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ASN Rollcage Certificate N°

HES4590714
Group
Car type N°
MONOBRAND CUP
TT cup

TECHNICAL FORM

TECHNICAL FORM valid as from 01 MARCH 2016

Audi Sport TT Cup Monobrand Technical Form

The parts featuring on this Technical form must not be used separately
and must imperatively be used all together as a whole
Each Audi TT Cup car must be in possession of its roll cage ASN certificate.
Only the safety cage bearing the extension n° HES4590714 may be used with this TT Cup car.

1. GENERAL

101. MANUFACTURER

AUDI

102. MODEL AND TYPE

a) Model and type TT CUP

b) Typical chassis number AS8S6TTCUPXXXXXXX X = VARIABLE DIGITS

103. CYLINDREE / CYLINDER CAPACITY

Cylinder capacity 1984 cm3

Corrected cylinder capacity 1984 X 1.7 = 3372.8 cm3

A1) Car seen from 3/4 front A2) Car seen from 3/4 rear

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2. DIMENSIONS, WEIGHT

202. OVERALL LENGTH

4260 + 10 mm

204. WIDTH OF BODYWORK


+0
a) At front axle centreline 1930 mm -1%

+0
b) At rear axle centreline 1940 mm -1%

WHEELBASE

2505 + 15 mm

209. OVERHANG

a) Front 925 + 15 mm

b) Rear 825 + 15 mm

3. ENGINE

Model of origin of the engine AUDI TT S Identification CJX / EA 888

FIA homologation form n° of the basic engine N/A

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302. NUMBER OF SUPPORTS

Number : 1 ENGINE / 2 GEAR BOX Material: Steel

C0-3) Engine position in the car seen from above

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C1-3) Dismounted engine – seen from front C1-4) Dismounted engine – seen from rear

C1-5) Engine distribution seal C1-6) Engine turbo seal

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C2-1) Engine support 1 dismounted (photo) III-B1) Engine support 1

C2-2) Engine support 2 dismounted (photo) III-B2) Engine support 2

C2-3) Engine support 3 dismounted (photo) III-B3) Engine support 3

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320. FLYWHEEL

a) Material IRON + RUBBER

b) Minimum weight 11380 g With fixings and starter ring

c) External diameter of the starter ring 281.6 + 3 mm

d) Number of teeth of the starter ring 129

Double
e) Type mass

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324. FUEL FEED BY INJECTION - ELECTRONICS


Direct

a) Make and type CONTINENTAL

b) Model SIMOS 18.1 b1) Software TTC_0003 Checksumm

Cylinder head

f) Injectors f1) Position

g) List of engine control system sensors

C1 THROTTLE PEDAL POSITION C9 INTAKE MANIFOLD FLAPS POTENTIOMETER

C2 KNOCKING SENSOR C10 INTAKE MANIFOLD AIR PRESSURE AND TEMP

C3 FUEL PRESSURE (LP) C11 FUEL PRESSURE (HP)

C4 HALL SENSOR (2) C12 BOOST PRESSURE

C5 WATER TEMPERATURE C13 LAMBDA PROBE

C6 WATER TEMPERATURE (AFTER RADIATOR) C14 OIL ENGINE PRESSURE (3)

C7 ENGINE SPEED C15 FUEL LEVEL SENSOR (2)

C8 ENGINE OIL LEVEL AND TEMP C16

h) List of engine control system actuators

A1 ELECTRIC THROTTLE A9 OIL PRESSURE REGULATION VALVE

A2 COILS (4) A10 WASTE GATE

A3 SPARK PLUGS (4) A11 COOLING PISTON VALVE

A4 COMBUSTION CHAMBER INJECTORS (4) A12 CAM ADJUSTMENT ACTUATOR (8)

A5 INTAKE MANIFOLD INJECTORS (4) A13 INTAKE MANIFOLD THROTTLE VALVE

A6 GEARBOX COOLING VALVE A14 FUEL PUMP

A7 TURBO CHARGER BYPASS VALVE A15 ENGINE WARMING VALVE

A8 VARIABLE DISTRIBUTION VALVES (2) A16 ADDITIONAL WATER PUMP

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C9-1) Engine control system sensors

