Audi TT 207 Repair Manual Download | Manualshive

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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.

2.3.6

Impact Member

1 - Side impact member

❑ Remove bolts -2- (quan‐

ity: 7)

2 - Bolt

❑ 23 Nm

Audi TT 2007 ➤

Body Exterior - Edition 11.2010

180

Rep. Gr.63 - Bumpers

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Summary of Contents for TT 207

Page 1: ...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 Repair Manual Audi TT 2007 Body Exterior Edition 11 2010 Service Service Department Technical Information ...

Page 2: ...Technical Data 50 Body Front 55 Hood Lids 57 Front Doors Central Locking System 61 Convertible Top 63 Bumpers 64 Glass Window Regulators 66 Exterior Equipment Technical information should always be available to the foremen and mechanics because their careful and constant adherence to the instructions is essential to ensure vehicle road worthiness and safety In addition the normal basic safety prec...

Page 3: ... 8 1 8 Fender Brace 8 1 9 Fender End Plate 9 55 Hood Lids 10 1 Description and Operation 10 1 1 Hood TT 10 1 2 Hood TT RS 12 1 3 Rear Lid Coupe 18 1 4 Rear Lid Roadster 20 2 Removal and Installation 26 2 1 Hood TT 26 2 2 Hood TT RS 38 2 3 Rear Lid Coupe 50 2 4 Rear Lid Roadster 59 2 5 Fuel Filler Door 67 3 Special Tools 72 57 Front Doors Central Locking System 73 1 Description and Operation 73 1 1...

Page 4: ...al Tools 189 64 Glass Window Regulators 190 1 Description and Operation 190 1 1 Flush Bonded Windows 190 1 2 Bolted Windows 193 2 Removal and Installation 196 2 1 Flush Bonded Windows 196 2 2 Bolted Windows 212 3 Special Tools 216 66 Exterior Equipment 219 1 Description and Operation 219 1 1 Exterior Rearview Mirror 219 1 2 Radiator Grille TT RS 220 2 Specifications 221 2 1 Lettering 221 2 2 Spoil...

Page 5: ... all rubber or plastic and adhesive are made of non conductive materials If you have doubts about the reusability of parts use new parts from the replacement parts catalog Note It is recommended to use only original replacement parts as they have been tested and are compatible with aluminum It is recommended to use Audi accessories Warranty does not cover contact corrosion damage 1 3 Adhesive Tape...

Page 6: ...einforcement page 6 1 6 Bumper Bracket page 7 1 7 Noise Insulation Frame page 8 1 8 Fender Brace page 8 1 9 Fender End Plate page 9 1 1 Front Fenders 1 Bolt 11 Nm 2 Bracket 3 Fender Removing Loosen sill panel cover in fender area Headlamp removed re fer to Electrical Equip ment Rep Gr 94 Removal and Installa tion Remove the front bump er Audi TT 2 1 2 Front Bumper page 165 Audi TT RS 2 2 1 Front B...

Page 7: ... by AUDI AG 1 2 Engine Mount Brace Roadster 1 Engine mount Removal refer to Engine Mechanical Fuel Injection and Ignition Rep Gr 10 Specifi cations 2 Engine mount brace Remove nut 5 and bolts 3 3 Bolt 23 Nm 4 Internally threaded pop rivet 5 Nut 10 Nm 6 Special bolt Do not remove for brace removal Torque refer to En gine Mechanical Fuel Injection and Ignition Rep Gr 10 Specifica tions Audi TT 2007 ...

Page 8: ...ing lock car rier 4 Bolt 6 Nm 5 Lock carrier Note Removing Remove the front bump er Audi TT 2 1 2 Front Bumper page 165 Audi TT RS 2 2 1 Front Bumper page 170 Remove headlight Re fer to Electrical Equip ment Rep Gr 94 Removal and Installa tion Disconnect the control cable for the front lid lock from the coupling Audi TT 2 1 6 Front Hood Lock Release Cable page 31 Audi TT RS 2 2 13 Hood Lock Contro...

Page 9: ...wn in the illustration 2 Plenum chamber cover Wiper arms removed Note Lid seal removed Remove trim panel up ward diagonally from edge strip beginning at window edge Vehicles with bolts page 6 Caution Risk of window breaking during installation Do not hit the trim when installing it Carefully press in trim sideways beginning in edge strip 3 Molding For easier removal in stallation of plenum chamber...

Page 10: ...lts 3 and 4 Remove rubber seal 1 Pull plenum chamber cover 2 vertically up from the window edge starting carefully with the windshield catches arrows 1 5 Engine Mount Brace Reinforcement 1 Engine mount brace If brace must be re moved from bracket re move bolts 2 WARNING When installing rein forcement 3 must be slid into brace 1 2 Bolt 23 Nm When tightening to tor que counterhold at nut 5 with open...

Page 11: ...ntee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 1 6 Bumper Bracket Removing 1 Right bumper bracket Remove bolts 2 from lock carrier 4 2 Bolt 5 Nm 3 Left bumper bracket Remove bolts 2 from lock carrier 4 4 Lock Carrier Audi TT 2007 Body Exterior Edition 11 2010 1 Removal and Installation 7 ...

Page 12: ...ormation in this document Copyright by AUDI AG 1 7 Noise Insulation Frame Removing 1 Frame Noise insulation re moved Remove bolts 2 and 3 and remove frame 2 Bolt 23 Nm 3 Bolt 23 Nm 4 Internally threaded pop rivet 5 Longitudinal member 1 8 Fender Brace Fender removed To remove only loosen bolts 2 and slide brace forward out of elongated holes Bolts 2 23 Nm Audi TT 2007 Body Exterior Edition 11 2010...

Page 13: ...respect to the correctness of information in this document Copyright by AUDI AG 1 9 Fender End Plate Removing 1 End plate Remove front wheel Remove wheel housing liner Refer to 3 8 1 Front Wheel Housing Liner page 255 Fluid reservoir loosen ing Remove plugs 3 and slide end plate 1 out downward 2 Plugs 3 Screws 11 Nm Audi TT 2007 Body Exterior Edition 11 2010 1 Removal and Installation 9 ...

Page 14: ...0 1 1 2 Hood Hinge Adjusting page 11 1 1 1 Hood Adjusting Special tools and workshop equipment required Adjusting Gauge 3371 Gap Dimensions for Hood In A area 3 5 mm 0 5 mm In B area 4 5 mm 0 5 mm In C area 4 5 mm 0 5 mm In D area 4 0 mm to 2 5 mm in transition area In E area 3 5 mm 0 5 mm In F area 3 5 mm 0 5 mm Buffer Stop for Height Adjustment Adjusting buffer 1 must lightly contact the lock ca...

Page 15: ...spect to the correctness of information in this document Copyright by AUDI AG Hood Projection For correct adjustment lid 1 must project in the headlamp area 2 Dimension a 3 5 mm 0 5 mm Projection dimension b 3 mm 0 5 mm 1 1 2 Hood Hinge Adjusting When changing the hinge ensure that a 12 5 mm and ad just if necessary Audi TT 2007 Body Exterior Edition 11 2010 1 Description and Operation 11 ...

Page 16: ...Anti rotation protection For the striker pin Removing and Instal ling refer to 2 2 4 Left and Right Striker Pins page 40 2 Bolt 2 Nm 3 Hood catch Removing and Instal ling refer to 2 2 4 Left and Right Striker Pins page 40 Adjusting refer to 1 2 3 Hood Adjust ing page 14 4 Hood Removing and Instal ling refer to 2 2 1 Hood page 38 5 Nuts 9 Nm 6 Striker pin with catch Removing and Instal ling refer t...

Page 17: ...Grille Bumper Headlamp A Hood to bumper Gap dimension a 4 5 0 5 mm 1 hood 2 bumper Adjusting refer to 1 2 3 Hood Adjust ing page 14 B Hood to radiator grille side Gap dimension b from top to bottom 4 0 to 2 5 0 5 mm 1 hood 3 Radiator grille Adjusting refer to 1 2 3 Hood Adjust ing page 14 C Hood to radiator grille Gap dimension c 4 4 0 5 mm Projection d 1 5 0 5 mm 1 hood 3 Radiator grille Adjustin...

Page 18: ...1 hood 2 fender front area Adjusting refer to 1 2 3 Hood Adjust ing page 14 B Hood to front door Gap dimension b 3 5 0 5 mm Projection c 0 0 1 0 mm 1 hood 3 Front door Adjusting refer to 1 2 3 Hood Adjust ing page 14 C Hood to fender A pillar area Gap dimension d 3 5 0 5 mm Projection e 2 0 0 5 mm 1 hood 4 fender rear area Adjusting refer to 1 2 3 Hood Adjust ing page 14 1 2 3 Hood Adjusting Speci...

Page 19: ...e stop bolt height adjustment page 39 Hood Lock Height Adjustment For the correct tightening specifications refer to 1 2 4 Hood Locks Assembly Overview page 16 Loosen the bolts arrows Adjust the height of hood lock 1 in front lock carrier 2 The striker pin with the hood catch must engage vertically in the hood lock Tighten the bolts Height Adjustment at Left and Right Hood Locks For the correct ti...

Page 20: ...em arrows 1 2 4 Hood Locks Assembly Overview 1 Nut 9 Nm 2 Brace 3 Bolt 11 Nm 4 Bolt 11 Nm 5 Anti theft protection 6 Right hood lock Removing and Instal ling refer to 2 2 8 Left and Right Hood Lock page 43 7 Right mount for hood lock 8 Bolt 3 Nm 9 Left mount for hood lock 10 Bolt 10 Nm 11 Left hood lock Removing and Instal ling refer to 2 2 8 Left and Right Hood Lock page 43 12 Front hood lock with...

Page 21: ...ing refer to 2 2 13 Hood Lock Control Cable Mount page 47 5 Cover For the cable 6 Grommet For the seal to the pas senger compartment 7 Bolt 10 Nm 8 Operating lever mounting bracket Removing and Instal ling refer to 2 2 9 Release Lever Mounting Bracket page 43 9 Hood release lever 10 Retaining clip For mount with control cable 11 Left hood lock Removing and Installing refer to 2 2 8 Left and Right ...

Page 22: ...sition The actuating links must allow the lock mechanisms on the lid locks to engage up to the stop Actuating links 1 and 2 must then be relieved Turn adjuster 3 on the respective actuating link accordingly arrows if necessary 1 3 Rear Lid Coupe 1 3 1 Rear Lid Gap Dimensions page 18 1 3 1 Rear Lid Gap Dimensions Special tools and workshop equipment required Adjusting gauge 3371 Gap Dimensions The ...

Page 23: ... 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 Dimension A 4 0 mm 0 5 mm Dimension B 4 5 mm 0 5 mm Dimension C 3 5 mm 0 5 mm Dimension D 2 mm all around Audi TT 2007 Body Exterior Edition 11 2010 1 Description and Operation 19 ...

Page 24: ...Cable Coupling page 22 1 4 4 Release Cable Routing on Hinge page 23 1 4 5 Release Cable Engaging in Handle page 24 1 4 1 Rear Lid Adjusting Special tools and workshop equipment required Adjusting gauge 3371 Gap Dimensions The gap dimensions can be checked with the Adjustment Gauge 3371 In A area 4 5 mm 0 5 mm In B area 3 5 mm 0 5 mm In C area 4 0 mm 0 5 mm In D area 2 0 mm 0 5 mm In E area 2 0 mm ...

Page 25: ...ect to the correctness of information in this document Copyright by AUDI AG 1 4 2 Release Cable Engaging in Rear Lid Lock Engaging 1 Rear lid latch 2 Cover After installing attach release cable to lid lock 3 Lid lock coupling plate 4 Release cable Engage in coupling plate as shown and en gage release cable on lid lock Audi TT 2007 Body Exterior Edition 11 2010 1 Description and Operation 21 ...

Page 26: ...information in this document Copyright by AUDI AG 1 4 3 Release Cable Coupling Release Cable Coupling 1 Release cable coupling Coupling is clipped into inner part of lid Remove retainer side ways and fold coupling up When installing retainer must be slid back into coupling 2 Cable Route cable ball in cou pling close lid and slide in retainer 3 Retainer Audi TT 2007 Body Exterior Edition 11 2010 22...

Page 27: ...y liability with respect to the correctness of information in this document Copyright by AUDI AG 1 4 4 Release Cable Routing on Hinge Cable Routing on Hinge 1 Cover Press cover sideways onto hinge 2 Release cable 3 Hinge grommet When pressing into hinge grommet must engage audibly 4 Rear lid hinge Audi TT 2007 Body Exterior Edition 11 2010 1 Description and Operation 23 ...

Page 28: ...ectness of information in this document Copyright by AUDI AG 1 4 5 Release Cable Engaging in Handle Engaging in Handle 1 Release cable Engage release cable ball 1 in handle 2 Caution The cable must be rout ed behind retaining tab as shown to ensure proper function 2 Emergency release handle 3 Grommet Slide into end plate and engage at sides Audi TT 2007 Body Exterior Edition 11 2010 24 Rep Gr 55 H...

Page 29: ...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 Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 25 ...

