Audi TT Platform 2009 Quick Reference Download Page 116

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Electrical Equipment

Audi TT Quick Reference Specification Book • May 2009

107

ELECTRICAL EQUIPMEnT

Battery – Tightening Torques

Location/Fastener

Battery post terminals/nuts

Battery post terminals/additional

terminal nuts

Battery hold-down bracket bolt

M8 x 35

Generator – Tightening Torques

Component

B+-wire to generator nut

Harness retainer to generator

Voltage regulator to generator screw

Protective cap to generator

Ribbed belt pulley with freewheel to

generator nut

M10

Ribbed belt pulley without freewheel to

generator nut

M10

Generator 2.0LTFSI – Tightening Torques

Component

Generator to mounting bracket bolts

M8 x 90

Tensioner to mounting bracket bolts

M8 x 90

Mounting bracket to engine block bolts

M10 x 45

A/C compressor to mounting bracket

M8 x 100

2.0L TFSI Generator Mounting Bracket Bolts –

Tightening Sequence

Component

A – B – C – D – E – F

Summary of Contents for TT Platform 2009

Page 1: ...2009 TT Platform Quick Reference Specification Book...

Page 2: ...ection Ignition 15 General Technical Data 15 Engine Number Location 2 0L CCTA 15 Engine Number Location 3 2L CBRA 16 Engine Data 16 Engine Removing and Installing 18 Engine to Transmission Tightening...

Page 3: ...ton Ring End Gaps 30 Piston Ring Clearance 31 Piston and Cylinder Dimensions 31 Cylinder Head 2 0L Engine CCTA 31 Crankcase Ventilation Tightening Sequence 31 Cylinder Head Tightening Torques 32 Cylin...

Page 4: ...ystem Components on Engine Tightening Torques 47 Cooling System Components on Body Tightening Torques 47 Recommended Coolant Mixture Ratios 47 Fuel Storage and Supply 2 0L CCTA 3 2L CBRA 47 Fuel Pump...

Page 5: ...Retainer Tightening Torques 60 Manual Transmission Installing 02Q 61 02Q Selector Mechanism Tightening Torques 61 02Q Transmission To Engine Tightening Torques 61 02Q Transmission Tightening Torques...

Page 6: ...ount Tightening Torques 73 Rear Final Drive 74 Identification 74 Identification Code Letters Allocation Gear Ratios and Capacities 77 Rear Final Drive Tightening Torques 78 Suspension Wheels Brakes St...

Page 7: ...ront Brakes Technical Data 88 Rear Brakes Front Wheel Drive Technical Data 89 Hydraulic Unit Brake Booster Brake Master Cylinder ABS Mark 70 ABS ASR and 60 ABS EDL ASR ESP Tightening Torques 90 ABS Sy...

Page 8: ...ousing Liner Tightening Torques 101 Rear View Mirror Tightening Torques 101 Radiator Grille Tightening Torques 101 Strips and Trim Tightening Torques 101 Body Interior 101 Storage Compartment Tighteni...

Page 9: ...ning Torques 108 Front Wiper Motor Tightening Torques 108 Washer Reservoir Tightening Torques 108 Rear Wiper Washer Tightening Torques 108 Headlamp Washer Spray Jets Tightening Torques 108 Front and R...

Page 10: ...0157 4 0 0 157 40 1 57 0 100 0 00394 0 50 0 0197 5 0 0 197 50 1 97 0 200 0 00787 0 60 0 0236 6 0 0 236 60 2 36 0 300 0 01181 0 70 0 0276 7 0 0 276 70 2 76 0 400 0 01575 0 80 0 0315 8 0 0 315 80 3 15 0...

Page 11: ...24 18 69 51 170 125 25 18 70 52 175 129 26 19 71 52 180 133 27 20 72 53 185 136 28 21 73 54 190 140 29 21 74 55 195 144 30 22 75 55 200 148 31 23 76 56 205 151 32 24 77 57 210 155 33 24 78 58 215 159...