C1 C2 C3 C4

C5 C6 C7 C8

C9 C10 C11 C12

N/A

C13 C14 C15 C16

C9-2) Engine control system actuators

A1 A2 A3 A4

A5 A6 A7 A8

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A9 A10 A11 A12

N/A N/A

A13 A14 A15 A16

C9-3) Control modules

ENGINE ECU ENGINE ECU (BACK SIDE)

FUSE BOX GATEWAY

IMMO

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III-I1) LOCATION OF SENSORS AND ACTUATORS

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III-I1I) FUEL INJECTION SCHEME

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327. INTAKE

a) Material of manifold PLASTIC

b) Number of manifold elements 4

b1) Internal volume of manifold 2.3 + 0.1 dm3 b2) Minimum weight of manifold 1420 g

b3) Dimensions of the intake pipe at the throttle valve 57 + 0.25 mm

C11-1) Intake manifold - dismounted C11-2) Intake manifold - dismounted

C11-3) Throttle unit - dismounted C11-4) Throttle unit - dismounted

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III-K4) Section drawing of the throttle-unit C11-6) Air Filter – dismounted

Air Filter – dimensions C11-8) FIA pressure measuring tube – in its location

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328. EXHAUST

a) Material of manifold Cast Aluminium

b) Number of manifold elements Integrated inside the cylinderhead

c) Manifold exit 2 exits

C12-1) Exhaust manifold before turbo (integrated) C12-2) Exhaust pipe after turbo - dismounted

__________________________________
Turbocharger direcly to the cilynderhead

EXHAUST
Drawings exhaust pipe - tolerances on dimensions : +/-2%

III-L2) Exhaust

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331. COOLING SYSTEM

c) Type and origin of the water pump Mechanical / Serial pump

C13-3) Water pump – dismounted C13-4) Water pump mounted on engine

C13-5) Water radiator – dismounted C13-6) Water radiator dimensions

C13-7) Water radiator + fan carcass – dismounted C13-8) Water add on radiator dimensions

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C13-9) Add on water radiator – dismounted C13-10) Water add on radiator – mounted in its location

332) COOLING SCHEME

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333. LUBRICATION SYSTEM

a1) Material of oil sump PLASTIC Capacity 6.5 +/- 0.5 L

a3) Type of lubrications Wet sump

C14-1) Oil sump – mounted C14-2) Oil sump – dismounted

C14-3) Oil catch-tank – dismounted C14-4) Oil catch-tank mounted in its location

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C14-2) Oil pump – dismounted C14-2) Oil pump – dismounted

N/A

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334. TURBOCHARGING

a) Make and type of the turbocharger OEM VW GROUP

Yes No
h) Cooling of intake air
h1)

Air
h2) System

h3) Air inlet diameter Ø 47 + 1mm

h4) Air outlet diameter Ø 40 + 1mm

III-01) Exhaust gas inlet to the turbine housing III-02) Exhaust gas outlet from the turbine housing

2 holes 25 x 42,1 ± 0.2 mm Ø 77.5 ± 0.2mm

III-03) Air (gas) inlet to the compressor housing III-04) Air (gas) outlet from the compressor housing

Ø 47 ± 0,2mm
Ø 40 ± 0,5 mm

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C15-1) Plan view of complete turbocharger unit C15-2) Front view of complete turbocharger unit

C15-3) Side view of complete turbocharger unit C15-4) Valve and by-pass installation of turbocharger

C15-5) General view of turbocharger mounted

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C15-8) Intercooler – dismounted C15-9) Intercooler – mounted in its location

III-05) Drawing of the intercooler with dimensions of core (Width x Height x Thickness)

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III-06) DEVICE REGULATING THE TURBOCHARGER PRESSURE

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III-07) INTAKE AIR SCHEME

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4. FUEL CIRCUIT

401. FUEL TANK

a) Number 1

b) Location Rear seat (series position)

c) Material FIA FT 3 – manufacturer: CONTINENTAL

d) Total capacity 110 + 10 litres

f) Fuel pump (intank) Partnr. 420 906 093 C


e) Fuel suction pump (intank)
Partnr. 5971530011A

g) Fuel pump highpressure (engine side) h) Roll over valve Partnr. 42A 201 811
Partnr. 06L127025M