Page 30: ...2 1 6 Front Hood Lock Release Cable page 31 2 1 7 Cable Cover page 32 2 1 8 Cable Coupling page 33 2 1 9 Hood Lock Release Cable page 34 2 1 10 Hood Release Lever Cover page 35 2 1 11 Hood Release Lever page 36 2 1 12 Hood Seal page 37 2 1 1 Hood 1 Hood A second person is needed during removal and instal lation to support and hold the hood Removing Remove the gas filled strut Item 5 page 27 from t...

Page 31: ...st be removed or supported securely Removing Remove gas filled strut 2 1 5 Gas Filled Strut page 30 Remove the bolts 2 and nuts 4 Installation in reverse order 4 Nuts 25 Nm 5 Gas strut Removing and installing refer to 2 1 5 Gas Filled Strut page 30 The gas filled strut tube is installed on the hood side 6 Ball stud 21 Nm 7 Protective film Self adhesive Remove protective paper before applying 8 Nut...

Page 32: ...the correctness of information in this document Copyright by AUDI AG 2 1 3 Hood Lock Removing 1 Bolt 11 Nm 2 Bolt 11 Nm 3 Center hood lock Loosen upper bumper cover and press to side Disconnect the hood lock cable at the cou pling Disconnect electrical connectors Remove the bolts 1 and 2 Note 4 Cover for hood lock 5 Nut 11 Nm 6 Brace Audi TT 2007 Body Exterior Edition 11 2010 28 Rep Gr 55 Hood Lid...

Page 33: ...s document Copyright by AUDI AG 2 1 4 Hood Hinge Removing 1 Hood 2 Gas strut Attach the gas filled strut tube on the lid side Removal 2 1 5 Gas Filled Strut page 30 3 Nut 25 Nm 4 Hood hinge Before removing a hinge support the lid or secure it against falling Gas filled strut re moved Remove the bolts 3 and nuts 5 When removing re move both hood hinges 5 Nut 25 Nm Audi TT 2007 Body Exterior Edition...

Page 34: ...emove gas filled strut from ball stud Note 2 Hood 3 Ball stud 21 Nm Removing Support the hood or secure it against falling Raise securing spring slightly using a small screwdriver and remove gas filled strut 1 from upper ball stud 2 Repeat procedure on lower ball stud Installation Note After complete removal of the gas filled strut ensure correct po sitioning during installation the gas filled str...

Page 35: ...st third of the overall cylinder length using the piston rod end of the cyl inder as a reference point 2 1 6 Front Hood Lock Release Cable 1 Front hood lock Removing and installing To adjust the hood slide up or down 2 Release cable for front hood lock Removing Cable disconnecting at coupling page 33 Disengage cable from bracket 7 Pull cable through to en gine compartment Installation in reverse o...

Page 36: ...orrectness of information in this document Copyright by AUDI AG 9 Retaining clip Slid sideways onto body flange 10 Clips Slid onto lock carrier from front 2 1 7 Cable Cover Removing 1 Cable 2 Cable cover To remove from body flange pull forward and then remove upward from fender flange Unclip cable from cover 3 Body flange 4 Fender flange Audi TT 2007 Body Exterior Edition 11 2010 32 Rep Gr 55 Hood...

Page 37: ...to the correctness of information in this document Copyright by AUDI AG 2 1 8 Cable Coupling Disconnecting and Connecting 1 Rear cable 2 Cable coupling To release remove foam tube and fold cou pling up Pry front cable with nip ple out of coupling 3 Foam tube Slide sideways over coupling after installing cable 4 Front cable Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 33 ...

Page 38: ...his document Copyright by AUDI AG 2 1 9 Hood Lock Release Cable Attaching 1 Hood lock 2 Cable nipple Insert cable nipple in op erating lever 5 Insert cable in direction of arrow into lower part of lid lock and slide in until it engages 3 Front cable 4 Guide Engage the control ca ble guide in the lower part of the lid lock 5 Hood release lever Insert cable nipple here Audi TT 2007 Body Exterior Edi...

Page 39: ...of information in this document Copyright by AUDI AG 2 1 10 Hood Release Lever Cover Removing 1 Lower A pillar trim 2 Hood release lever cover Before removal first dis engage cable in cou pling in engine compart ment page 33 Raise operating lever approximately 90 and pull toward center of ve hicle and out of release lever 3 Hood release lever Audi TT 2007 Body Exterior Edition 11 2010 2 Removal an...

Page 40: ...opyright by AUDI AG 2 1 11 Hood Release Lever Removing 1 Screws 12 Nm 2 Hood release lever mount ing bracket No replacement part 3 Cable If installed correctly ca ble must be guided in id ler pulley arrow in mounting bracket 2 4 Hood release lever Release lever cover re moved Lower A pillar trim re moved Remove screws 1 and disengage release ca ble 3 5 Internally threaded pop rivet Audi TT 2007 Bo...

Page 41: ...elf adhesive Remove protective pa per and press onto fend er flange 3 Plenum chamber seal Slide into sealing profile with pre tension begin ning at sides Press seal onto oppo site side in stages Install seal with tension in the curved areas Caution Buckling in the rounded areas is not permitted Slide seal into sealing profile on opposite side 4 Plenum chamber cover Must be slid under lip of plenum...

Page 42: ... Cable page 44 2 2 11 Left Hood Lock Control Cable page 46 2 2 12 Right Hood Lock Control Cable page 46 2 2 13 Hood Lock Control Cable Mount page 47 2 2 1 Hood Removing Remove the spray nozzles Electrical Equipment Rep Gr 92 Removal and Installation Pull sealing plug 2 out of the hood Guide electrical wiring harness 3 and washer fluid line 1 out of the hood WARNING Risk of injury A second person i...

Page 43: ...einstallation Remove the bolts 4 and 5 Note Screws 4 and 5 are different lengths Remove the lid hinge Installing For the correct tightening specifications refer to 1 2 1 Hood Assembly Overview page 12 Install in reverse order of removal Note the following Adjust lid hinge stop screw 1 to dimension a Dimension a 34 mm Install the lid hinge according to the marking applied during removal Adjust the ...

Page 44: ...ng page 14 2 2 5 Impact Guard Special tools and workshop equipment required Hot air gun V A G 1416 Cleaning solution D 009 401 04 Removing Open the hood Carefully warm impact guard 1 with the V A G 1416 and remove from hood 2 in the area of the adhesive surface Remove the impact guard Installation Install in reverse order of removal Note the following Use VAS 6349 to remove any remaining adhesive ...

Page 45: ...rut with the plastic clip Use commercially available needle nose pliers to press plastic clip 1 together as shown and remove gas filled strut 2 from the ball pin Installation Install in reverse order of removal Note the following The gas filled strut tube is installed on the lid side Press the gas filled strut onto the ball stud until it engages au dibly Gas Filled Strut Releasing Gas Clamp gas fi...

Page 46: ...ease lever on control cable 1 in the direction of arrow A Move the bracket with the control cable in the direction of arrow B and detach from front hood lock 2 Installation For the correct tightening specifications refer to 1 2 4 Hood Locks Assembly Overview page 16 Install in reverse order of removal Note the following Engage bracket 5 with the control cable on front hood lock 2 arrow and move it...

Page 47: ...iver side instrument panel cover Refer to Body Interior Rep Gr 70 Removal and Installation Remove lower A pillar trim Refer to Body Interior Rep Gr 70 Removal and Installation Remove the bolts 1 and 2 Remove hood control cable 4 from the bracket and remove at the idler pulley arrow Detach control cable fitting 5 from operating lever 6 Remove operating lever mounting bracket 3 Installation Install ...

Page 48: ...y AUDI AG 2 2 10 Center Hood Lock Control Cable Removing Remove bumper Refer to 2 2 1 Front Bumper page 170 Remove the bolts arrows Remove air guide 1 Remove the nuts 1 and bolts 3 and 4 Remove brace 6 Detach bottom theft protection 2 from lock carrier 5 arrows and remove Pry up retaining clips 3 on control cable guide 2 Remove the bolts arrows Remove front hood lock 1 from the lock carrier Audi T...

Page 49: ...cable mount 6 to the side Cut through the cable tie arrow Release the retaining clips and open the cover Remove control cable bracket 4 from control cable mount 1 Detach the control cable fitting for the front lid lock from con necting piece 2 Note Ignore 3 and 5 Conduct the control cable forward through the opening in the lock carrier Installation Install in reverse order of removal Note the foll...

Page 50: ...ease the retaining clips and open the cover Remove control cable bracket 3 from control cable mount 1 Detach the control cable fitting for the left lid lock from con necting piece 2 Note Ignore 4 and 5 Disconnect the cable ties and remove the lid lock control cable Installation Install in reverse order of removal Note the following Note When installing position cable ties in same place Install the...

Page 51: ...ting piece 2 Note Ignore 3 and 4 Remove the screws arrows and the air guide Remove the right hood lock Refer to 2 2 8 Left and Right Hood Lock page 43 Disconnect the cable ties and remove the lid lock control cable Installation Install in reverse order of removal Note the following Note When installing position cable ties in same place Install the right hood lock Refer to 2 2 8 Left and Right Hood...

Page 52: ...trument panel cover Refer to Body Interior Rep Gr 70 Removal and Installation Remove lower A pillar trim Refer to Body Interior Rep Gr 70 Removal and Installation Remove hood control cable 2 from bracket 1 and remove at the idler pulley arrow Detach control cable fitting 3 from operating lever 4 Remove windshield wiper arms Refer to Electrical Equip ment Rep Gr 92 Removal and Installation Remove t...

Page 53: ...ion Install in reverse order of removal Note the following Install the plenum chamber cover Refer to 1 4 Plenum Chamber Cover page 5 Install the engine compartment E box cover Refer to Elec trical Equipment Rep Gr 97 Removal and Installation Attach control cable fitting 3 in operating lever 4 Conduct hood control cable 2 over the idler pulley arrow and press it into bracket 1 Installing the lower ...

Page 54: ...e the rear lid trim panel Refer to Body Interior Rep Gr 70 Removal and Installa tion Disconnect the electri cal wires and remove from the lid Remove left and right gas filled struts Refer to 2 3 5 Gas Filled Strut page 53 Remove the bolts at the connection for the rear lid hinge rear lid refer to 2 3 3 Rear Lid Hinge page 52 Remove the rear lid Installation in reverse order Adjusting The gas dampe...

Page 55: ...ten combi bolts Item 5 page 51 by hand it must still be possible to slide striker Carefully close the rear lid so that it is flush with the side panels Carefully open lid and tighten bolts Item 5 page 51 8 Nuts 21 Nm 9 Protective film Self adhesive Remove protective paper before applying 10 Rear lid hinge Removing and installing 2 3 3 Rear Lid Hinge page 52 2 3 2 Rear Lid Stop Buffer Close the rea...

Page 56: ...tee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 2 3 3 Rear Lid Hinge 1 Rear lid hinge Only remove bolts 3 to remove lid Loosen headline in area of nut 4 To remove remove cov er page 53 and nut 4 2 Hood 3 Bolt 21 Nm 4 Nut 21 Nm Audi TT 2007 Body Exterior Edition 11 2010 52 Rep Gr 55 Hood Lids ...

Page 57: ...n in this document Copyright by AUDI AG 2 3 4 Rear Lid Hinge Cover Removing 1 Lid hinge cover First pry out of bottom of rear lid hinge cover and remove When installing first en gage at top and then at bottom 2 3 5 Gas Filled Strut WARNING There is a risk of an accident Support the lid or secure it against falling down before re moving a gas filled strut Audi TT 2007 Body Exterior Edition 11 2010 ...

Page 58: ...ch the gas filled strut tube on the body side Note different versions 3 Ball stud 21 Nm 4 Retaining clip To release raise slightly with a small screwdriv er Note different versions Note Different gas filled struts are installed and their removal varies Removing the gas filled strut with the steel spring Detach the gas filled strut for the rear lid by lifting retaining spring 2 using a small screwd...

Page 59: ...etely removing gas filled strut ensure correct po sition when installing Tube of gas filled strut must be engaged on body side Press gas filled strut onto ball stud first at bottom and then at top Gas Filled Strut Releasing Gas Clamp gas filled strut in a vise in area x 50 mm 2 in WARNING Clamp only within this area otherwise accident could oc cur Wear protective eyewear when sawing Note Cover are...

Page 60: ...t by AUDI AG 2 3 6 Rear Lid Latch 1 Hood 2 Rear lid latch The read lid trim panel is removed Refer to Body Interior Rep Gr 70 Removal and Instal lation Before removal remove lid lock cover Emergency release ca ble disengaging Remove nuts and re move lid lock 3 Cover for lid lock When installing cover must engage audibly in lid lock 4 Nut 21 Nm 5 Anti theft cover Lid Lock Emergency Release Audi TT ...

Page 61: ...ccept any liability with respect to the correctness of information in this document Copyright by AUDI AG 1 Cable Before removal unclip anti theft cover Cable secured with clips arrows 2 Rear lid latch 3 Hood 4 Emergency release operat ing lever Clipped into rear lid trim 5 Lid trim cover cap Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 57 ...