Page 12: ...5 133 153 40 354 408 16 142 163 41 363 418 17 150 173 42 372 428 18 159 184 43 381 438 19 168 194 44 389 449 20 177 204 45 398 459 21 186 214 46 407 469 22 195 224 47 416 479 23 204 235 48 425 489 24...

Page 13: ...or a suitable workplace for any procedure described in this manual we suggest you leave such repairs to an authorized dealer service department or other qualified shop Do not reuse any fasteners that...

Page 14: ...ert Illuminate your work area adequately but safely Use a portable safety light for working inside or under the car Make sure the bulb is enclosed by a wire cage The hot filament of an accidentally br...

Page 15: ...second time Do not allow battery charging voltage to exceed 16 5 volts If the battery begins producing gas or boiling violently reduce the charging rate Boosting a sulfated battery at a high charging...

Page 16: ...er seek medical attention Aerosol cleaners and solvents may contain hazardous or deadly vapors and are highly flammable Use only in a well ventilated area Do not use on hot surfaces such as engines or...

Page 17: ...tery cables before disconnecting On some models battery cables are not color coded Disconnecting the battery may erase fault code s stored in control module memory Check for fault codes prior to disco...

Page 18: ...E 5W 30 or SAE 0W 40 n A TT quattro 8J359L Coupe 8J959L Roadster 2 0 TFSI 200 hp CCTA 4 5L 4 8 qt Audi oil Spec VW 502 00 Use synthetic oil SAE 5W 40 SAE 5W 30 or SAE 0W 40 9 0L 9 5 qt TTS quattro 8J3...

Page 19: ...n VIN on Lower Edge of Front Window The VIN is on the left side of the vehicle in the windshield in the area of the windshield wiper mount It is visible from the outside VIN on Suspension Strut Mount...

Page 20: ...Vehicle Identification Audi TT Quick Reference Specification Book May 2009 11 VIN Decoder...

Page 21: ...A is fastened behind the right strut tower on the plenum chamber Vehicle Data Sticker The vehicle data sticker is located in the left rear of the vehicle in the spare wheel well under the foam storage...

Page 22: ...es Audi TT Quick Reference Specification Book May 2009 13 Sales Codes Engine Codes CCTA 2 0L 4 cylinder 4V turbo CBRA 3 2L 6 cylinder 4V Transmission Codes 02Q 6 speed manual 02E 6 speed direct shift...

Page 23: ...ints for Lifting Platform and Trolley Jack Front On the floor longitudinal reinforcement in the area of the marking Rear On aluminum case part in front of rear axle mounting point Note The support pla...

Page 24: ...Number Location 2 0L CCTA The engine number engine code and serial number is located at the left on the engine transmission partition The engine code is also stamped on the right side of the cylinder...

Page 25: ...ter 3 189 3 189 Output kW at RPM 184 6300 184 6300 Torque Nm at RPM 320 2500 to 3000 320 2500 to 3000 Bore dia mm 84 84 Stroke mm 95 9 95 9 Compression ratio 10 85 10 85 RON at least 98 1 98 1 Fuel in...

Page 26: ...t gas recirculation No No Variable intake manifold No No Variable valve timing Yes Yes Secondary Air Injection AIR No No 1 Unleaded RON 95 is also permissible although with reduced power Engines Gasol...

Page 27: ...orques CBRA Components Bolt Size Nm Bolts nuts M6 10 M7 15 M8 22 M10 40 M12 65 Exceptions Ground GND wire 22 Manual Transmission to Engine Item Bolt Nm 11 3 M12 x 55 80 22 M12 x 65 80 4 52 M10 x 50 40...

Page 28: ...Quick Reference Specification Book May 2009 19 Direct Shift Automatic Transmission to Engine Mounting Item Bolt Nm 1 3 6 M12 x 55 80 2 4 M10 x 45 Starter Mount 40 5 10 M12 x 65 80 7 8 M10 x 50 40 9 M1...