D1-1) Fuel tank dismounted D1-2) Fuel tank in its location

D1-3) Fuel tank in its location – with cover D1-4) Fuel cell service plates

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D1-1) Container for fuel cell mounted in bodyshell (seen from floor) D1-2) Frame and container for fuel tank mounted in bodyshell

D2-1) Fuel pump(s) - dismounted D2-2) Fuel pump(s) - in its location

D2-3) Fuel filler – mounted in its location D2-4) Fuel filler - dismounted

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5. ELECTRICAL EQUIPMENT

501. STEERING WHEEL AND SWITCH BOX

E x-1) Steering wheel - dismounted E x-2) Steering wheel - dismounted

STEERING WHEEL - FUNCTION OF SWITCHES

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502. CENTER PANEL AND SWITCH BOX

CENTER PANEL - FUNCTION OF SWITCHES

503. BATTERY

E x-1) Battery – cover dismounted E x-2) Battery – cover mounted

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504. FIRE EXTINGUISHER

a) System KIDDE DEUGRA

Fire extinguisher – in its location (luggage compartement) Control panel for fire extinguisher – in its location (tunnel)

505. STARTER

a) Position FRONT OF ENGINE & ABOVE THE GEARBOX

E1-1) Starter – dismounted E1-2) Starter – mounted in its location

506. WINDSCREEN WIPER

E 1-3) Windscreen wiper drive - dismounted E 1-4) Windscreen wiper – mounted in its location

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504. DATA LOGGING SYSTEM


1. System : AIM MXG (dashboard + logger)
2. Channels: Published by driver information
3. AIM Smarty cam

LOOM SUMITOMO

C9-2) Data logging system

BOOST PRESSURE SENSOR UNIT


DATA LOGGING UNIT IN ITS LOCATION ABS/ESP MODULE IN ITS LOCATION
IN ITS LOCATION

DASHBOARD AND LOGGER WIRE LOOM DISMOUNTED

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ENGINE SPEED SENSOR IN ITS LOCATION FRONT WHEEL SPEED SENSOR IN ITS LOCATION

REAR WHEEL SPEED SENSOR IN ITS LOCATION FUEL PRESSURE SENSOR IN ITS LOCATION

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6. POWER TRAIN

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603 GEARBOX

b) Type
Automatic gear box with double axle and double clutch

c) Supports 1
d) Type and location of control Mechatronic Paddle shift: Yes Make: VW Group Identification: C-XXX
e) Gear ratios

SET OF RATIOS N°1 SET OF RATIOS N°2

Number of teeth Ratio Constant Synchro Number of teeth Ratio Constant Synchro

1 13/38 0.342 1
2 22/45 0.486 2
3 28/41 0.683 3
4 38/41 0.927 4
5 32/35 0.914 5
6 38/35 1.086 6
AR/R 13/27 14/22 0,300 AR/R

Final 1-2-3-4 15/72 0.208 Constant

Final drive 5-6-


20/72
R 0.278

F2-1) Gearbox casing and clutch bell housing F2-2) Gearbox casing and clutch bell housing

F2-3) Gearbox command - dismounted F2-4) Gearbox control - mounted

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F2-5) Gearbox control (MEchtronic) - dismounted F2-6) Gearbox cooling (Heatexchanger) - mounted

605. FINAL DRIVE

F4-5) Final drive casing F4-6) Final drive casing

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F2-3) Drive shaft - dismounted F2-4)

Minimum weight 5800 g (left) 6150 (right) (with boots and clamps)

607. ELECTRONIC SLIP DIFFERENTIAL

a) Type of final drive ELECTRONIC COMMANDED (HALDEX)

F4-1) Electronic slip differential underneath view F4-2) Electronic slip differential rear view and seal

F4-3) Gear box + electronic slip differentia -mounted- F4-4) Differential dismantled

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7. AXLES AND SUSPENSION

FRONT

Supports: Number: 4 Type: BOLT


Shock absorber: Make & type: ZF Sachs McPherson Setting identification:

G2-1) Subframe for fixing the axle parts - dismounted G2-2) Subframe for fixing the axle parts - dismounted

G2-3) Subframe – Modification of axle mounting points G2-4) Subframe – Modification of axle mounting points

G2-5) Subframe – Modification of axle mounting points G2-6) Subframe – Modification of axle mounting points