Page 62: ...rantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 2 3 7 Rear Lid Seal 1 Lid seal To remove remove seal from body flange When assembling align seal with butt joint arrow on left ball stud and press on all around body flange Audi TT 2007 Body Exterior Edition 11 2010 58 Rep Gr 55 Hood Lids ...

Page 63: ...ove the rear lid trim panel Refer to Body Interior Rep Gr 70 Removal and Installa tion Disconnect the electri cal wires and remove from the lid Remove left and right gas filled struts Refer to 2 4 4 Gas filled Strut page 61 Remove the bolts at the connection for the rear lid hinge rear lid refer to 2 4 3 Rear Lid Hinge page 61 Remove the rear lid Installation in reverse order Adjusting The gas dam...

Page 64: ...sting Tighten combi bolts Item 5 page 60 by hand it must still be possible to slide striker Carefully close the rear lid so that it is flush with the side panels Carefully open lid and tighten bolts Item 5 page 60 8 Nuts 21 Nm 9 Protective film Self adhesive Remove protective paper before applying 10 Hood hinge Removing and installing refer to 2 4 3 Rear Lid Hinge page 61 2 4 2 Stop Buffer Removin...

Page 65: ...nt Copyright by AUDI AG 2 4 3 Rear Lid Hinge 1 Bolt 21 Nm 2 Bolt 21 Nm 3 Rear lid hinge Only remove nuts 6 to remove the lid To remove remove the cover and screws 1 and 2 4 Hood 5 Gas strut Note different versions 6 Nut 21 Nm 2 4 4 Gas filled Strut WARNING There is a risk of an accident Support the lid or secure it against falling down before re moving a gas filled strut Audi TT 2007 Body Exterior...

Page 66: ... 1 Rear lid 2 Gas strut Note location Note different versions 3 Ball stud 21 Nm 4 Retaining clip Note different versions Note Different gas filled struts are installed and their removal varies Removing the gas filled strut with the steel spring Detach the gas filled strut for the rear lid by lifting retaining spring 2 using a small screwdriver 1 arrow Now remove gas filled strut 3 from the ball st...

Page 67: ...letely removing gas filled strut ensure correct po sition when installing gas filled strut tube must be engaged on hood side Press gas filled strut onto ball stud first at bottom and then at top Gas Filled Strut Releasing Gas Clamp gas filled strut in a vise in area x 50 mm 2 in WARNING Clamp only within this area otherwise accident could oc cur Wear protective eyewear when sawing Note Cover area ...

Page 68: ...nt Copyright by AUDI AG 2 4 5 Rear Lid Latch 1 Rear lid 2 Rear lid latch The read lid trim panel is removed Refer to Body Interior Rep Gr 70 Removal and Instal lation Before removal remove lid lock cover Emergency release ca ble disengaging Remove nuts and re move lid lock 3 Cover for lid lock When installing cover must engage audibly in lid lock 4 Nut 21 Nm 5 Anti theft cover Audi TT 2007 Body Ex...

Page 69: ...f lid page 22 With lid opened insert handle side of release cable through hinge into luggage compartment and engage grommet 6 on hinge page 23 Clip cover 5 onto hinge Grip release cable in luggage compartment and guide through hole in rear of roof frame 10 and down Engage release cable in end plate 11 in center of convertible top cover page 24 Engage release cable in handle 4 Lid grommet 5 Cover S...

Page 70: ...ss of information in this document Copyright by AUDI AG 1 Release cable bracket Riveted to lid 2 Release cable 3 Hood 4 Rear lid latch Release cable arrow engaged in the lid lock as shown in the magni fied area of the illustra tion Engage release cable in operating lever Refer to Body Interior Rep Gr 70 Removal and Installation 5 Rivet Quanity 3 Audi TT 2007 Body Exterior Edition 11 2010 66 Rep Gr...

Page 71: ... AG 2 4 7 Rear Lid Seal 1 Lid seal To remove remove seal from body flange When assembling align seal with butt joint arrow on left ball stud and press on all around body flange 2 5 Fuel Filler Door 2 5 1 Fuel Filler Door page 67 2 5 2 Fuel Filler Door Drain Hose page 70 2 5 3 Fuel Filler Door Installation Position page 71 2 5 1 Fuel Filler Door Special tools and workshop equipment required Audi TT...

Page 72: ...with lower part of fuel filler door 4 Fuel filler door When removing re move cable 1 on the fuel filler door Proceed as follows when installing a new fuel filler door Guide cable through opening in fuel filler door cup Insert fuel filler door di agonally until catches on protruding flange en gage in side panel Press fuel filler door down against fuel filler door cup tension until sliding catches v...

Page 73: ... the correctness of information in this document Copyright by AUDI AG Removing Remove 3 bolts arrows Unlock the locking mechanism arrow with the hook T40207 or a hook made as an assisting tool of welding wire for example Pull fuel filler door vertically out of body opening using Special Hook 3370 Remove bolts arrows on cable Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 69 ...

Page 74: ...val noting the following For overflow hose to be routed without kinking fuel filler door cup must be installed as follows The edge of the drain hole in the flap cup must align with the edge of the hole in the body arrows as shown in the illustra tion 2 5 2 Fuel Filler Door Drain Hose 1 Drain hose Press in drain hose un der wheel housing line into clips 3 as show and position on body pins 2 Fuel fi...

Page 75: ...lity with respect to the correctness of information in this document Copyright by AUDI AG 2 5 3 Fuel Filler Door Installation Position 1 Fuel Filler Door Cover Adjust distance A evenly to side panel 2 Tank cap 3 Fuel filler door 4 Fuel filler door cup Slide all around onto body flange as shown 5 Drain hose Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 71 ...

Page 76: ...s not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 3 Special Tools Special tools and workshop equipment required Special hook 3370 Hot air gun V A G 1416 Cleaning solution D 009 401 04 Adjusting gauge 3371 Audi TT 2007 Body Exterior Edition 11 2010 72 Rep Gr 55 Hood Lids ...

Page 77: ...1 1 1 Door Adjusting Special tools and workshop equipment required Adjusting gauge 3371 Template T40038 7 Adjusting with Template T40038 7 The position of the door in relation to the sides the height and the rear window can be checked using the template The distance to the side window can be checked using the grading for dimension a The recess of the door to the fender or the side panel to the doo...

Page 78: ...adjusted to far inward In the illustration shown max marking on window side the window is adjusted correctly when the contact surfaces makes contact with the roof trim molding and the upper contact sur face a of the template shows a small gap If the contact surface of the template does not make contact with the roof trim molding the door window is too far out Height adjustment Apply a marking to a...

Page 79: ...or seal 3 The door window must be in the area of the small groove Gap dimensions The gap dimensions can be checked with the Adjustment Gauge 3371 Dimension A 3 5 mm 0 5 mm Dimension B 3 5 mm 0 5 mm Dimension C 0 mm to 1 mm Dimension D 0 mm to 1 mm Adjustment via striker Loosen bolts 2 Slide striker 1 until the door shell is flush with the contour of the chassis Tighten screws to 20 Nm Note The str...

Page 80: ...eways at back end Pull door handle back diagonally out of mount ing bracket or door 2 Bracket 3 Actuating link Door lock removed Engage actuating link in door lock operating lev er arrow Caution The release cable must not be kinked under any circumstances when in stalling otherwise mal functions may result Perform a function test after installing Slide actuating link side ways into door lock then ...

Page 81: ...talling back ing plates 2 and 5 must be installed Slide door handle into front door opening until it engages in brace on mounting bracket arrow Press door handle on rear lock cylinder into mounting bracket Insert lock cylinder with cover cap Completely install bolt to secure lock cylinder page 97 3 Bracket 4 Front backing Slide onto door handle 5 Door When installing door handle 1 rear end must sl...

Page 82: ...val and Installation Rear cover on inner panel removed page 90 Raise window up Lock cylinder removed Remove bolts 2 and slide door lock down Disengage internal mechanism cable 7 from door lock Install in reverse se quence 5 Lock cylinder shaft So called paddle must be guided into groove arrow in door lock during installation 6 Lock cylinder 7 Inside door release mechanism cable Internal mechanism ...

Page 83: ... interior After an accident in which the airbag deploys the central lock ing system control module opens any doors which were locked The central locking control module is located inside the right rear side panel 1 Front passenger door con trol module J387 2 Anti Theft Alarm System Sensor G578 Removing and Instal ling refer to Electrical Equipment Rep Gr 96 Removal and Instal lation 3 Comfort syste...

Page 84: ...2 Door Components page 87 2 3 Central Locking page 98 2 1 Front Door 2 1 1 Door page 80 2 1 2 Door Seals page 82 2 1 1 Door Special tools and workshop equipment required Socket wrench T10011 Box spanner 3320 2 Socket 3410 Note For various assembly work the entire door can be completely raise from the door hinges after electrical connectors on lower A pillar have been disconnected Adjustments must ...

Page 85: ...or and fender from damage Carefully lift door up and out of hinges 2 Upper door hinge upper part No replacement part Remains installed on door side 3 Upper door hinge lower part No replacement part Remains installed on A pillar 4 Securing nut 25 Nm 5 Cover Attach to nut 6 Securing spring Only installed on replacement part Remove after installing new hinge 7 Bottom door hinge upper part Remove any ...

Page 86: ...rim and B pillar trim re moved Refer to Body Interior Rep Gr 70 Re moval and Installation Removing Remove door seal all around from flange or from upper seal guides and side window Installing First press door seal into seal guide at upper B pillar arrow Then press door seal in to seal guide at upper A pillar arrow First press door seal into seal guide at center of door frame then along the entire ...

Page 87: ... starting at the A pillar Remove any adhesive residue from where the seal was secured with adhesive tape Adhesion surfaces must be free of dust and grease clean with cleaning solution D 009 401 04 Reinigungslö sung Attach the seal to the upper left and right cor ners of the roof flange Slide the seal on the roof frame Attach the seal in a downward direction on to the flange of the A pillar Secure ...

Page 88: ...the A pillar on the front seal Caution The door seal must be installed without a gap at the junction to the front seal Press the door seal in the lower radii areas onto the flange while distributing any excess length in the sill area Align the molded pieces of the door seal on the upper B pillar with respect to the side piece and install Press the door seal on both sides backward in the convertibl...

Page 89: ... under side of the door to the B pil lar Press on the outer door seal beginning from the lower B pillar on the un der side of the door and working forward and up ward Remove the protective film in stages upwardly and press on the outer door seal Caution Do not stretch or crush the seal when installing it The seal will come off wherever it is stretched or crushed along the bot tom or on the B pilla...

Page 90: ...en it is possible to remove the door outer seal without any left over ad hesive on it Bend and remove the door outer seal laterally as illustrated arrow Proceed the same way and remove the door outer seal com pletely Remove any left over adhesive with adhesive strip remover VAS 6349 Press on end of Outer Door Seal Raise the outer door seal in direction of arrow A and press down firmly on the end o...

Page 91: ...lator 1 Door window Removing and instal ling refer to 2 2 1 Front Door Win dow page 212 2 Window regulator Door trim removed Re fer to Body Interior Rep Gr 70 Removal and Installation Window removed Door inner panel cover removed page 90 Disconnect or unclip electrical wires Window regulator motor removed Remove nuts 4 and 7 Lift the window regulator out of the door through the side door opening 3...

Page 92: ...DI AG 1 Window regulator 2 Door 3 Nut 8 Nm 4 Nut 8 Nm 5 Adjusting screw For side adjustment window regulator can be adjusted via the adjust ing screws Loosen nuts 3 and in stall or remove adjusting screws corresponding to door seal on roof or rear window Window regulator height adjustment Note The height of the window regulator can be adjusted without removing door trim Audi TT 2007 Body Exterior ...

Page 93: ...ght by AUDI AG 1 Window regulator To adjust run window regulator all the way down Guide 5 mm hex socket head wrench through door panel from below into adjusting screws and arrows and adjust 2 Rear driver Rear adjusting screw arrow 3 Front driver Front adjusting screw arrow Window regulator motor removing Door trim removed Refer to Body Interior Rep Gr 70 Removal and Installation Audi TT 2007 Body ...

Page 94: ...rs Remove bolts 2 and remove nut 1 from threaded pins Installation When installing ensure threaded pins 3 engage with retain ers in inner door panel Slide window regulator motor 1 onto threaded pin 3 and se cure with screws 2 Note Only switch ignition on after installing motor and connecting wires Then move door window upward to stop and keep pressing switch for window regulator for approximately ...

Page 95: ...ment Copyright by AUDI AG 1 Inside door release mecha nism cable 2 Grommet Must be pressed into cover 4 completely 3 Door inner panel 4 Cover To removal release cover retaining tabs in stages using a thin ob ject Retaining tab location 5 Cover retainers Release retainers arrows on cover 1 from inner door panel 2 in stages using a thin object Replace seal 3 if necessary Audi TT 2007 Body Exterior E...

Page 96: ...Copyright by AUDI AG Inner door panel front covers removing and installing Insert centering pin arrow on cover 1 into inner door panel 4 and press on Replace seal 2 on cover 3 if necessary A pillar trim removing 1 Trim Attach trim from above as shown arrow and secure with bolt 4 2 Door 3 Outer window shaft strip Trim 1 removed for disassembly 4 Bolt 2 5 Nm Audi TT 2007 Body Exterior Edition 11 201...