Page 29: ...onal 90 turn Support to mounting at body always replace 20 plus an additional 90 turn Transmission assembly mount to body always replace 60 plus an additional 90 turn Transmission assembly mounting br...

Page 30: ...ft Cylinder Block 4 Cylinder Turbo Engine 2 0L CCTA Accessory Assembly Bracket Tightening Sequence Tighten bolts in three stages as follows Step Component Nm 1 Tighten bolts 1 5 in sequence Hand tight...

Page 31: ...180 turn Rear toothed belt cover bolt 10 Semi automatic tensioning roller to rear tooth belt cover bolt 25 Damper roller to rear toothed belt cover bolt 25 Coolant pump bolt 15 Damper roller to sealin...

Page 32: ...nt Nm 1 Tighten bolts 1 8 in sequence Hand tighten 2 Tighten bolts 1 8 in sequence 9 Flywheel Drive Plate Tightening Torques Component Nm Flywheel drive plate to cylinder block bolt 60 plus an additio...

Page 33: ...Crankshaft Assembly Tightening Sequence Step Component Nm 1 Tighten bolts 1 10 in sequence and Hand tighten 2 Tighten bolts 1 10 in sequence 65 3 Tighten bolts 1 10 in sequence An additional 90 turn 4...

Page 34: ...shells are allocated to the cylinder block with the correct thickness from the factory Colored spots serve to identify the bearing thicknesses The letters marked on the lower sealing surface of the cy...

Page 35: ...to 0 50 0 8 Piston Ring Clearance Piston ring Ring to groove clearance New Wear limit Compression rings mm 0 04 to 0 08 0 15 Oil scraping ring mm 0 02 to 0 06 0 15 Piston and Cylinder Dimensions Honi...

Page 36: ...pecification Book May 2009 27 Crankshaft Cylinder Block 6 Cylinder 3 2L CBRA Accessory Assembly Bracket Tightening Sequence Tighten bolts in two stages as follows Step Component Nm 1 Tighten bolts 1 5...

Page 37: ...1 in sequence 10 Assembly Attachments Mounting Tightening Torques Component Nm Assembly bracket bolts 23 Bracket with lower relay pulley for ribbed belt for A C compressor to assembly bracket bolt 25...

Page 38: ...ant pump ribbed pulley bolts 20 Idler roller bolts 40 Dual mass flywheel bolts 60 plus an additional 90 turn Cylinder block locking bolt 30 Knock Sensor KS 1 G61 to cylinder block bolt 20 Knock Sensor...

Page 39: ...r 30 Crankshaft Assembly Tightening Torques Component Nm Bearing cap to cylinder block bolts 30 plus an additional 180 turn Crankshaft Dimensions Reconditioning dimension dimensions in mm Crankshaft b...

Page 40: ...sion ring 0 04 to 0 09 0 15 Tapered ring 0 03 to 0 06 0 15 Oil scraping ring 0 02 to 0 06 0 15 Piston and Cylinder Dimensions Reconditioning dimension dimensions in mm Piston diameter Cylinder bore di...

Page 41: ...ng to cylinder head cover bolt 4 Camshaft adjustment valve 1 N205 to housing bolt 4 Cable bracket to housing bolt 10 Housing to cylinder block bolt 10 Transport strap to cylinder block bolt 25 Stud bo...

Page 42: ...on Book May 2009 33 Cylinder Head Tightening Sequence Step Component Nm 1 Tighten bolts 1 5 in sequence 40 2 Tighten bolts 1 5 in sequence An additional 90 turn 3 Tighten bolts 1 5 in sequence An addi...

Page 43: ...34 Audi TT Quick Reference Specification Book May 2009 Cylinder Head Valve Cover Loosening Sequence Loosen cylinder head cover bolts 1 to 6 in sequence...