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G3-1) Bare hub-carrier – dismounted G3-2) Bare hub-carrier dimounted – dismounted

Material Aluminium
Minimum weight 4630 g

G3-3) Steering arm mounting bracket – dismounted G3-4) Steering arm mounting bracket – dismounted

Material Steel
Minimum weight 875 g

G4-1) Bare Wheel Hub – dismounted G4-2) Bare Wheel Hub – dimensions

Material Steel
Minimum weight 3570 g (with wheel studs)

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G5-1) Complete wishbone – dismounted G5-2) Complete wishbone – dismounted

Material steel
Minimum weight 2870 g (with spacers)

VII-E1) Positions of the pivot points on the wishbone/arm VII-E2) wishbone in its position

G6-1) Front Damper – dismounted G6-2) Front Damper – dimensions

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G5-3) Top mount (stru adapter) – dismounted G7-2) Antin roll bar in location

G7-1) Anti roll bar – dismounted G7-3) Anti roll bar linkage / adjustment

D = 22x3 mm

VII-E3) Pivot points positions on the body shell / cross memeber wishbone in its position

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REAR

Supports: Number: 4 Type: BOLT


Shock absorber: Make & type: ZF Sachs Setting identification:

H2-1) Subframe for fixing the axle parts - dismounted H2-2) Subframe for fixing the axle parts - dismounted

H2-3) Subframe – Modification of axle reinforcenments H2-4) Subframe – Modification of axle reinforcenments

H2-5) Subframe – Modification of axle pick up points H2-6) Subframe – Modification of axle mounting points

NA

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H3-1) Bare hub-carrier – dismounted H3-2) Bare hub-carrier assembly – dismounted

Material Aluminium
Minimum weight 3825 g

G4-1) Bare Wheel Hub – dismounted G4-2) Bare Wheel Hub – dimensions

Material Steel
Minimum weight 2495 g (with wheel studs)

H5-1) Complete Upper arm – dismounted VIII-E1) Positions of the pivot points on the upper arm

Material Steel
Minimum weight 1400 g (with ball joints)

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H5-2) Complete Rear arm – dismounted VIII-E2) Positions of the pivot points on the rear arm

Material Steel
Minimum weight 2025 g (with ball joints)

H5-3) Complete Lower-Front arm – dismounted VIII-E3) Positions of the pivot points on the lower-front arm

Material Steel
Minimum weight 690 g (with ball joints)

H5-4) Complete Lower-Rear arm – dismounted VIII-E4) Positions of the pivot points on the lower-rear arm

Material Steel
Minimum weight 1030 g (with ball joints)

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H6-1) Rear Damper – dismounted H6-2) Rear Damper – dimensions

G6-3) Anti roll bar – dismounted G6-4) Anti roll bar linkage / adjustment

D = 22x3 mm

G6-5) Adapter shock absorber – dismounted

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8. RUNNING GEAR

801. WHEELS RIMS

FRONT REAR

e) Material ALU CASTED ALU CASTED

e1) Size / offset 10 x 18 ET 36 10 x 18 ET 36

e2) min. Weight 11.000 g 11.000 g

Wheel front Wheel rear

807. WHEELS TYRES (MANDATORY FOR TT CUP EVENTS)

SLICK RAIN

HANKOOK HANKOOK
e) Manufacturer

260/660-18 260/660-18
e1) Size

e2) Compound C52 W52

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803. BRAKES

FRONT
ABS yes / no
TYPE 1 TYPE 2

e) Number of cylinders per wheel 6

e1) Bore 27 / 31.8 / 38.1 + 0.1 mm + 0.1 mm

g1) Number of pads per wheel 2

g2) Number of calipers per wheel 1

g3) Caliper material alu / /

g4) Thickness of new disc 32 +1 mm +1 mm

g5) External diameter of disc 380 +1.5 mm +1.5 mm

g6) Max pad thickness 25 +0.5 mm +1.5 mm

Yes No Yes No
g9) Ventilated discs

Number of venting channels 48

g10) Min. weight of new disc (with bell and screws) 8480 g g

g11) Number of fixation points 11

J4-1) Front brake caliper in its location J4-2) Front brake caliper dismounted

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J5-1) Front brake disc dismounted J5-2) Front brake disc dismounted

