Forged aluminium wheel
Summer: 245/40 R18 93Y Summer: 255/35 R19 96Y Summer: 255/35 R19 96Y Summer: 255/30 ZR20 92Y
Reference
You will find an up-to-date overview of approved wheel-tyre combinations and other wheels in the "Wheels and Tyres" cata-
logue on the Audi Servicenet and in the Electronic Parts Catalogue (ETKA).
45
Downloaded from www.Manualslib.com manuals search engine
Brake system
The large wheels conceal high-performance brakes. All four discs Four-piston calipers, painted black and sporting the RS logo on the
are ventilated. They have a diameter of 310 millimetres on the rear front axle, clamp the discs with a vice-like grip. The calipers are
axle and 370 millimetres on the front axle. The front friction rings also manufactured from aluminium - this reduces the unsprung
are drilled for maximum heat dissipation and are connected to the masses.
aluminium brake drums by hollow-drilled pins.
Front brake
451_047
Note
! ESP Sport mode should only be activated for agile handling and sporty driving if the road, weather, visibility and traffic con-
ditions permit.
46
Downloaded from www.Manualslib.com manuals search engine
Service
Maintenance work
Engine oil change interval Up to 30,000 km or up to 24 months depending on SIA1) (the change interval is
with LongLife oil dependent on driving style)
with engine oil specifications Engine oil according to VW standard 50400
Engine oil change quantity (service) 5.7 litres (including oil filter)
1)
SID = Service Interval Display
451_054 451_055
Removing and installing the engine in combination with the engine Mounting the engine on the engine and gearbox support VAS 6095
and gearbox support V.A.G 1383 A or support clamp VW 313
47
Downloaded from www.Manualslib.com manuals search engine
T03003 Wrench T03004 Assembly sleeve
451_056 451_057
Set crankshaft to TDC Replace the crankshaft sealing flange on the belt pulley side
451_058 451_059
451_060 451_061
Drain engine oil out of the oil filter module Assembly of the gearbox mounting
48
Downloaded from www.Manualslib.com manuals search engine
Annex
Glossary
This glossary explains all terms indicated in italics or marked with
an asterisk (*) in this Self-Study Programme.
DFS ring
Top-bevelled oil control ring with coil expander
PVD process
PVD = Physical Vapour Deposition is a coating process in which the
coating material is physically vapour deposited (by kinetic or
DNA impact energy) on a material in a vacuum environment. The advan-
This abbreviation stands for "deoxyribonucleic acid". Deoxyribonu- tage of this process over the conventional electroplating process is
cleic acid is a biomolecule which occurs in all living organisms and the greater diversity of coating materials (sputter bearings).
is the carrier of genetic information. It is used in everyday speech
to explain the origin or basis of a concept.
Viscous damper
Downsizing
To reduce the radial vibration caused by the impulse-like transmis-
Increased efficiency through synergy effects. This means that less
sion of force from the piston to the crankshaft via the gudgeon pin
material and equipment is needed to achieve the same perform-
and the connecting rod, torque is briefly increased to peak levels.
ance level.
The result: noise and wear. Torsional vibration dampers attenuate
this radial vibration. High-viscosity silicones and oils – so-called vis-
codampers – are used for this purpose.
Event duration
Besides the valve opening cross-section (valve lift), the shape of
the cam on a camshaft determines the opening duration of the
valve. The valve opening duration (event duration) is given in
° crank angle.
Wastegate
To control the charge pressure in a turbocharger, a wastegate is
integrated in the exhaust gas flow. If the charge pressure rises
above a certain limit, an actuator opens the wastegate. The
Nitriding or nitrocarburizing exhaust gases bypass the turbine and are admitted directly into
Surface treatments improve the running-in behaviour of the pis- the exhaust system, thus preventing the turbine speed from rising
ton rings and minimise wear on the piston lining and flanks. any further.
49
Downloaded from www.Manualslib.com manuals search engine
Test yourself
Which of the following answers is correct?
In some cases, only one answer will be correct.
However, more than one answer might be correct – or even all of them!
A It is measured dynamically by means of a thermal oil level sender (TOLS) while the vehicle is being driven, and a warning is given
when the oil level is low.
B Using a dip stick.
C It is measured by an ultrasound oil sensor (PULS) when the vehicle is at idle and at a standstill, and is displayed via the dash panel
insert or MMI.
A By a balancer shaft which is integrated in the cylinder block and driven by the secondary drive chain.
B By two counteropposed balancer shafts in a balancer shaft module (oil pan).
C No additional balancing is needed in a five-cylinder inline engine due to its structural design.
6. How is power flow established for the reverse gear in manual gearbox 0A6?
6. B
5. A, C
4. C
3. C
2. A, B
1. C
Solutions
50
Downloaded from www.Manualslib.com manuals search engine
Summary
Five-cylinder engines are inherent to Audi's DNA*. Now Audi is The following table of performance specifications speaks for itself.
building another one – a high-performance powerplant. The The Audi TT RS will also be offered with a dual-clutch gearbox at a
Audi TT RS developed by quattro GmbH sports a turbocharged five- later date, still unspecified when this SSP went to press.
cylinder 2.5-litre engine with FSI petrol direct injection that pro-
duces 250 kW (340 hp) and 450 Nm of torque, yet consumes only
9.2 litres per 100 km. In conjunction with quattro permanent all-
wheel drive, the powerful five-cylinder model offers explosive per-
formance, making the compact Audi TT RS - whether the Coupé or
the Roadster - a purist driving machine.
Self-Study Programmes
51
Downloaded from www.Manualslib.com manuals search engine
Audi Vorsprung durch Technik
451
Copyright
AUDI AG
I/VK-35
[email protected]
AUDI AG
D-85045 Ingolstadt
Technical status: 01/10
Printed in Germany
A10.5S00.67.20