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Audi TT RS Service Training

With 2.5l r5 tfsi engine
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Self-Study Programme 451
Audi TT RS
with 2.5l R5 TFSI Engine
Audi
Service Training

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Summary of Contents for Audi TT RS

  • Page 1 Self-Study Programme 451 Audi TT RS with 2.5l R5 TFSI Engine Audi Service Training...
  • Page 2 1600 rpm to 5300 rpm, giving the car formidable pulling power. generation of the Audi quattro ahead of the competition. And yet, the TT RS Coupe gets by on only 9.2 litres of fuel per The new engine generation combines turbocharging with petrol 100 km (Roadster: 9.5 litres per 100 km), making it another...

  • Page 3: Table Of Contents

    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.

  • Page 4: Presentation

    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.
  • Page 5 Heated sports seats trimmed with leather / Alcantara Rigid rear spoiler (as an option, it can be deselected for the adjustable rear spoiler of the volume TT model) Rear wheel drive with generation IV all-wheel-drive clutch 18 inch alloy wheels with 245/40 tyres 451_008...

  • Page 6: Dimensions

    Dimensions Audi TT RS Coupe 451_009 max. headroom All dimensions are given in millimetres Dimensions refer to the vehicle's kerb weight...
  • Page 7 Audi TT RS Roadster 451_010 Coupe Roadster Kerb weight in kg 1450 1510 Permissible gross weight in kg 1830 1830 Luggage capacity (seats folded down) in l 290/700 250/- Fuel tank capacity in l Drag coefficient c 0.32 0.34...

  • Page 8: Body

    From the side, the 18-inch wheels, the large brakes and the flared From a purely visual standpoint, the Audi TT RS Coupe and the side skirts of the Audi TT RS instantly catch the eye. The door Roadster are both charismatic athletes. Even when stationary, they mirror housings have a matt aluminium finish as standard and seem to be straining at the leash.
  • Page 9 Rear view The rear bumper includes an integrated diffuser insert that sur- rounds the two large, oval tailpipes. A "TT RS" logo also adorns the rear of the car. The TT RS comes as standard with a wide, stationary spoiler that increases the downforce on the rear axle and thus improves stabil- ity at high speeds.

  • Page 10: Technical Features And Occupant Protection

    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".

  • Page 11: Interior

    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"...

  • Page 12: 2.5L R5 Tfsi 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". The five-cylinder engines combined the efficiency of a four-cylin- der with the cultivation of a six-cylinder at a lower weight and in a compact size.
  • Page 13 1979. With an output of 125 kW (170 hp) and 265 Nm of torque, the Audi 200 5 T was the new flagship model and one of the fastest saloons of its day.

  • Page 14: Specifications

    Specifications Torque/power curve Max. power in kW Max. torque in Nm Engine speed [rpm] 451_005 Engine code CEPA Engine type Five-cylinder inline engine Displacement in cm 2480 Stroke in mm 92.8 Bore in mm 82.5 Valves per cylinder Firing order 1-2-4-5-3 Compression ratio 10:1...

  • Page 15: Cylinder Block

    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. It lends itself very well to transverse mounting due to its very short overall length, and is the shortest and most powerful engine in its class (see figure below).

  • Page 16: Oil Pan

    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.

  • Page 17: Crank Train

    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.

  • Page 18: Pistons And Conrods

    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.

  • Page 19: Cylinder Head

    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 •...

  • Page 20: Chain Drive

    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).

  • Page 21: Belt Drive

    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.

  • Page 22: Positive Crankcase Ventilation

    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. A windage tray is integrated in the upper part of the oil pan as pro- in the cylinder block.
  • Page 23 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.

  • Page 24: Crankcase Breather

    "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.

  • Page 25: Oil Supply

    Oil supply Oil circulation system The oil pressure (raw oil) produced by the oil pump is initially circu- Since high longitudinal and transverse acceleration forces are to be lated through the oil filter module and then through the oil cooler. expected in a sports engine of this kind, the oil supply has to The clean oil now flows along oilways to the lubrication points function reliably even in extreme conditions.

