Audi TT (2007 year). Manual — part 256

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383

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specifications subject to
change without notice.

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AUDI AG
I/VK-35
Service.training@audi.de
Fax +49-841/89-36367

AUDI AG
D-85045 Ingolstadt
Technical status: 05/06

Printed in Germany
A06.5S00.28.20

Audi TT Coupé ´07 - Body

Self-Study Programme 383

Vorsprung durch Technik www.audi.de

Service Training

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi-Space-Frame ASF

®

of the Audi TT Coupé

The development targets for the bodyshell of the Audi TT

With a weight advantage of 48 % over a comparable all-steel bodyshell, in addition to an optimised weight
distribution, the new composite aluminium-steel spaceframe body of the Audi TT marks yet another mile-
stone in the development of modern Audi bodyshells.

Crash safety of the bodyshell is enhanced by means of load-bearing structures at the front end, sides and rear
end, with a heavy emphasis on pedestrian safety.

To ensure efficient volume bodyshell production, various new joining and production techniques are
employed.

The repair concept is based heavily on the well-known aluminium repair concept. However, of course, the
materials combination of aluminium and steel necessitated that new approaches be taken.

383_001

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note

Reference

The self-study programme teaches the design and function of new vehicle models,
new automotive parts or new technologies.

The self-study programme is not a repair manual!
All values given are intended as a guideline only and refer to the software version valid at the time of
preparation of the SSP.

For maintenance and repair work, always refer to the current technical literature.

Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Punch riveting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Clinching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

MIG welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Resistance spot welding and MAG welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Structural bonding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

New joining technique: solid punch riveting (Kerb-Konus riveting) . . . . . . . . . . 16

New joining technique: Flow Drill screwing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

New joining technique: aluminium laser welding . . . . . . . . . . . . . . . . . . . . . . . . . 18

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technological concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Combination of steel and aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Comparison of ASF concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Audi Space Frame of the Audi TT

Joining techniques and production processes

Bodyshell safety concept

Repair concept

Aluminium repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Steel repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Aluminium-steel repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Workshop equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Qualification of aluminium. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Head-on collision, side impact and rear collision . . . . . . . . . . . . . . . . . . . . . . . . . 26

Pedestrian safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Electromechanical rear spoiler

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4

Dimensions

Audi Space Frame of the Audi TT

383_002

Audi TT Coupé ’ 07

2,0

3,2 quattro

Transmission

Manual gearbox

S tronic

Manual gearbox

S tronic

Kerb weight without driver in kg

1260

1280

1410

1430

Max. perm. gross weight in kg

1660

1680

1810

1830

cw (rear spoiler extended)

0.3

0.3

0.31

Boot capacity in l

290 (700*)

290 (700*)

Max. power output in kW

147 (200 bhp)

184 (250 bhp)

vmax in kph

240

250

Acceleration 0-100 kph in s

6.6

6.4

5.9

5.7

Fuel consumption in l/100 km

7.7

7.7

10.3

9.4

* with the rear-seat back folded forward