TT%20RS%20w%202500cc%205%20cylinder%20TFSI.pdf

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Self-Study Program 990713
Audi TT RS with the 2.5L TFSI Engine
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Audi of America, LLC
Service Training
Printed in U.S.A.
Printed 6/2011
Course Number 990713
©2011 Audi of America, LLC
All rights reserved. Information contained in this manual is
based on the latest information available at the time of printing
and is subject to the copyright and other intellectual property
rights of Audi of America, LLC., its affi liated companies and its
licensors. All rights are reserved to make changes at any time
without notice. No part of this document may be reproduced,
stored in a retrieval system, or transmitted in any form or by
any means, electronic, mechanical, photocopying, recording or
otherwise, nor may these materials be modifi ed or reposted to
other sites without the prior expressed written permission of
the publisher.
All requests for permission to copy and redistribute
information should be referred to Audi of America, LLC.
Always check Technical Bulletins and the latest electronic
service repair literature for information that may supersede any
information included in this booklet.
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Audi Space Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5L TFSI Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Crankshaft Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Oil Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Crankshaft Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Intake Manifold with Flaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Exhaust System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Exhaust System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Engine Load Sensing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Sport Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Manual Transmission 0A6 . . . . . . . . . . . . . . . . . . . . . . . . . .37
Running Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Drive Concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Audi Magnetic Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Electronic Stabilization Program (ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
New Special Tools for the TT RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Self-Study Programs for the Audi TT . . . . . . . . . . . . . . . . .46
Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . .47
i
The Self-Study Program provides introductory information regarding the design
and function of new models, automotive components, or technologies.
The Self-Study Program is not a Repair Manual!
All values given are intended as a guideline only.
For maintenance and repair work, always refer to current technical literature.
Reference
Note
!
iii
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Introduction
The original Audi TT, named after the legendary
“Tourist Trophy” race in the United Kingdom,
was a milestone in automotive design. The
design followed pure geometry, with the central
theme being a circle refl ected in the wheel
arches, roofl ine arches, and both the front and
rear fascias of the vehicle.
The Audi TT RS, developed by quattro GmbH,
breathes new life into old traditions. Thanks to
a turbocharged 2.5-liter fi ve cylinder engine,
permanent all-wheel drive, and a sporty yet
comfortable suspension and design, both the
RS Coupe and RS Roadster are uncompromising
sports cars.
TT_BodyShop_1
The production of the Audi TT RS involves the
use of two factories. The Audi Space Frame (ASF)
body is constructed in Ingolstadt, Germany,
while fi nal assembly is completed in Györ,
Hungary.
TT_BodyShop_2
TT_BodyShop_3
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