803. BRAKES

REAR

TYPE 1 TYPE 2

e) Number of cylinders per wheel 1

e1) Bore 36 + 0.1 mm + 0.1 mm

g1) Number of pads per wheel 2

g2) Number of calipers per wheel 1

g3) Caliper material alu / iron /

g4) Thickness of new disc 10 +1 mm +1 mm

g4b) Minimum thickness of disc (maximum wear) 8 mm mm

g5) External diameter of disc 272 +1.5 mm +1.5 mm

g6) Max pad thickness 14.3 +0.5 mm +1.5 mm


Yes No Yes No
g9) Ventilated discs

Number of venting channels

g10) Min. weight of new disc (with bell and screws) 3800 g g

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K4-1) Rear brake caliper type 1 K4-2) Rear brake caliper type 1

K5-1) Rear brake disc type 1 K5-2) Rear brake disc type 1

803. BRAKEMASTERCYLINDERS

BRAKE BIAS yes / no


FRONT REAR

e) Make & Type AP - CP2623 AP - CP2623

e1) Bore 17,8 optional 19,1 + 0.1 mm 22,2 + 0.1 mm

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Mastercylinders in its location

L2-1) Pedal box - dismounted seen from front L2-2) Pedal box - dismounted seen from side

L2-1) Master cylinder - dismounted L2-2) Brake bias (braking regulator) - dismounted

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803. BRAKE RESERVOIR

Reservoir

FRONT REAR

e) Type TILTON 74-20X TILTON 74-203

e1) Volume 304 + 5 mL 193 + 5 mL

Reservoir dismounted Reservoir in its location

803. ABS

Yes / No

CONTINENTAL MK 100

e) 2 circuit system (black and white) Front rear

e1) Software (ABS / TCS) MQ7BAO00021

ABS unit – in its location

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J9-3) Front brake cooling J9-4) Rear brake cooling

N/A

804. STEERING

Type: RACK AND PINION (ELECTRIC) Origin and identification: OEM VW GROUP

J11-1) Steering rack – dismounted J11-2) Steering rack – mounted in its position

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J11-3)Steering rack - sketch

J11-4) Steering column – dismounted

J11-5) Steering wheel hub J11-6) Hub spacer – OPTIONAL USE (20mm or 40mm)

J12-1) Steering wheel J12-2) Steering wheel release mechanism

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9. BODYWORK - CHASSIS (BODYSHELL)

901. INTERIOR

DRIVER SEAT: Make & type AUDI PS1 Weight: 11.500 g (L seat) 11.000 g ( M seat)

DASHBOARD: Material: Plastic Weight: 2.096 g + 2x 97 g (Sidewings)

Driver seat - dismounted Driver seat – mounted in its position

L1-1) Dashboard - mounted

L1-1) Dashboard - dismounted

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L2-1) Pedal box and footrest - mounted in its location L2-2) Centre panel – mounted in its location

L2-3) Fixation points of seat-belts - mounted in its location L2-4) Scrotch-straps - mounted in its location

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902. EXTERIOR

XIII-A1) MATERIALS OF BODYWORK PANELS

METALLIC MATERIALS

Label Part Material

03 FRONT BONNET ALU

05 ROOF ALU

06 REAR WING ALU Profile

09 DOOR ALU

15 REAR BONNET ALU

16 REAR WING POSTS ALU 8.00 ± 0.5 mm

PLASTIC MATERIALS

Label Part Material

01 RADIATOR GRILL PLASTIC

02 BONNET AIR SCOOP CARBON

04 REAT BUMPER FIBER GLASS

07 ENDPLATES REAR WING ALU min 3.00 ± 0.5 mm

08 LEFT / RIGHT REAR FENDER EXTENSION CARBON (painted)

10 LEFT /RIGHT SILL TRIM PANEL CARBON (painted)

11 LEFT / RIGHT FRONT FENDER CARBON (painted)

12 LEFT / RIGHT FRONT FENDER EXTENSION CARBON/KEVLAR (painted)

13 FRONT BUMPER FIBER GLASS (painted)

14 FRONT SPLITTER CARBON

17 REAR BONNET COVER CARBON (painted) / OPTION : STEEL

GLAZING

Label Part Material Min. thickness

18 WINDSCREEN GLASS 4.46 ± 1 mm

19 LEFT / RIGHT FRONT DOOR WINDOW GLASS 3.85 ± 0.5 mm

20 LEFT REAR TRIANGLE WINDOW GLASS 3.15 ± 0.5 mm

21 RIGHT REAR TRIANGLE WINDOW LEXAN MARGARD FMR5XT 4.00 ± 0.5 mm

22 REAR WINDOW GLASS 4.00 ± 1 mm

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DRAWING

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XIII-D1) Engine bonnet – dimensions of openings