Page 44: ...p Component Nm 1 Replace bolts and tighten bolts 1 6 in sequence Hand tighten in several stages 2 Tighten bolts 1 6 in sequence 8 3 Tighten bolts 1 6 in sequence An additional 90 turn Compression Pres...

Page 45: ...er to cylinder block bolts 10 Chain case cover to cylinder head 10 Coolant distribution housing to chain case cover 10 Chain tensioner for camshaft timing chain 40 Camshaft adjustment valve 1 N205 to...

Page 46: ...9 37 Cylinder Head Tightening Sequence Tighten bolts 1 to 20 in four stages as follows Step Component Nm 1 Tighten bolts 1 20 in sequence Hand tighten 2 Tighten bolts 1 20 in sequence 30 3 Tighten bol...

Page 47: ...etrain 2 0L Engine CCTA Valvetrain Tightening Torques Component Nm Camshaft sprocket to cylinder head bolt 50 plus an additional 180 turn Bearing bracket bolts 8 plus an additional 90 turn Camshaft ad...

Page 48: ...on Book May 2009 39 Valve Dimensions Dimension Intake valve Exhaust valve Dia a mm 33 85 0 10 28 0 0 1 Dia b mm 5 98 0 01 5 96 0 01 c mm 104 0 0 2 101 9 0 2 degrees 45 45 Camshaft Tightening Torques C...

Page 49: ...90 turn Chain sprocket for exhaust camshaft bolt 60 plus an additional 90 turn Camshaft adjuster for intake camshaft bolt 60 plus an additional 90 turn Valve Dimensions Dimension Short intake valve Lo...

Page 50: ...on Ignition Audi TT Quick Reference Specification Book May 2009 41 Camshaft Tightening Sequence Camshaft Tightening Torques Component Nm Bearing cap to cylinder head 5 plus an additional 45 Control ho...

Page 51: ...rication 2 0L CCTA Oil Pan Upper Section Tightening Sequence Tighten bolts in three stages as follows Step Component Nm 1 Tighten bolts 1 14 in sequence Hand tighten 2 Tighten bolts 1 14 in sequence 1...

Page 52: ...ion Book May 2009 43 Oil Pan Lower Section Tightening Sequence Tighten bolts in three stages as follows Step Component Nm 1 Tighten bolts 1 20 in sequence Hand tighten 2 Tighten bolts 1 20 in sequence...

Page 53: ...15 Oil drain plug to oil pan bolt 15 Oil level thermal sensor G266 protective cap bolt 10 Chain sprocket to oil pump with balance shaft drive bolt 20 plus an additional 90 turn Oil pump with balance...

Page 54: ...ning Torques Component Nm Oil pump drive cover 8 Oil filter bracket with attachments to cylinder block bolt 23 Oil pump to cylinder block bolt 23 Intermediate shaft 10 Oil level thermal sensor G266 10...

Page 55: ...bolt 5 Coolant Pump Tightening Sequence Step Component Nm 1 Tighten bolts 1 5 in sequence 9 Coolant Pump Tightening Torques Component Nm Drive gear to toothed belt bolts 10 plus an additional 90 turn...

Page 56: ...ion housing to pipe connection nut 10 Automatic Transmission Fluid ATF cooler coolant line nut only for vehicles with automatic transmission 10 Cooling System Components on Body Tightening Torques Com...

Page 57: ...cket bolt 3 Bolt cup for fuel filter 3 Accelerator Pedal Module Tightening Torques Component Nm Accelerator pedal module to body bolt 9 EVAP Canister System Tightening Torques Component Nm EVAP canist...

Page 58: ...n Book May 2009 49 Turbocharger 2 0L CCTA Turbocharger Tightening Sequence Tighten bolts in four stages as follows Step Component Nm 1 Tighten bolts 1 5 in sequence 5 2 Tighten bolts 1 5 in sequence 1...

Page 59: ...ine to turbocharger bolts 20 plus an additional 45 1 8 turn Coolant supply line bracket bolt 30 Coolant supply line bolt 9 Oil return line bolts 9 Oil return line to turbocharger bolts 9 Turbocharger...