  • Page 26: Oil Pump

    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.

  • Page 27: Cooling Circuit

    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.

  • Page 28: Air Supply

    Air supply Fresh gas side 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.
  • Page 29 G336 and monitored by design - a design which openly displays the technology behind this the engine control unit. Audi RS model, too. Intake manifold pressure sender G71 Intake air temperature sensor G42 Intake manifold flaps...
  • Page 30 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"...
  • Page 31 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.

  • Page 32: Exhaust System

    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.

  • Page 33: Fuel System

    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".

  • Page 34: System Overview

    System overview Sensors Charge pressure sender G31 Intake air temperature sensor 2 G299 Intake manifold pressure sender G71 Intake air temperature sensor G42 Engine speed sender G28 Throttle valve control unit J338 Angle sender G188, G187 Hall sender G40 (intake) Hall sender 3 G300 (exhaust) Accelerator pedal position sender G79 Accelerator pedal position sender 2 G185...
  • Page 35 Actuators Fuel pump control unit J538 Fuel pump (pre-supply pump) G6 Injectors for cylinders 1 – 5 N30 – 33 and N83 Ignition coils for cylinders 1 – 5 N70, N127, N291, N292, N323 Throttle valve control unit J338 Throttle-valve drive G186 Intake manifold flap valve N316 Engine component current supply relay J757 Motronic current supply relay J271...

  • Page 36: Engine Management

    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.
  • Page 37 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: • Charge pressure sender G31, intake air temperature sensor 2 G299 •...
  • Page 38 1 valve 1 N321 by the engine control unit. • The sporty driving mode of Audi magnetic ride is activated. • The sport program indicator lamp K91 comes on.

  • Page 39: Power Transmission

    As is usual for Audi, all gearshifts are light, precise and slick. Shift travel has been reduced, and both the selector lever and the gear knob have been matched to the interior design of the Audi TT RS. 451_070 Specifications...
  • Page 40 Configuration Selector shaft Output shaft – 1st + 2nd gear Reversing light switch F4 Output shaft – reverse gear Right stub shaft Angle drive Output flange to prop shaft 451_062 Output shaft – 3rd – 6th gear Front axle drive gear wheel Input shaft Left stub shaft Reverse gear...

  • Page 41: Drive Concept

    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.
  • Page 42 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...

  • Page 43: Introduction

    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 Front axle Rear axle The front wheel suspension system, with a track width of...

  • Page 44: Suspension System

    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".

  • Page 45: Wheels And Tyres

    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. A number of other wheel variants are optionally available in sizes of up to 20 inches in diameter.

  • Page 46: Brake System

    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.

  • Page 47: Service

    Timing gear chain replacement interval Lifetime Timing gear tensioning system Lifetime SID = Service Interval Display New special tools for the TT RS T03000 Engine support T03001 Engine support 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...
  • Page 48 T03003 Wrench T03004 Assembly sleeve 451_056 451_057 Set crankshaft to TDC Replace the crankshaft sealing flange on the belt pulley side T03005 A Oil pump clamp T03006 Locking pin 451_058 451_059 Oil pump clamp Chain tensioner clamp T40226 Gauge T40057 Oil drain adapter (already on the market) 451_060 451_061 Drain engine oil out of the oil filter module...

  • Page 49: Annex

    This gives the piston skirt higher rigidity and allows the use of blow-by gases despite its very compact design. Both Audi and Lam- a shorter gudgeon pin. borghini currently fit the so-called Polyswirl in their V10 and V8 rocker covers.

  • Page 50: Test Yourself

    By two counteropposed balancer shafts in a balancer shaft module (oil pan). No additional balancing is needed in a five-cylinder inline engine due to its structural design. 4. How is the power steering pump in the Audi TT RS driven? By track 1 of the belt drive.

  • Page 51: Summary

    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.
  • Page 52 Audi Vorsprung durch Technik All rights reserved. Technical specifications are subject to change without notice. Copyright AUDI AG I/VK-35 Service.training@audi.de AUDI AG D-85045 Ingolstadt Technical status: 01/10 Printed in Germany A10.5S00.67.20...

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