Page 97: ...long hole in door 2 and tighten bolts 3 to 12 Nm Roadster side impact member It is removed and installed through the oblong hole for the bel lows For installation insert the impact member through the oblong hole into the door First insert the impact member into the hole on the A pillar and then secure slightly with screw 1 Then secure impact member 2 with bolt 1 Tighten the screws from back to fro...

Page 98: ... and drive out rivet shafts Outer Window Shaft Strip Removing and Installing 1 Door 2 Spring nut Pressed into door flange 3 Window shaft strip Door trim and door win dow removed Refer to Body Interior Rep Gr 70 Removal and Installation Remove A pillar trim Remove bolts and re move window shaft strip When installing align shaft strip on B pillar and secure with bolts 4 4 Bolt 1 5 Nm Inner window sh...

Page 99: ...ctness of information in this document Copyright by AUDI AG 1 Door 2 Inner window shaft strip The door trim panel is removed Door window removed To installed slide into guide rail on A pillar Attach shaft strip to A pillar arrow Then clip into door at B pillar Press shaft strip onto door flange from above 3 Door window 4 A pillar trim Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Instal...

Page 100: ...nel page 97 4 Bracket Removing and installing with door handle and lock cylinder handle removed Cable disengaging at door lock To remove remove the bolt 11 slide mounting bracket slightly to rear and remove from door 5 Actuating link Engage in door lock Item 3 page 76 6 Rear backing Insert in door panel 7 Lock cylinder housing Removing Unclip cover cap on front side of door Remove door handle Remo...

Page 101: ...ft cover 1 is slid between the door lock 2 and mounting bracket 3 onto the door panel 4 as shown Lock cylinder removing and installing Pry off cover 1 Pull door handle and hold firmly Remove bolt 2 as far as stop using socket wrench AF T20 The lock cylinder housing is only completely released with light pressure on the socket wrench or bolt Remove lock cylinder housing 2 sideways from door or moun...

Page 102: ...ed separately The first motor locks the door and the second motor locks the interior door mechanism Safe function Now doors also can no longer be opened from the interior After an accident in which the airbag deploys the central lock ing system control module opens any doors which were locked The central locking control module is located inside the right rear side panel Removing Note When installi...

Page 103: ...2 4 Hood Locks Assembly Overview page 16 Install in reverse order of removal Note the following Install the bumper 2 2 1 Front Bumper page 170 2 3 2 Fuel Filler Door Unlock Motor V155 Note Central locking functions electronically Actuators in doors are integrated in the door lock and have 2 motors Actuators cannot be replaced separately The first motor locks the door and the second motor locks the...

Page 104: ...ent Copyright by AUDI AG 1 Emergency release 2 Bracket 3 Fuel filler door unlock motor V 155 Installing page 101 4 Fuel Filler Door Release Cable 5 Fuel filler door Removing 2 5 1 Fuel Filler Door page 67 6 Bolt With bracket 2 instal led loosen bolts clock wise using Socket Wrench T10010 2 Nm 7 Nut 9 Nm Fuel filler door emergency release cable routing Audi TT 2007 Body Exterior Edition 11 2010 100...

Page 105: ...ny liability with respect to the correctness of information in this document Copyright by AUDI AG 1 Emergency release motor 2 Emergency release clip Press into emergency release bracket 3 Emergency release bracket Fuel Filler Door Unlock Motor Installing Insert emergency release clip 2 in motor 1 Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 101 ...

Page 106: ...uarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Insert motor in bracket 2 and tighten with bolts 1 Guide emergency release 2 through clip 3 on motor 1 Connect emergency release 2 to cable 3 Audi TT 2007 Body Exterior Edition 11 2010 102 Rep Gr 57 Front Doors Central Locking System ...

Page 107: ...ty with respect to the correctness of information in this document Copyright by AUDI AG Insert cable 1 in operating rod 2 and turn until it engages audibly Slide emergency release cap 3 onto operating rod and press cable bracket 2 into bracket mount arrow Secure assembly 2 in upper wheel housing with nuts 1 Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 103 ...

Page 108: ...ith respect to the correctness of information in this document Copyright by AUDI AG 3 Special Tools Special tools and workshop equipment required Special tools and workshop equipment required Template T40038 7 Roller 3356 Adjusting gauge 3371 Socket wrench T10011 Box spanner 3320 2 Socket 3410 Audi TT 2007 Body Exterior Edition 11 2010 104 Rep Gr 57 Front Doors Central Locking System ...

Page 109: ...s 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 Audi TT 2007 Body Exterior Edition 11 2010 3 Special Tools 105 ...

Page 110: ...nt Trim page 106 1 1 4 Safety Precautions page 108 1 1 5 Convertible Top Assembly Overview page 109 1 1 6 Convertible Top Adjusting page 110 1 1 2 Convertible Top Compartment Latch Assembly Over view page 107 1 1 3 Convertible Top Latch Height Adjustment page 108 1 1 1 Front Convertible Top Compartment Trim 1 Front convertible top com partment trim Removing and Instal ling refer to 2 1 4 Front Con...

Page 111: ...ht by AUDI AG 1 1 2 Convertible Top Compartment Latch Assembly Overview Note Only on manual convertible top 1 Release cable 2 Cable bracket Clip cable bracket with wind screen support 3 Clip Clip into upper end plate as shown 4 Front convertible top com partment wall 5 Convertible top latch brack et Height adjustment refer to page 108 6 Screws 8 Nm 7 Convertible top latch handle Audi TT 2007 Body ...

Page 112: ...justed so top is 4 mm below front convertible top compartment trim 3 Markings To adjust height adjust latch according to mark ings Front rail height adjustment When convertible top is adjusted correctly front rail must en gage with dimension a 4 mm in center of vehicle under front convertible top compartment trim 1 1 4 Safety Precautions To avoid personal injury or damage to the convertible top no...

Page 113: ...trap Bolted under converti ble top compartment from luggage compart ment out 3 Hydraulic System Must be removed when installing convertible top 4 Screws 36 Nm 5 Spring Bracket securing spring 6 Bracket Must be removed before removing convertible top Loosen spring and re move bracket sideways from retaining pins 7 Convertible top frame cover Removing and instal ling refer to 2 1 7 Convertible Top F...

Page 114: ...draulic pump switches off The front side of the convertible top main bearing must be in stalled parallel to the front wall of the convertible top compart ment The dimension between the roof frame crossmember and front rail must now be 35 5 mm If the dimension 35 5 mm is not maintained the position of the main bearing must be checked for parallel alignment with respect to the convertible top front ...

Page 115: ... main bearing to the convertible top compart ment front wall distance a When installing the con vertible top the same parallel distance must be set Note 3 Main bearing front side 4 Convertible top compart ment front wall Adjusting Screw for Spring back Dimension Note If the spring back dimension is not within the tolerance range de spite the correct settings at the main bearing it can additionally...

Page 116: ...e top compartment front wall with respect to the upper edge of the main bearing front side Gap Dimensions on Convertible Top Note The gap dimensions are set by adjusting at the main bearing Measure the dimension c from the forward edge of the rear lid outward Dimension d must be measured from the side panel starting at the main bearing Dimension f can be adjusted by placing adjustment shims on the...

Page 117: ... Working Conditions page 114 1 2 3 Hydraulic System Filling and Bleeding page 114 1 2 4 Hydraulic System Assembly Overview page 114 1 2 5 Hydraulic Pump Oil Level Checking page 116 1 2 6 Hydraulic Cylinder Assembly Overview page 117 1 2 1 Hydraulic System General Information The hydraulic system is self bleeding and maintenance free After all work where the oil circuit was opened or parts of the h...

Page 118: ...to contact with painted surfaces Seal open hydraulic lines with cover caps to prevent hydraulic oil from leaking out 1 2 3 Hydraulic System Filling and Bleeding Note The electro hydraulic convertible top operation involves a closed hydraulic system Generally filling is necessary after a loss of oil accident leaks etc Due to the lift and displacement effect of the pistons in the hydraulic cylinders...

Page 119: ...Cyl inder Assembly Over view page 117 2 Hydraulic line Unclip hydraulic line to body arrows 3 Hydraulic pump housing To remove remove bolts 4 and raise hous ing out of body 4 Bolt 10 Nm 5 Electric wire To remove hydraulic pump disconnect at connector 6 Body crossmember Hydraulic Pump Valve Open hydraulic pump valve by rotating valve bolt 180 coun terclockwise using a screwdriver 2 through the open...

Page 120: ...ng Caution To check oil level convertible top must be stored in convertible top compartment Hydraulic pump removed and placed on a level surface in lug gage compartment Oil level must be between both markings 4 fill oil if neces sary Remove filler plug 5 Fill with oil until the level is between Min and Max mark ings Install filler plug and tighten to 5 Nm Operate convertible top electrically sever...

Page 121: ... liability with respect to the correctness of information in this document Copyright by AUDI AG 1 2 6 Hydraulic Cylinder Assembly Overview 1 Spring Connecting piece se curing spring 2 Hydraulic line Supply 3 Convertible top cylinder 4 Spring Connecting piece se curing spring 5 Hydraulic line Return Audi TT 2007 Body Exterior Edition 11 2010 1 Description and Operation 117 ...

Page 122: ...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 Audi TT 2007 Body Exterior Edition 11 2010 118 Rep Gr 61 Convertible Top ...

Page 123: ...p to VAS 6586 page 130 2 1 12 Part Designations On Convertible Top Frame page 131 2 1 13 Roof Guide Stop page 131 2 1 14 Convertible Top Cover Tension Cable Disengaging page 132 2 1 15 Tension Cable Tightening page 132 2 1 16 Convertible Top Cover page 133 2 1 17 Convertible Top Cover Retaining Strips page 134 2 1 18 Guide Cable Mount on Roof Guide page 135 2 1 19 Rear Convertible Top Cover page 1...

Page 124: ... strap Before removing con vertible remove bolts 6 release tensioning strap at retaining tabs and pull strap into con vertible top compart ment If tensioning strap must be replaced also re move bolts on bracket and remove retaining strip 4 with tensioning strap from bracket When installing first slide into convertible top compartment from be low and engage at rear on retaining tabs 3 Bracket Remov...

Page 125: ... is not inserted damage can occur when the convertible top is stored Unclip hydraulic lines from rear wall of convertible top com partment Refer to 1 2 4 Hydraulic System Assembly Overview page 114 Note When storing convertible top in compartment press bracket down so that it doesn t get stuck on the compartment seal Store convertible top in compartment completely Remove left and right convertible...

Page 126: ... removal 2 1 4 Front Convertible Top Compartment Trim Special tools and workshop equipment required Pry lever 80 200 Removing Remove rear wall cover Position convertible top or linkage removal flaps so that ex panding clips A can be unclipped with 80 200 Note Secure expanding clips A against falling Unclip remaining expanding clips and remove front convertible top compartment trim B Installation I...

Page 127: ...y with respect to the correctness of information in this document Copyright by AUDI AG 2 1 5 Bracket Disengaging at Main Bearing Disengaging 1 Main bearing 2 Bracket To remove press secur ing spring sideways off pins and remove brack et sideways 3 Securing spring To install slide on side ways as far as stop Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 123 ...

Page 128: ...op Seals 1 Washers May be used if necessa ry for side adjustment of seals 2 Bolt 3 Nm 3 Rear guide hinge 4 Rear seal 5 Center roof guide seal 2 6 Front roof guide seal 1 7 Center guide rail for roof guide 2 8 Front guide rail for roof guide 1 Seal Removing Seals are slid into guide rails To remove remove from guide rails For easier assembly coat seal 1 with soapy solution if nec essary and slide o...

Page 129: ...olts 1 on guide rails to the specification 2 1 7 Convertible Top Frame Flap 1 Trim Is clipped to flap Flap releasing refer to page 126 2 Convertible top frame cover To adjust loosen bolts 4 on body and adjust flap so it is flush with convertible top Height adjustment to side panel page 126 Panel gap dimensions page 126 3 Push rod Caution During convertible top emergency operation push rod must fir...

Page 130: ...G Flap Trim Disengaging Using a small screwdriver for example press retainer arrow down and slide trim 2 back away from flap 1 For side adjustment to flap loosen bolts 3 and slide flap car rier 1 according to gap dimensions Flap Gap Dimensions Dimension a 3 6 mm Dimension b 3 6 mm Dimension c 3 6 mm Height Adjustment to Side Panel Height to side panel is adjusted using adjusting screws arrows Audi...

Page 131: ...this document Copyright by AUDI AG 2 1 8 Convertible Top Compartment Trim 1 Rear convertible top com partment trim To remove first disen gage upward all around from the bracket and in sert between the outer wall and plastic strip Caution If the trim is not inserted damage can occur when the convertible top is stored 2 Clip Quantity 12 3 Body flange 4 Bracket Audi TT 2007 Body Exterior Edition 11 2...