Page 60: ...Idle speed RPM 620 to 800 Engine control module System designation Motronic MED 9 1 Replacement part number Electronic Parts Catalog ETKA Engine speed RPM limitation RPM Approximately 6800 Fuel press...

Page 61: ...e manifold support nut 10 Throttle valve control module J338 bolts 5 Fuel pressure sensor G247 27 Intake manifold bolts 9 Retaining clip stud bolt 10 Fuel supply line union nut 18 Throttle valve contr...

Page 62: ...ector same on all valves Injection quantity 30 s 128 to 140 ml 1 Current values Data sheets for exhaust emission test Intake Manifold Tightening Torques Component Nm Intake manifold to cylinder head 1...

Page 63: ...to turbocharger nuts 40 Tunnel brace bolts 23 Mount to subframe 25 Exhaust System 3 2L CBRA Exhaust System Tightening Torques Component Nm Front exhaust pipe to exhaust manifold 40 Catalytic converte...

Page 64: ...fold 9 Secondary Air Injection AIR pump to bracket 9 Secondary Air Injection AIR pump bracket M6 9 To cylinder block M8 20 Ignition System 2 0L CCTA 3 2L CBRA Ignition Tightening Torques Component Nm...

Page 65: ...TT Quick Reference Specification Book May 2009 Manual Transmission General Technical Data 02Q Transmission Identification Identification and date of construction 1 Manual transmission 02Q All Wheel D...

Page 66: ...on Audi TT Quick Reference Specification Book May 2009 57 Manual transmission 02Q All Wheel Drive 2 Transmission code letters and date of manufacture Example GUM 04 08 3 Code letters Day Month Year 20...

Page 67: ...47 14 3 357 47 14 3 357 47 14 3 357 2nd Gear 48 23 2 087 48 23 2 087 48 23 2 087 3rd Gear 47 32 1 469 47 32 1 469 47 32 1 469 4th Gear 37 34 1 088 37 34 1 088 37 34 1 088 5th Gear 41 37 1 108 41 37 1...

Page 68: ...ch pedal to mounting bracket replace self locking nut 25 Hydraulic System Tightening Torques Component Nm Self locking nut 25 Hydraulic system bolts 20 Slave Cylinder Tightening Torques Component Nm M...

Page 69: ...iner Dimensions Allocation of cable retainers Dimension a mm Shift cable to transmission shift lever 10 Selector cable to relay lever 8 Shift Cable Retainer Tightening Torques Component Nm Shift mecha...

Page 70: ...6 8 02Q Transmission To Engine Tightening Torques Item Bolt Nm 11 3 M12 x 55 80 22 M12 x 65 80 4 52 M10 x 50 40 62 M12 x 80 80 A Alignment sleeves for centering 1 Bolt with threaded pin M8 2 Install i...

Page 71: ...flywheel 10 Right drive axle heat shield to cylinder block 25 Cable mounting bracket to transmission 20 Ground GND wire to upper starter bolt 23 Bracket for electrical wiring to lower starter bolt 23...

Page 72: ...or 1st and 2nd gear C Selector rod for 5th and 6th gear D Reverse gear shift fork 02Q Input Shaft Output Shaft Pinion Shaft Differential and Shift Forks Tightening Torques Component Nm Reverse gear sh...

Page 73: ...ce Specification Book May 2009 Automatic Transmission General Technical Data 02E Transmission Identification Example GKF Transmission code 10 05 2 Production date May 10th 2002 The rest of the numbers...

Page 74: ...tios Final drive I for 1st to 4th gear 72 15 4 800 69 17 4 059 72 15 4 800 Z2 Z1 Final drive II for 5th 6th gear and reverse gear 72 20 3 600 69 22 3 136 72 20 3 600 1st gear 44 15 2 933 45 13 3 462 4...