Tolerance + 1% (not applicable to opening max. area)


Sizes seen from plain top-view

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M5-1) Front fender mounted

M6-1) Rear fender - mounted

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M7-1) Door Sill (Underbody) - dismounted

M7-2) Mini-Fender (front) – mounted in its position M7-3) Mini-Fender (front) - dismounted

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M8-1) Front side protection panel - mounted

M8-2) Bare modified front door – inner face M8-3) Front door energyabsorbing device (2x plate) – in position

H–crash-bar (aluminium)

Plate 8S0 837 103/104 and 8S6 837 103/104

M8-4) Front door energyabsorbing device (kevlar-cover) – in position M8-5) Front door energyabsorbing device (foam) – in position

Cover 8S6 867 197/198 (Kevlar) Foam 8S6 867 129/130 (NEOPOLEN)

M8-2, M8-3, M8-4 and M8-5 are mandatory to be installed left-hand-side and optional to be mounted right-hand-side

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7-4) Rear side protection panel - mounted

NA

M8-1) Bare standard rear door – inner face M8-2) Rear door energy espng device – dismounted

NA NA

M8-3) Rear side protection panel - dismounted M8-4) Rear side protection panel - mounted

NA NA

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M8-6) Front wheelarch – modification of wheel arch

M8-6) Rear wheelarch – modification of wheel arch

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M9-1) Front bumper - dismounted c/w radiator grill M9-2) Front bumper - dismounted without radiator grill

XIII-I1) Front bumper seen from front - dimensions of openings

OPTIONAL: Mounting of steel-mesh 5x5x1, 8x8x1 or 10x10x1 to be added to each air-intake for stone-protection

Tolerance + 1% (not applicable to opening max. area)

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M11-1) Rear bumper - dismounted outer side M11-2) Rear bumper - dismounted inner side

M14-2) Rear wing regulation - mounted

M14-3) Complete rear wing – in position

DRAWING

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XIII-N1) COMPLETE REAR WING DISMOUNTED

M15-1) Complete front splitter - dismounted M15-2) Complete front splitter- dismounted

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XIII-N2) REAR WING AND SPLITTER MOUNTED ON CAR SEEN FROM THE SIDE (WITH LONGITUDINAL POSITION)

896 mm + 0 / - 5 mm
Reference = end of wing-profile 910 mm + 0 / - 5 mm

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903. CHASSIS (BODYSHELL)

N1-1) Bare bodyshell – General view ¾ front N1-2) Bare bodyshell – General view ¾ rear

N1-3) Bare bodyshell – Cockpit seen from the right door N1-4) Bare bodyshell – Cockpit seen from windscreen opening

N1-6) Bare bodyshell – Roof seen from cockpit

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N1-7) Bare bodyshell – Luggage compartment N1-8) Bare bodyshell – Seen from underneath

MODIFICATIONS OF CHASSIS (BODYSHELL)

N3-1) Front bulkhead – Modification for steering column passage N4-1) Front member – Engine support

N4-2) Front member – Gearbox support N10-1) Front wheel housing – mounted

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N10-2) Front suspension turret – top mount N10-3) Front suspension turret – top mount

N10-4) Cut out for fuel-cell N10-5) Modification of tunnel for seat-clearance left

N10-6) Seat brackets left and right

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COMPLEMENTARY INFORMATION

Air jack – nozzle connector – in its position Foot stopper (heel) – MOUNTING OPTIONAL – NOT MANDATORY

Foot stopper (pedal) – MOUNTING OPTIONAL – NOT MANDATORY Numberplate – MOUNTING OPTIONAL – NOT MANDATORY

Bracket throttle-pedal – OPTIONAL 15° - 30° Bracket throttle-pedal – OPTIONAL 15° - 30°

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