Page 132: ...front trim 1 3 Bolt 2 5 Nm 4 Front cover Remove bolts 8 on front cover Only on manual convertible top Remove latch handle page 145 Unclip cover 9 Remove cover forward out of latches 5 Left roof guide front trim 1 6 Left roof guide rear trim 2 7 Bolt 2 5 Nm 8 Bolt 2 5 Nm 9 Cover Only on manual conver tible top 10 Handle Only on manual conver tible top latch 2 1 10 Convertible Top Cover Special tool...

Page 133: ...ion it must be secured to the main bearing via threaded holes A B C D and E of the mounting plates page 130 First screw the mounting plates slightly onto the main bearing Insert the convertible top with the mounting plates into the VAS 6586 and tighten the screws on the main bearing For proper functioning the hydraulic pump must be placed with the oil reservoir and hydraulic pump motor in the half...

Page 134: ... Clamping Note Lightly secure both mounting plates with mounting points B and E on the main bearing The arrows must point forward in the direction of travel Lightly secure the main bearing on the left and right with the bore holes shown in the figure arrows to the mounting plates via mounting points B and E Insert the convertible top with the mounting plates into the mounts on the VAS 6586 from ab...

Page 135: ...rtible Top Frame Note These parts designations are used in the description 1 Rail 1 Fixed rail 2 Rail 2 Rotatable rail 3 Rail 3 Guided rail 4 Rear window guide 5 Rail tensioning strap 6 Bracket tensioning strap 7 Bracket 8 Hydraulic pump housing 9 Main bearing 10 Angle bracket for rear guide rail 11 Roof guide 2 12 Roof guide 1 13 Front rail 2 1 13 Roof Guide Stop Secure stop 2 with bolts 3 to roo...

Page 136: ...ble at spring Disengage tension ca ble at front rail and re move back from conver tible top cover 3 Convertible top cover 4 Adhesive tape After installing the ten sion cable tape it over with adhesive tape as shown for noise insula tion 5 Main guide 6 Spring 2 1 15 Tension Cable Tightening Note Make a hook from welding wire to help tighten the tension cable With manual convertible top cover slide ...

Page 137: ...ion cable in the hook as shown and pull for ward Engage tension cable nipple 1 in front rail Engage spring 3 in eyes arrow on main guide 1 and rear tension cable 2 2 1 16 Convertible Top Cover Removing Convertible top compartment cover trim disengaged from bracket Refer to 2 1 8 Convertible Top Compartment Trim page 127 Front cover removed page 128 Convertible top headliner removed 2 1 20 Headline...

Page 138: ...strip 1 2 1 17 Convertible Top Cover Retaining Strips Note Only on vehicles with electro hydraulic convertible top On vehicles with manual convertible top plastic retaining rails must be removed from rails 1 Guide cable To remove cover re move guide cable on both sides from roof guide 2 page 135 2 Bolt 2 5 Nm 3 Guide retaining strip 1 Retaining strips for rails 1 2 and 3 are removed to remove cove...

Page 139: ...emove bolt 2 for guide cable 3 on roof guide 2 1 Loosen all tension cable threaded connections and tensioning straps for securing cover Remove cover retaining strips at rails On angle bracket 1 drill out rivet heads arrows for securing the cover and drive out rivet shafts Remove rear window securing screw 1 Tighten to 6 Nm when installing Loosen the screw on the upper release cable on the rear win...

Page 140: ... top headliner Removed 3 Bracket Disengage convertible top cover assembly bracket on convertible top frame 4 Bolt 2 5 Nm 5 Convertible top cover Drill out rivet heads on the angle bracket and pull out the main guide with cover Remove bolts on retain ing strip 6 and remove from convertible top frame 6 Retaining strip No replacement part part of the convertible top cover delivery pack age 7 Bolt 3 N...

Page 141: ...rmation in this document Copyright by AUDI AG 1 Front convertible top head liner Front trim removed Front cover removed page 128 To remove remove bolts 4 2 Retaining strip Removed 3 Convertible top front rail 4 Bolt 1 5 Nm Rear Headliner Note In the case of a new convertible top headliner missing outer holes must be replaced by the retaining strip Audi TT 2007 Body Exterior Edition 11 2010 2 Remov...

Page 142: ...tible top headliner is secured all around to the rear win dow with Velcro strip To remove pull from the rear window 3 Bracket 4 Bolt 2 5 Nm 2 1 21 Headliner Retaining Strip on Bracket Installing Caution The bracket has two grooves The heating element cable for the rear window heater must be routed in the upper groove The screws for securing the retaining strip must be screwed into the lower groove...

Page 143: ...ht by AUDI AG 2 1 22 Bracket Tensioning Strap Removing 1 Convertible top 2 Bracket tensioning strap Remove bolts 3 and pull tensioning strap through into convertible top compartment 3 Bolt 2 Nm 4 Convertible top compart ment 2 1 23 Headliner Tensioning Straps Removing Remove bolts 1 on front rail 3 Pull tensioning strap 2 forward out of retainer and remove upward from front rail Audi TT 2007 Body ...

Page 144: ...with respect to the correctness of information in this document Copyright by AUDI AG Remove retainer bolts on tensioning strap from rail 1 as shown Remove retainer bolts on tensioning strap from rail 2 Remove retainer bolts on tensioning strap from rail 3 Remove bolt 3 on guide strap 1 as shown on roof guide 2 Audi TT 2007 Body Exterior Edition 11 2010 140 Rep Gr 61 Convertible Top ...

Page 145: ... correctness of information in this document Copyright by AUDI AG 2 1 24 Rear Window Release Cable Removing 1 Rear Window No replacement part 2 Rear window release When removing conver tible top cover discon nect release at upper rear window Note 3 Bolt 2 Nm 4 Main bearing Headliner installing Install in reverse order of removal Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation...

Page 146: ...ss 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 2 1 25 Water Tray Removing 1 Water tray 2 Clip 3 Bolt 2 Nm 4 Expanding clip Audi TT 2007 Body Exterior Edition 11 2010 142 Rep Gr 61 Convertible Top ...

Page 147: ...ate 2 Nut 9 Nm 3 Convertible top lock The locks on the conver tible top are preset above the locking rods and do not need to be adjusted 4 Convertible top 5 Bolt 9 Nm 6 Convertible top latch 7 Convertible top latch motor Removal page 144 8 Bolt 10 Nm 2 1 27 Convertible Top Lock Removing Note Shims with different inner diameters are located between the convertible top lock and front rail The first ...

Page 148: ...y liability with respect to the correctness of information in this document Copyright by AUDI AG Front trim removed Remove nuts and remove convertible top lock with linkage 2 1 28 Convertible Top Latch Motor Removing Roof crossmember trim removed Remove bolts 1 and nuts 3 on convertible top latch 2 Audi TT 2007 Body Exterior Edition 11 2010 144 Rep Gr 61 Convertible Top ...

Page 149: ...rmation in this document Copyright by AUDI AG 2 1 29 Manual Convertible Top Removing 1 End plate 2 Nut 9 Nm 3 Convertible top lock 4 Convertible top 5 Bolt 9 Nm 6 Convertible top latch Front cover removed 2 1 30 Latch Handle Removing Fold up the handle turn it approx 90 and unscrew the screw Slide bolt 3 sideways out of handle 2 using a thin wire 2 Audi TT 2007 Body Exterior Edition 11 2010 2 Remo...

Page 150: ...bility with respect to the correctness of information in this document Copyright by AUDI AG Tighten bolt to 2 Nm when installing Unclip collar 1 in direction of arrow Unclip cover 2 at front trim 1 arrow 2 1 31 Convertible Top Latch Handle Removing Tighten handle 2 with bolts 1 to 8 Nm Clip 3 clipped in Audi TT 2007 Body Exterior Edition 11 2010 146 Rep Gr 61 Convertible Top ...

Page 151: ...ct to the correctness of information in this document Copyright by AUDI AG 2 1 32 End Plate Removing 1 End plate Window crossmember cover removing refer to Body Interior Rep Gr 70 Removal and Installation To remove disconnect the electrical connector and unscrew the screws 2 Bolt 15 Nm 3 End plate cover To remove unclip Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 147 ...

Page 152: ...or page 153 2 2 1 Hydraulic Cylinder Removing Convertible top completely removed 1 Convertible top main bear ing 2 Hydraulic cylinder Remove securing spring 4 from pins 3 on piston rod and cylin der Remove pins sideways from main bearing and remove cylinder Remove supply and re turn line from cylinder After installing check oil level at hydraulic pump add hydraulic oil if nec essary 3 Securing pin...

Page 153: ...by AUDI AG Slide securing spring 1 sideways under connecting piece 3 out of cylinder using a screwdriver Remove connecting piece 1 from cylinder using sealing ring 2 Carefully remove sealing ring 1 using a small hook 2 if nec essary without damaging 3 cylinder Slide new sealing ring 2 onto connecting piece 1 Insert connecting piece 3 vertically in cylinder no resistance must be felt Audi TT 2007 B...

Page 154: ... in with force otherwise damage to the O ring and leaks could result Lock securing spring 2 in direction of arrow After performing work check oil level and add oil if necessary 2 2 3 Hydraulic Pump Hydraulic Line Removing from Pump page 151 1 Hydraulic pump housing Removed from body 2 Noise Insulation 3 Housing cover Removed 4 Screws 4 Nm 5 ABS Hydraulic Pump To remove remove bolts 4 and remove co...

Page 155: ...of housing To remove remove se curing bolt 1 and re move connector pieces with hydraulic line from pump block 4 Before installing slide new O ring seals onto connecting pieces Caution When inserting con necting pieces must lie flush before bolts are tightened To install slide connect ing pieces completely into pump block and tighten securing bolts 1 to 6 Nm 3 Oil reservoir With Min and Max marking...

Page 156: ...r off of pump block alternat ing sides Always replace O ring seals Before install first loos en filler plug 2 to bleed When installing slide oil reservoir on to the first retainer Then slide oil reservoir in the correct position completely onto pump block The oil reservoir then engages in the pump block O ring seal must lie cleanly in the intended groove After checking slide on clamp 6 and tighten...

Page 157: ...lt loosened oil reservoir can be turned far enough for this After aligning correctly tighten locking bolt to the specification and fill oil 2 2 4 Pump Motor Caution If pump motor is replaced hydraulic oil escapes when re moving Collect escaping hydraulic oil with suitable containers and dispose of properly Hydraulic oil damages paint Immediately remove any hy draulic oil that has come in contact w...

Page 158: ...does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 3 Special Tools Special tools and workshop equipment required Convertible top bracket VAS 6586 Scissor lift table VAS 6131 A Pry lever 80 200 Audi TT 2007 Body Exterior Edition 11 2010 154 Rep Gr 61 Convertible Top ...

Page 159: ...mper Audi TT RS page 160 1 1 Front Bumper Audi TT 1 1 1 Front Bumper Assembly Overview page 155 1 1 1 Front Bumper Assembly Overview 1 Upper right bumper cover Removing page 164 2 Radiator Grille Removing and instal ling refer to 3 3 1 Radiator Grille page 235 3 Upper left bumper cover Removed 4 Bolt 1 5 Nm 5 Right guide piece Removing and instal ling refer to page 169 6 Left guide piece 7 Headlam...

Page 160: ...nd Instal ling refer to 2 2 3 Air Intake Grille page 172 4 Right spray nozzle cover for the headlamp wash er system Removing and Instal ling refer to Electrical Equipment Rep Gr 92 Removal and Instal lation 5 Bolt Quantity 4 2 Nm 6 Guide piece Removing and Instal ling refer to 2 2 2 Front Bumper Guide Piece page 172 7 Nut Quantity 4 4 Nm 8 Inner cover Removing and Installing refer to 2 2 4 Inner C...

Page 161: ...G AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 13 Bolt Quantity 4 2 Nm Tightening Torques and Sequence for Upper Bumper Tighten the bolts in a 1 to 4 sequence to 5 Nm Audi TT 2007 Body Exterior Edition 11 2010 1 Description and Operation 157 ...

Page 162: ...respect to the correctness of information in this document Copyright by AUDI AG 1 2 2 Impact Member and Impact Absorber Assembly Overview 1 Impact absorber Removing and Instal ling refer to 2 2 7 Impact Absorb er page 174 2 Bolt 30 Nm 3 Side impact bar Removing and Instal ling refer to 2 2 8 Impact Mem ber page 174 4 Bumper Audi TT 2007 Body Exterior Edition 11 2010 158 Rep Gr 63 Bumpers ...

Page 163: ... Overview 1 Bumper Removing refer to 2 3 1 Rear Bumper page 174 2 Left inner guide piece 3 Bolt 2 5 Nm 4 Left outer guide piece 5 Clip Slid into side panel 6 Bolt 2 5 Nm 7 Clip Slid into side panel 8 Bracket 9 Right inner guide piece 10 Right outer guide piece 11 Bolt 2 5 Nm 12 Nut 4 Nm 13 Side impact bar 14 Bolt 23 Nm 15 Impact absorber Slid onto impact mem ber 16 Bolt 2 5 Nm 17 Left cover strip ...