Page 75: ...o 4th gear 72 15 4 800 72 15 4 800 72 15 4 800 Z2 Z1 Final drive II for 5th 6th gear and reverse gear 72 20 3 600 72 20 3 600 72 20 3 600 1st gear 44 15 2 933 44 15 2 933 44 15 2 933 2nd gear 44 24 1...

Page 76: ...15 4 800 62 13 4 769 72 15 4 800 62 13 4 769 Z2 Z1 Final drive II for 5th 6th gear and reverse gear 72 20 3 600 62 18 3 444 72 20 3 600 62 18 3 444 1st gear 44 15 2 933 38 13 2 923 44 15 2 933 38 13 2...

Page 77: ...Transmission Controls 02E 02E Selector Mechanism Tightening Torques Component Nm Selector lever and selector mechanism bolt with spring 3 5 Mounting bracket bolts 20 plus an additional 90 turn Shift...

Page 78: ...pport overflow tube 8mm hex socket head 3 Mechatronic cover bolts 10 Oil pump cover bolts install bolts in a diagonal sequence 8 Cable bracket on large cover nuts 10 02E Direct Shift Gearbox DSG Mecha...

Page 79: ...e Specification Book May 2009 02E Oil Pan Tightening Torques Component Nm Tighten the bolts diagonally in steps 16 02E Drain Plug and Filter housing Tightening Torques Component Nm Oil drain plug M24...

Page 80: ...2E Transmission To 2 0L TFSI Engine Tightening Torques Item Bolt Nm 1 31 M12 x 55 80 2 M10 x 45 Starter Mount 40 4 M10 x 40 Starter Mount 40 5 M12 x 65 80 6 7 8 M10 x 50 40 9 M12 x 70 80 10 M12 x 55 8...

Page 81: ...50 40 9 M10 x 45 40 A Alignment sleeves for centering 02E Oil Cooler Tightening Torques Component Nm Oil cooler bolts replace bolts 20 plus an additional 45 1 8 turn 02E Oil Pump Tightening Torques S...

Page 82: ...e Specification Book May 2009 73 02E Transmission Mount Tightening Torques Component Nm Transmission mount to body replace bolts 40 plus an additional 90 turn Transmission mount to transmission suppor...

Page 83: ...74 Audi TT Quick Reference Specification Book May 2009 Rear Final Drive Identification Part number transmission code and rear final drive production date...

Page 84: ...Specification Book May 2009 75 Rear final drive 02D A Rear final drive part number B Rear final drive code letters C Rear final drive production date Example 02D 525 010 AQ HEZ 12 01 04 Part number Co...

Page 85: ...ference Specification Book May 2009 Rear final drive 0AV A Rear final drive part number B Rear final drive code letters C Rear final drive production date Example HHJ 09 08 05 Code letters Day Month P...

Page 86: ...3 2 L 184 kW 3 2 L 184 kW 3 2 L 184 kW Gear ratio Z2 Z1 Rear final drive 27 17 1 588 27 17 1 588 27 17 1 588 Drive shaft flange dia 100 mm 100 mm 100 mm Capacity in final drive 0 95 liters Capacity in...

Page 87: ...cement capacity in Haldex clutch 1 0 65 liters 1 Change interval See Maintenance Service Circular for appropriate model and year Please retrieve the following information from Electronic Parts Catalog...

Page 88: ...nuts when dimension a between wheel hub center and lower edge of wheel housing is reached Subframe Tightening Torques Threaded connection Thread Nm To body M12 x 1 5 x 100 70 plus an additional 90 tur...

Page 89: ...tening Torques Threaded connection Thread Nm To subframe M8 x 80 70 plus an additional 90 turn To coupling rod M12 65 Coupling rod to suspension strut M12 65 Pendulum Support Tightening Torques Thread...

Page 90: ...iagonal sequence to M8 x 48 M10 x 52 M10 x 23 40 70 70 Intermediate shaft to mounting bracket M8 x 25 20 Wheel Bearing Housing Tightening Torques Threaded connection Thread Nm Wheel hub with wheel bea...