Page 164: ... 2 4 2 Rear Bumper Spoiler page 184 3 Lower bumper trim Removing and Instal ling refer to 2 4 2 Rear Bumper Spoiler page 184 4 Bolt Quantity 4 2 Nm 5 Left exhaust pipe trim Removing and Instal ling refer to 2 4 4 Exhaust Pipe Trim page 185 6 Bolt Quantity 2 2 5 Nm 7 Cover strip For bumper Removing and Instal ling refer to 2 4 1 Rear Bumper page 182 8 Bumper Removing and Instal ling refer to 2 4 1 ...

Page 165: ...refer to Item 10 page 160 4 Left holder for bumper Removing and Instal ling refer to 2 4 7 Rear Bumper Bracket page 187 5 Nut Quantity 2 4 Nm 6 Bolt Quantity 6 Tightening Specifica tions and Sequence page 162 7 Left inner guide piece Removing and Instal ling refer to 2 4 9 Inner Guide Piece page 188 8 Bolt Quantity 2 2 Nm 9 Guide piece holder 10 Nut Quantity 2 Tightening Specifications and Sequenc...

Page 166: ...ge 188 15 Right holder for bumper Removing and Installing refer to 2 4 7 Rear Bumper Bracket page 187 16 Side impact bar Observe country specific versions Removing and Installing refer to 2 4 6 Impact Member page 186 Tightening Torque and Sequence for Inner Guide Piece Tighten the bolts in a 1 through 3 sequence to 2 5 Nm Tightening Torque and Sequence for Guide Piece Tighten the screws and nuts i...

Page 167: ...art 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 Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 163 ...

Page 168: ...er Audi TT 2 1 1 Upper Bumper Covers page 164 2 1 2 Front Bumper page 165 2 1 3 Impact Member page 166 2 1 4 Inner Wheel Housing Liner page 167 2 1 5 Lower Bumper Bolting Points page 168 2 1 6 Noise Insulation page 168 2 1 7 Bumper Guide Piece page 169 2 1 8 Air Grille page 170 2 1 1 Upper Bumper Covers Removing 1 Left cover To remove unclip up ward from lock carrier and remove sideways from coole...

Page 169: ... Loosen wheel housing liner in nut area 10 and pull back page 167 Remove zero gap con nection nuts 10 Remove the lower screws from the noise insulation in the bumper area Unclip bumper side ways from guide pieces and pull forward slightly Remove electrical wire to fog lamp clamp off line to headlamp washer system if necessary Bumper completely from vehicle Installing Use markings on radia tor gril...

Page 170: ...plate No replacement part Slide into support 8 on lock carrier as shown 8 Carrier piece No replacement part Part of lock carrier delivery package 9 Left cover Unclip 10 Nut Use T40078 to loosen or tighten nut 6 5 Nm 2 1 3 Impact Member 1 Impact absorber Connected to impact member 2 Bolt 30 Nm 3 Side impact bar After bolts 2 are re moved clamping wash ers on top and bottom of bracket must be re mov...

Page 171: ...pt any liability with respect to the correctness of information in this document Copyright by AUDI AG Removing Bumper removed Remove right bolts 2 and left bolts as well as clamping washers 3 2 1 4 Inner Wheel Housing Liner Removing Remove bolts in bumper area and pull back wheel housing liner Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 167 ...

Page 172: ...ion in this document Copyright by AUDI AG 2 1 5 Lower Bumper Bolting Points 1 Bumper 2 Nut Use T40078 to loosen or tighten nut 6 5 Nm 3 Grommet 4 Fender 5 End plate Part of bumper delivery package No replacement part 6 Bolt 2 Nm Remove bolts on noise insulation 7 Bolt 1 5 Nm 2 1 6 Noise Insulation Removing Remove bolts 1 to remove bumper from noise insulation 3 Audi TT 2007 Body Exterior Edition 1...

Page 173: ...I AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 2 1 7 Bumper Guide Piece Removing 1 Bolt 2 5 Nm 2 Bumper Removed 3 Fender 4 Clip 5 Guide piece 6 Wheel housing liner 7 Bolt 1 5 Nm Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 169 ...

Page 174: ...ows must engage com pletely in bumper 2 2 Front Bumper Audi TT RS 2 2 1 Front Bumper page 170 2 2 2 Front Bumper Guide Piece page 172 2 2 3 Air Intake Grille page 172 2 2 4 Inner Cover page 173 2 2 5 Spoiler Upper Part page 173 2 2 6 Spoiler Lower Part page 173 2 2 7 Impact Absorber page 174 2 2 8 Impact Member page 174 2 2 1 Front Bumper Special tools and workshop equipment required Engine bung s...

Page 175: ...2 Front Wheel Spoiler page 239 Release the securing clamp arrow and remove washer fluid line 1 on connecting piece 2 Seal the connecting piece of the washer fluid line with a clean plug from the VAS 6122 Remove the bolts arrows Remove the upper bumper covers Refer to 3 4 2 Radiator Grille Cover page 236 Unscrew screws 1 2 3 5 and nuts 6 and 7 Remove the bumper rear edge from the guide piece fender...

Page 176: ...al direction Tighten the screws in the sequence 1 4 2 2 2 Front Bumper Guide Piece Removing Remove bumper Refer to 2 2 1 Front Bumper page 170 Remove the screws arrows and guide piece 1 on the fend er Installation For the correct tightening specifications refer to 1 2 1 Front Bumper Assembly Overview page 156 Install in reverse order of removal Note the following Install the bumper Refer to 2 2 1 ...

Page 177: ...Part Removing Remove the bolts 2 and 3 Remove spoiler upper part 1 on the outside starting at the bumper arrows Installation For the correct tightening specifications refer to 1 2 1 Front Bumper Assembly Overview page 156 Install in reverse order of removal Note the following During installing the retaining tabs must engage completely in the bumper 2 2 6 Spoiler Lower Part Removing Remove the bolt...

Page 178: ...r 96 Removal and Installation Install the bumper Refer to 2 2 1 Front Bumper page 170 2 2 8 Impact Member Removing Remove the impact absorber Refer to 2 2 7 Impact Absorber page 174 Unscrew screws 2 and remove clamping washers 3 Remove the impact bar 1 Installation Install in reverse order of removal Note the following For the correct tightening specifications refer to 1 2 2 Impact Member and Impa...

Page 179: ... Copyright by AUDI AG 1 Screws 1 5 Nm 2 Rear Bumper To remove remove bolts 1 on wheel hous ing liner bolts 3 under cover strip Item 17 page 159 and bolts 5 from brack et 6 First disengage bumper from outer guide piece then remove toward rear from inner guide piece 3 Bolt Cover strip removing page 178 2 5 Nm 4 Inner guide piece 5 Bolt 2 5 Nm 6 Bracket 7 Wheel housing liner Audi TT 2007 Body Exterio...

Page 180: ...ith respect to the correctness of information in this document Copyright by AUDI AG 2 3 2 Outer Guide Piece Removing 1 Rear Bumper Removed 2 Side panel 3 Internally threaded pop rivet Riveted into side panel 4 Clip 5 Bolt 2 5 Nm 6 Guide piece When installing ob serve tightening se quence from bottom to top 7 Bolt 2 5 Nm Audi TT 2007 Body Exterior Edition 11 2010 176 Rep Gr 63 Bumpers ...

Page 181: ... liability with respect to the correctness of information in this document Copyright by AUDI AG 2 3 3 Inner Guide Piece Removing 1 Bolt 2 5 Nm 2 Clip Slid into side panel 3 Side panel 4 Inner guide piece When installing ob serve tightening se quence from inside to ward outside 5 Rear Bumper Removed Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 177 ...

Page 182: ...ith respect to the correctness of information in this document Copyright by AUDI AG 2 3 4 Rear Bumber Cover Strip and Bracket Cover Strip Removing Unclip cover strip on upper bumper from retainers arrows Lower Bumper Threaded Connection Remove bolt 3 from bracket 1 from bottom side of bumper Bracket Removing Nut 2 4 Nm Audi TT 2007 Body Exterior Edition 11 2010 178 Rep Gr 63 Bumpers ...

Page 183: ...es not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 2 3 5 Lower Cover Removing 1 Rear Bumper 2 Lower cover To remove bumper must not be removed Unclip from bumper in stages and remove to ward rear Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 179 ...

Page 184: ...less 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 2 3 6 Impact Member 1 Side impact member Remove bolts 2 quan ity 7 2 Bolt 23 Nm Audi TT 2007 Body Exterior Edition 11 2010 180 Rep Gr 63 Bumpers ...

Page 185: ...t guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 2 3 7 Rear Bumper Shock Absorber Removing 1 Impact absorber Observe country specif ic versions Slid into impact mem ber 2 Side impact bar 3 Bumper Removed Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and Installation 181 ...

Page 186: ...185 2 4 5 Impact Absorber page 186 2 4 6 Impact Member page 186 2 4 7 Rear Bumper Bracket page 187 2 4 8 Guide Piece page 187 2 4 9 Inner Guide Piece page 188 2 4 1 Rear Bumper Removing Remove the screws arrows from the wheel housing liner and remove expanding clip 3 To remove the expanding clip press in clamping pin 1 care fully by dimension x until it audibly engages in the expanding clip arrow ...

Page 187: ... and right tail lamp Refer to Electrical Equipment Rep Gr 94 Removal and Installation Remove the right luggage compartment side trim Refer to Body Interior Rep Gr 70 Removal and Installation Disconnect fog lamp electrical harness connector 1 In the case of vehicles with a parking aid disconnect electrical harness connector 2 Unclip cover strip 2 on upper bumper 1 from the locking mechanisms arrows...

Page 188: ...ust be carefully lifted arrow B Thread the electrical wiring harness out of the body opening and remove the bumper Installation For the correct tightening specifications refer to 1 4 1 Rear Bumper Assembly Overview page 160 Install in reverse order of removal Note the following The bumper must engage completely Install the left and right tail lamp Refer to Electrical Equip ment Rep Gr 94 Removal a...

Page 189: ... Remove the bolts 1 and 3 Remove diffuser trim 2 arrows Installation For the correct tightening specifications refer to 1 4 1 Rear Bumper Assembly Overview page 160 Install in reverse order of removal Note the following The diffuser trim must engage completely 2 4 4 Exhaust Pipe Trim Removing Remove the rear bumper Refer to 2 4 1 Rear Bumper page 182 Remove the bolts arrows Remove the exhaust pipe...

Page 190: ...w B Installation Install in reverse order of removal Note the following Install the bumper Refer to 2 4 1 Rear Bumper page 182 2 4 6 Impact Member Removing Remove bumper Refer to 2 4 1 Rear Bumper page 182 Remove the bolts arrows Note There is a different number of screws on the left and right Remove the impact bar 1 Installation For the correct tightening specifications refer to 1 4 2 Impact Memb...

Page 191: ... Shock Absorber and Guide Piece Assembly Overview page 161 Install in reverse order of removal Note the following Note The threaded pin arrow is only used for fastening the bracket Install the bumper Refer to 2 4 1 Rear Bumper page 182 2 4 8 Guide Piece Removing Remove bumper Refer to 2 4 1 Rear Bumper page 182 Remove the screws arrows and nuts 2 Remove guide piece 1 Installation For the correct t...

Page 192: ...per Refer to 2 4 1 Rear Bumper page 182 Remove Radio frequency controlled clock receiver J489 1 if applicable Refer to Electrical Equipment Rep Gr 90 Removal and Installation Remove the bolts arrows Remove inner guide piece 2 Installation For the correct tightening specifications refer to page 162 Install in reverse order of removal Note the following Tighten the screws in the sequence 1 3 Install...

Page 193: ...r accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 3 Special Tools Special tools and workshop equipment required Hose Clamps up to 25 mm diameter 3094 Socket T40078 Engine bung set VAS 6122 Hose Clamps up to 25 mm diameter 3094 Socket T40078 Audi TT 2007 Body Exterior Edition 11 2010 3 Special Tools 189 ...

Page 194: ...e 192 1 1 1 Windshield Assembly Overview Coupe 1 Windshield Distance to roof dimen sion a 2 mm Even out side distance dimension c 3 mm 2 Adhesive sealing material Observe minimum cur ing time page 197 Apply adhesive directly near window molding or lower molding Dimension d 8 mm 2 mm Dimension e 23 mm 2 mm 3 Molding To remove pull off of window edge Before installing com pletely remove adhe sive re...

Page 195: ...ours Removing Protective Tubing With a new windshield 1 protective tubing 2 must be re moved from molding 3 before installing plenum chamber cover 4 1 1 2 Windshield Assembly Overview Roadster 1 Windshield Distance to roof dimen sion a 2 mm Even out side distance dimension c 3 mm 2 Adhesive sealing material 3 Spacer Bond the same number in the same positions as on the removed window 4 Plenum chamb...

Page 196: ... B pillar area If a removed window is reinstalled window must be secured to C pillar with adhesive tape 2 Pop rivet To remove side window drill out rivet heads and drive out rivet shafts 3 Retaining clip 4 Roof trim molding Before roof trim molding can be removed from the clips pop rivets in upper door area must first be removed Refer to 3 1 1 Roof Trim Molding page 227 5 Securing pin No replaceme...

Page 197: ...ve stopper profiles Bead width 8 mm 2 mm Bead height 12 mm 2 mm 3 Connector Disconnect when re moving window Clipped into lid flange 4 Adhesive stopper profile Apply window adhesive between profiles Undamaged Rear Window Removing Remove rear lid trim Refer to Body Interior Rep Gr 70 Removal and Installation Disconnect rear window defroster and window antenna con nectors and secure to center of win...

Page 198: ...AUDI AG Height adjustment checking page 73 1 Rear height stop Completely lower the window regulator To adjust height guide a hex socket wrench and 5 mm socket into adjust ing sleeve from under side of door through door plate Adjust stop up or down accordingly Note 2 Front height stop It is adjusted as with the rear height stop Side Adjustment Adjustment checking refer to page 73 Audi TT 2007 Body ...

Page 199: ...tness of information in this document Copyright by AUDI AG 1 Window regulator Removing and instal ling refer to 2 2 1 Window Regu lator page 87 2 Door 3 Nut 9 Nm 4 Nut 9 Nm 5 Collar screw For a lateral adjustment loosen the upper or low er nuts 3 with the V A G 1739 and un screw or screw in the upper or lower collar screw accordingly Audi TT 2007 Body Exterior Edition 11 2010 1 Description and Ope...

Page 200: ...it V A G 1755 Cartridge gun V A G 1628 Cartridge heater V A G 1939 A Window cutter V A G 1561 A Cutting blade 58 mm V A G 1561 2 Cutting blade U shaped V A G 1561 3 Scraper 25 mm V A G 1561 8 Cutting blade bent at right angle V A G 1561 10 Double cartridge gun VAS 5237 Spooling tool V A G 1654 A Window Repair Kit VAS 6092 Servicing windows with Window Repair Kit VAS 6092 Windshields with stone dam...

Page 201: ...le can only be used after the minimum curing time has elapsed Window type Vehicle Adhesive sealing material Curing time in hours Windshield with without airbag 2K Window Adhesive Kit DA 004 600 A2 3 Rear lid Coupe 2K Window Adhesive Kit DA 004 600 A2 3 Side windows 1K window adhesive DH 009 100 03 3 Adhesive Sealant Removing from Window Using adhesive remover D 002 000 10 is recommended Always fol...

Page 202: ...upper A pillar trim on left and right Refer to Body Interior Rep Gr 70 Removal and Installation WARNING When removing a window always wear protective eyewear and leather gloves Use awl to pierce through adhesive sealing material on lower left of window from inside to outside Pull cutting cord through adhesive sealing material into inside of vehicle using awl Lay cutting cord underneath and all aro...

Page 203: ... Secure beginning of cutting cord in spooling tool and cut out first area of adhesive up to about center of windshield Move spooling tool as shown and continue to cut out adhesive sealing material Move spooling tool as shown and attach relay pulley Route cord as shown Cut window free until cutting cord is no longer fed through idler pulley Remove idler pulley and continue cutting window free Audi ...

Page 204: ... windshield from windshield opening using suction lifter Preparations for Installing Windshield When reusing the undamaged window cut rest of adhesive material on window and flange with V A G 1561 A and V A G 1561 8 so it is even but do not remove completely Note Residual material acts as a base for the new adhesive sealing material Caution Keep adhesive surface free of dirt and grease Only cut ba...

Page 205: ...window flange was damaged paint structure must be recreated and if necessary perform corrosion protection measures First clean corrected area with Cleaning Solution D 009 401 04 and then apply Glass and Paint Primer D 009 200 02 Windshield Installing Note Cross section thickness of adhesive bead is determined by di mension of opening in nozzle tip and rate of application Dimensions for adhesive ap...

Page 206: ...indow apply adhesive to re maining bead Using double suction cups install the windshield Caution The window must be installed within 15 minutes or the adhe sive sealing material will not adhere properly Center window along sides Spacing between edge of window and roof frame must be 5 mm 0 5 mm Slide adjusting wedge 1 as shown between clamping strip 5 and body flange Before installing plenum chambe...

Page 207: ... out rivet shafts 2 Sealing molding No replacement part 3 Sealing band Self adhesive 4 Pop rivet Quantity 5 5 A pillar seal Roof frame trim re moved Refer to Body Interior Rep Gr 70 Removal and Installa tion To remove remove from guide rail For easier assembly coat seal with soapy sol ution When installing engage in guide rail as shown Removing Protective Tubing With a new windshield 1 protective ...

Page 208: ...t any liability with respect to the correctness of information in this document Copyright by AUDI AG 2 1 4 Side Window Undamaged Side Window Removing Caution In window separation area protect side panel and roof against paint damage with adhesive tape Remove door seal in side window area Audi TT 2007 Body Exterior Edition 11 2010 204 Rep Gr 64 Glass Window Regulators ...

Page 209: ...t through Then pull cutting cord through in direction of arrow B down ward through adhesive sealing material Remove window from window opening Broken Side Window Removing Protect body and interior from glass splinters Remove glass pieces from adhesive material Bond flange all around with fabric reinforced adhesive tape WARNING When removing a window always wear protective eyewear and leather glove...

Page 210: ...of opening in nozzle tip and rate of application Dimensions for adhesive application 1 Adhesive sealing material 2 Primer 3 Window Dimension a 8 mm 2 mm Dimension b 12 mm 3 mm Distance c to window edge is given through the window molding Position complete surface of nozzle 2 onto window Application direction arrow for adhesive bead 1 Apply adhesive sealing material all around near window mold ing ...

Page 211: ...through the adhesive bead from the inside to the outside with needle nose pliers as shown Route cutting wire around rear window under the glass as shown in the illustration Loosen the hex bolt arrow on the rear lid hinge 1 and clamp the end of cutting wire 2 securely with it Clamp the cutting wire in the spool After removing window tighten bolt to 21 Nm Cut first area free Move spooling tool as sh...

Page 212: ...pect to the correctness of information in this document Copyright by AUDI AG Remove idler pulley and continue cutting window free Replace spool as shown and position idler puller in upper part of window Wire run according to figure Cut window free until the cutting wire is no longer fed through the idler pulley Audi TT 2007 Body Exterior Edition 11 2010 208 Rep Gr 64 Glass Window Regulators ...

Page 213: ... Remove glass pieces from adhesive material Disconnect rear window defroster and window antenna con nectors Bond flange all around with fabric reinforced adhesive tape Remove adhesive material with glass residue from window opening using V A G 1561A and V A G 1561 10 with stop per roll Preparations for Installing Rear Window Note When reusing the undamaged window cut rest of adhesive material on w...

Page 214: ...ed before the application of adhesive sealing material Applying Primer Caution Primer conducts electricity and must not touch rear window defroster distributing wire Apply primer 3 with applicator 2 evenly in one stroke be tween adhesive stopper profiles on window 4 Beginning applying with saturated felt Apply primer over entire width between stopper profiles Drying time 10 minutes Note If the pai...

Page 215: ...ouble suction cups 2 Inner adhesive stopper pro file Prevents adhesive from touching distributing wire 3 Outer adhesive stopper pro file Prevents adhesive from leaking to outside Installation Note Cross section thickness of adhesive bead is determined by di mension of opening in nozzle tip and rate of application Dimensions for adhesive application 1 Adhesive sealing material 2 Primer 3 Window Dim...

Page 216: ...amaged removed window apply adhesive to re maining bead Insert the rear window into window cut out using double suc tion cups Caution The window must be installed within 15 minutes or the adhe sive sealing material will not adhere properly Center window along sides Note distance to upper lid edge 2 mm Observe minimum curing time page 197 2 2 Bolted Windows 2 2 1 Front Door Window page 212 2 2 2 Fr...

Page 217: ...aft Installing Insert in window regula tor in reverse sequence Press window back into window guide and tight en bolts 2 and 6 slightly Run window up into door seal this centers the window in the door opening Using Suction Lifter V A G 1344 press win dow up into seal on roof and forward into seal on A pillar and hold in this position A second technician must tighten bolts 2 and 6 to the specificati...

Page 218: ...to the correctness of information in this document Copyright by AUDI AG 2 2 2 Front Inner Door Plate Cover Removing Cover 1 and cover 3 are each radio dependent Before installing cover check butyl cord 2 and correct if nec essary To install insert centering pin arrow in cover 1 and press cover into inner door plate Audi TT 2007 Body Exterior Edition 11 2010 214 Rep Gr 64 Glass Window Regulators ...

Page 219: ...s of information in this document Copyright by AUDI AG 2 2 3 Rear Inner Door Plate Cover Removing 1 Rear cover Door trim removed Body Interior Rep Gr 70 Removal and Instal lation To remove release re taining tabs arrows on cover using a thin ob ject 2 Door inner panel 3 Seal Before installation check the cover seal and replace if necessary Audi TT 2007 Body Exterior Edition 11 2010 2 Removal and I...

Page 220: ...val Kit for Flush Bonded Windows V A G 1474 A or V A G 1474 B Suction lifter V A G 1344 Cutting tools for glass V A G 1351 Window removing kit V A G 1755 Cartridge gun V A G 1628 Cartridge heater V A G 1939 A Window cutter V A G 1561 A Cutting blade 58 mm V A G 1561 2 Cutting blade U shaped V A G 1561 3 Scraper 25 mm V A G 1561 8 Cutting blade bent at right angle V A G 1561 10 Double cartridge gun...

Page 221: ...d 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 Side window installation tool V A G 1739 and screwdriver Torx T25 T10248 Audi TT 2007 Body Exterior Edition 11 2010 3 Special Tools 217 ...

Page 222: ... 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 Audi TT 2007 Body Exterior Edition 11 2010 218 Rep Gr 64 Glass Window Regulators ...

Page 223: ...Mirror Assembly Overview 1 Exterior rearview mirror housing Removing and instal ling refer to 3 2 2 Mirror Hous ing page 233 2 Bolt 2 Nm 3 Seal Seal set 4 Screws 6 5 Nm 5 Mirror base cover 6 Mirror base 7 Seal Seal set 8 Mirror adjustment electrical wire 9 Door 10 Adjusting piece Used for mirror angle adjustment 11 Carrier plate Must be removed to re move mirror adjusting unit 12 Mirror adjusting ...

Page 224: ...mbly Overview 1 Bolt Quantity 2 0 9 Nm 2 License plate bracket Versions for specific countries Removing and Instal ling refer to 3 4 1 License Plate Bracket page 236 3 Radiator Grille Removing and Instal ling refer to 3 4 3 Radiator Grille page 237 4 Bolt Quantity 4 Tightening Specifica tions and Sequence page 157 5 Right cover Removing and Instal ling refer to 3 4 2 Radiator Grille Cover page 236...

Page 225: ...2 Spoiler TT page 223 2 3 Spoiler TT RS page 224 2 1 Lettering Caution The adhesive surfaces on the body must be free of dirt and grease Clean the adhesive surfaces using cleaning solution D 009 401 04 Warm the adhesive surfaces and lettering to approximate ly 104 F 40 C using a hot air blower After assembly press the lettering with the T10314 Special tools and workshop equipment required Roller T...

Page 226: ...DI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Dimension a 33 mm Dimension b 22 mm Dimension c 27 mm Dimension d 27 mm Dimension e 17 5 mm Dimension e 22 mm Dimension f 4 mm Audi TT 2007 Body Exterior Edition 11 2010 222 Rep Gr 66 Exterior Equipment ...

Page 227: ...Fender Dimensions Pull off the protective film arrow prior to installation Dimension a 41mm Dimension b 42 mm Dimension c 34 mm 2 2 Spoiler TT 2 2 1 Rear Lid Spoiler Gap Dimensions page 223 2 2 1 Rear Lid Spoiler Gap Dimensions Coupe Gap Dimensions The gap dimensions can be checked with the Adjustment Gauge 3371 Dimension D 2 mm Dimension E 2 mm Roadster Gap Dimensions Dimension D 2 mm Dimension E...

Page 228: ...y 1 Connector housing Adhered to the spoiler base plate For bridging the extend able spoiler connector 2 Nut Quantity 9 2 Nm 3 Sealing cord Replacing Secure to the spoiler lower part with instant adhesive AMV 195 KD 101 Process the ends with out a joint 4 Nut Quantity 2 2 Nm 5 Spoiler base plate Removing and Instal ling refer to 3 6 1 Spoiler page 240 Assembly refer to 3 6 2 Spoiler As sembling pa...

Page 229: ...nsparent 13 Double sided adhesive tape Rear 14 Double sided adhesive tape Long straight Quantity 2 15 Upper part of spoiler Assembly refer to 3 6 2 Spoiler Assembling page 241 16 Double sided adhesive tape Rear 17 Foil Transparent 18 Double sided adhesive tape Front 19 Foil Ring shaped Transparent Quantity 5 20 Bolt With collar Quantity 5 Insert with locking compound locking compound refer to elec...

Page 230: ...rt 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 Audi TT 2007 Body Exterior Edition 11 2010 226 Rep Gr 66 Exterior Equipment ...

Page 231: ... 255 3 1 Trim Moldings and Trim 3 1 1 Roof Trim Molding page 227 3 1 2 Roof Trim Molding End Piece page 228 3 1 3 A Pillar Trim page 228 3 1 4 Outer Sill Panel Strip page 229 3 1 5 Lower Sill Panel Cover page 230 3 1 6 Lower Sill Panel Cover Bracket page 230 3 1 7 Upper Sill Panel Cover page 231 3 1 1 Roof Trim Molding Note To remove roof trim molding it is not necessary to remove the side window ...

Page 232: ...m Molding End Piece Removing When installing first slide roof trim molding 1 into window molding 2 on side window then press into clips 2 3 1 3 A Pillar Trim 1 A pillar trim Adhesion surfaces must be free of dust and grease Clean adhesive surfa ces with Cleaning Solu tion D 009 401 04 Align trim on A pillar position and press on firmly 2 Double sided adhesive tape Remove protective pa per before a...

Page 233: ...3 1 4 Outer Sill Panel Strip 1 Outer door sill molding Removing First unclip bottom of sill panel strip then pull front of it up from door flange and remove un der door seal Installing Remove protective film from adhesive tape When installing ensure sill panel strip slides in under door seal on body flange arrow and is pressed onto front of door flange arrow 2 Door seal Outer door seal 3 Door Audi...

Page 234: ... information in this document Copyright by AUDI AG 3 1 5 Lower Sill Panel Cover Removing 1 Bracket for sill panel cover Remove clips 3 quan ity 8 2 Sill panel cover trim 3 Clip Quanity 8 Remove locking pin and remove clip 3 1 6 Lower Sill Panel Cover Bracket Removing Bolt 5 2 Nm Bolt Clip 3 inserted in fender 2 Secure bracket 4 with bolts 5 Audi TT 2007 Body Exterior Edition 11 2010 230 Rep Gr 66 ...

Page 235: ...er 1 Clip 2 Sill panel cover trim Sill panel strip removed Remove bolts 3 under sill panel strip and unclip clips from bottom side Unclip trim on lower A pillar and from side pan el and remove 3 Bolt 1 5 Nm 3 2 Exterior Rearview Mirror 3 2 1 Mirror Glass page 231 3 2 2 Mirror Housing page 233 3 2 3 Electric Mirror Adjusting Unit page 234 3 2 1 Mirror Glass Special tools and workshop equipment requ...

Page 236: ...ottom edges of the mirror housing from damage using cloth adhesive tape Press mirror glass 1 off of the mirror adjusting unit first at the bottom and then at the top using the 80 200 Installation Always use protective gloves when installing Insert mirror glass 2 into the guide pins of carrier adjusting unit 1 and the friction finger into the friction spring and press on Only put pressure on center...

Page 237: ... mirror heating elec trical connectors Fold mirror all the way forward Remove bolt 6 on mir ror base Remove housing up ward from mirror base Installation is reverse of removal noting the fol lowing Note When installing hous ing must be pressed completely onto hous ing base before it is fol ded back 2 Bolt 2 Nm 3 Carrier plate 4 Bolt 6 5 Nm 5 Mirror base housing Mirror housing removed Remove bolts ...

Page 238: ...ed forward when pressed onto the adapter and is then tilted back into the installation position The adapter then engages in the carrier plate Removing Mirror Housing Remove bolts arrows from bottom side of housing and from carrier plate Remove carrier plate from housing 3 2 3 Electric Mirror Adjusting Unit Removing Screws 1 Nm Remove mirror glass Refer to 3 2 1 Mirror Glass page 231 Remove bolts a...

Page 239: ...ty with respect to the correctness of information in this document Copyright by AUDI AG 3 3 Radiator Grille Audi TT 3 3 1 Radiator Grille page 235 3 3 1 Radiator Grille 1 Bolt 1 Nm 2 Radiator Grille Remove bolts loosen clips in stages and dis engage radiator grille from bumper 3 Front Bumper Bumper removed Audi TT 2007 Body Exterior Edition 11 2010 3 Removal and Installation 235 ...

Page 240: ...red grille arrow while detaching clips 4 Remove the license plate bracket Installation For the correct tightening specifications refer to 1 2 1 License Plate Bracket Assembly Overview page 220 Install in reverse order of removal Note the following The license plate bracket must be fully inserted into the hon eycomb structured grille 3 4 2 Radiator Grille Cover Removing Unlock spring clip 2 on the ...

Page 241: ... from mount 5 arrow Remove radiator grille 6 from the bumper Installation For the correct tightening specifications refer to 1 2 1 License Plate Bracket Assembly Overview page 220 Install in reverse order of removal Note the following Press on the radiator grille until it engages completely Install the bumper Refer to 2 4 1 Rear Bumper page 182 Install the license plate bracket Refer to 3 4 1 Lice...

Page 242: ...and bond to spoiler Insert spoiler in drive unit and align slides top and bottom With assistants press spoiler in evenly and hold firmly Open lid and tighten bolts 4 through water drain hose opening Install water drain hose ensuring it is seated correctly and does not leak 2 Adjusting element Always replace Clip into spoiler The adjusting elements are self adjusting That means height differences c...

Page 243: ...ling Installation is performed in the reverse order of removal Note 6 Water drain hose Always replace 7 Clip 8 Nut Note 2 Nm 9 Stop Self adhesive 3 5 2 Front Wheel Spoiler 1 Lower part of wheel housing liner Wheel spoiler removed Remove bolts 2 from bottom part and remove under upper part of wheel housing liner 2 Bolt 2 Nm 3 Wheel spoiler To remove remove bolts 2 4 Upper part of wheel housing line...

Page 244: ...2 Nm 4 Wheel spoiler Slide wheel spoiler in under wheel housing lin er as shown Loosen wheel housing liner in wheel spoiler area and move to side Remove bolt 2 and nut 3 and remove wheel spoiler 5 Rear Wheel Housing Liner 3 6 Spoiler TT RS 3 6 1 Spoiler page 240 3 6 2 Spoiler Assembling page 241 3 6 1 Spoiler Note After painting the spoiler of the TT RS is assembled from the components shown in th...

Page 245: ...art of the spoiler Installation For the correct tightening specifications refer to 2 3 1 Rear Spoiler Assembly Overview page 224 Install in reverse order of removal Note the following Attach the control cable at the mount Refer to 2 4 1 Rear Lid page 59 Install the lower rear lid trim Refer to Body Interior Rep Gr 70 Removal and Installation 3 6 2 Spoiler Assembling Note After painting the spoiler...

Page 246: ...r components Place the spoiler base plate on a soft clean surface on the workbench Remove the protective film on the attachment points arrow Rotate the spoiler base plate The threaded pins point up Clean the sealing cord recess with cleaning solution D 009 401 04 Secure sealing cord 1 in the recess with instant adhesive AMV 195 KD 101 2 The start and end of the sealing cord must be in the back in ...

Page 247: ...hesive tape 1 and 3 to the outside of attachment surface 2 on the left and right as shown in the figure Screw in the hex socket screws with the dimensions a and b as centering pins in the 3 center mounting holes of the spoiler upper part Dimension a approximately 9 8 mm Dimension b 5 5 mm Place the spoiler center part on a soft clean surface on the workbench Remove the protective films on the cont...

Page 248: ...tape 3 through 6 to spoiler center part 2 as shown in the figure Rotate the spoiler center part with the upper part Adhere ring shaped films arrows to the attachment points Remove all protective films of the double sided adhesive tape and attach spoiler center part 1 via centering aids 2 to spoiler upper part 3 Manually press the parts firmly together Coat the screws including the collar with lock...

Page 249: ...e sided adhesive tape on spoiler upper part 2 Manually press the cap firmly on Clean the base plate and spoiler center part of the adhesion area arrow with cleaning solution D 009 401 04 Position the spoiler center part with the upper part on the base plate and secure it on the left and right with two screws each arrows Check the gap size arrows between spoiler base plate 1 and spoiler center part...

Page 250: ...opening 1 Press glue into the bore hole until it comes out of the other bore hole 2 Repeat the process on the opposite side WARNING Note that the minimum curing time is 3 hours The vehicle can only be used after the minimum curing time has elapsed Use the glue cartridge from the installation kit to place an ad hesive bead around the screw heads arrows of the left and right screws and spread Apply ...

Page 251: ...t any liability with respect to the correctness of information in this document Copyright by AUDI AG Position bridging connector 2 as shown in the figure between the markings arrows and manually press on it until the glue is firm Bridging wire 1 must point to the left in the direction of travel Audi TT 2007 Body Exterior Edition 11 2010 3 Removal and Installation 247 ...

Page 252: ...unnel Heat Shield page 250 3 7 4 Center Bearing Heat Shield page 251 3 7 5 Center Muffler Heat Shield page 252 3 7 6 End Muffler Heat Shield page 253 3 7 7 Center Muffler Trim page 254 3 7 8 Trim Angled Bracket page 254 3 7 1 Noise Insulation 1 Bolt 6 Nm 2 Bolt 2 Nm 3 Noise Insulation Removing Remove the bolts 1 and 2 and remove the noise insulation toward the rear under the bumper When installing...

Page 253: ...rantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 3 7 2 Bulkhead Heat Shield Removing 1 Nut 2 Nm 2 Heat shield 3 Bulkhead insulation Routed on joint over center tunnel insulation as shown 4 Center tunnel insulation Audi TT 2007 Body Exterior Edition 11 2010 3 Removal and Installation 249 ...

Page 254: ...less 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 3 7 3 Center Tunnel Heat Shield 1 Bolt 8 Nm 2 Heat shield 3 Nut 8 Nm Audi TT 2007 Body Exterior Edition 11 2010 250 Rep Gr 66 Exterior Equipment ...

Page 255: ...ted 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 3 7 4 Center Bearing Heat Shield 1 Bolt 8 Nm 2 Heat shield Audi TT 2007 Body Exterior Edition 11 2010 3 Removal and Installation 251 ...

Page 256: ...r accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 3 7 5 Center Muffler Heat Shield Removing 1 Lock washer When removing re move from threaded pins When installing lock washer is driven onto threaded pins 2 Nut 2 Nm 3 Heat shield Audi TT 2007 Body Exterior Edition 11 2010 252 Rep Gr 66 Exterior Equipment ...

Page 257: ...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 3 7 6 End Muffler Heat Shield Removing 1 Nut 4 5 Nm 2 Heat shield Audi TT 2007 Body Exterior Edition 11 2010 3 Removal and Installation 253 ...

Page 258: ...ity with respect to the correctness of information in this document Copyright by AUDI AG 3 7 7 Center Muffler Trim Removing 1 Center muffler trim 2 Nut 2 Nm 3 Bolt 2 Nm 3 7 8 Trim Angled Bracket Removing Secure angled bracket 3 with bolt 5 and nut 2 on mounting frame 4 Clip 1 pressed into angled bracket Audi TT 2007 Body Exterior Edition 11 2010 254 Rep Gr 66 Exterior Equipment ...

Page 259: ... Liner page 255 3 8 2 Rear Wheel Housing Liner page 256 3 8 1 Front Wheel Housing Liner 1 Front Wheel Housing Liner Removing Press in front wheel ac cordingly Remove all bolts and nuts from wheel housing liner Remove expanding clips from wheel hous ing liner and from front sill panel cover Disengage wheel hous ing liner from fender and pull downward and out Installation in reverse order 2 Expandin...

Page 260: ...d bolts Item 3 page 256 Vehicles with an ex panding clip page 256 Remove wheel housing liner downward Installation in reverse order 2 Nut 2 Nm 3 Screws 1 5 Nm 4 Side panel 5 Expanding nut Pressed into side panel Rear Wheel Housing Liner with Expanding Clip Remove the screws arrows from the wheel housing liner and remove expanding clip 3 To remove the expanding clip press in clamping pin 1 care ful...

Page 261: ...ctness of information in this document Copyright by AUDI AG 4 Special Tools Special tools and workshop equipment required Roller T10314 Hot air gun V A G 1416 Instant adhesive AMV 195 KD 101 Locking compound D 000 006 Cleaning solution D 009 401 04 2K plastic adhesive D 180 KU2 A1 3 hex socket screws M6 x 5 5 mm Pry lever 80 200 Edition 06202011 Audi TT 2007 Body Exterior Edition 11 2010 4 Special...

Page 262: ...rts and specifications are made applicable to earlier models Therefore part numbers listed in this manual are for reference only Always check with your authorized Audi retailer parts department for the latest information Any time the battery has been disconnected on an automatic transmission vehicle it will be necessary to reestablish Transmission Control Module TCM basic settings using the VAG 15...

Page 263: ...Finger rings should be removed so that they cannot cause electrical shorts get caught in running machinery or be crushed by heavy parts Before starting a job make certain that you have all the necessary tools and parts on hand Read all the instructions thoroughly do not attempt shortcuts Use tools that are appropriate to the work and use only replacement parts meeting Audi specifications Makeshift...

Page 264: ...at automatically deploys an airbag in the event of a frontal impact The airbag is operated by an explosive device Handled improperly or without adequate safeguards it can be accidentally activated and cause serious personal injury To guard against personal injury or airbag system failure only trained Audi Service technicians should test disassemble or service the airbag system Do not quick charge ...

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