Page 91: ...es Threaded connection Thread Nm Eccentric bolt and nut to lower transverse link M12 x 1 5 95 Eccentric bolt and nut to upper transverse link M12 x 1 5 95 Stone impact protection on transverse link M6...

Page 92: ...ielding plate M6 x 12 10 Trailing Link Tightening Torques Threaded connection Thread Nm To wheel bearing housing M12 x 25 90 plus an additional 45 1 8 turn To mounting bracket M12 x 1 5 x 80 90 plus a...

Page 93: ...ded connection Thread Nm To lower transverse link M12 x 1 5 95 To upper transverse link M12 x 1 5 95 To body M12 x 1 5 x 125 90 plus an additional 90 turn To tie rod M12 x 1 5 x 100 90 plus an additio...

Page 94: ...ielding plate M6 x 12 10 To speed sensor M6 x 16 8 Trailing Link Tightening Torques Threaded connection Thread Nm To wheel bearing housing M12 x 25 90 plus an additional 90 turn To mounting bracket M1...

Page 95: ...To wheel hub M16 x 1 5 x 80 200 plus an additional 180 turn Wheels Tires Wheel Alignment Wheel Bolts Tightening Torques Model type Nm Audi models except RS 2 and RS 4 type 8D 120 RS 2 130 RS 4 type 8...

Page 96: ...e AMR 1BQ Individual toe 5 5 5 5 5 5 5 5 Total toe 10 10 10 10 10 10 10 10 Camber 41 30 41 30 41 30 41 30 Maximum permissible difference between both sides max 30 max 30 max 30 max 30 Toe differential...

Page 97: ...20 30 1 20 30 1 20 30 1 20 30 Maximum permissible difference between both sides max 30 max 30 max 30 max 30 Light Alloy Wheels with Metal Valve Tightening Torques Component Nm Metal valve hex nut 4 D...

Page 98: ...Rear Brakes Front Wheel Drive Technical Data Rear wheel brake Front wheel drive Brake caliper PR number 2ED 1KZ Rear brake caliper CII 38HR CII 38HR Pistons dia mm 38 38 Brake disc PR number 2ED 2EE...

Page 99: ...2 Brake disc wear limit mm 9 9 19 19 19 Brake pads Pad thickness new not including backing plate mm 12 12 12 12 12 Brake pad wear limit not including backing plate mm 2 2 2 2 2 Hydraulic Unit Brake Bo...

Page 100: ...line to brake hose FNR G 12 Rear Brakes Disc Brakes Rear Brake CII CII 38 Tightening Torques Component Nm ABS speed sensor to stub axle Rear 8 Wheel bearing housing multipoint socket head bolts 90 plu...

Page 101: ...t shield self locking hex nuts always replace 20 Master brake cylinder secondary piston circuit to hydraulic unit brake line 14 Master brake cylinder primary piston circuit to hydraulic control unit b...

Page 102: ...rmediate plate screws 9 Driver s side instrument panel cover mounting bracket screws 3 Universal joint to steering gear M8 x 32 20 plus an additional 90 turn Lower steering column trim to steering col...

Page 103: ...4 Audi TT Quick Reference Specification Book May 2009 Body Body Dimensions Front Dimensions Component mm A 4 5 mm 0 5 mm B 4 5 mm 0 5 mm C 3 5 mm 0 5 mm D 3 5 mm 0 5 mm E 3 5 mm 0 5 mm F 3 5 mm 0 5 mm...

Page 104: ...Body Audi TT Quick Reference Specification Book May 2009 95 Center Dimensions Component mm A 3 5 mm 0 5 mm B 3 5 mm 0 5 mm C 0 mm to 1 mm D 0 mm to 1 mm E 3 5 mm 0 5 mm...

Page 105: ...96 Audi TT Quick Reference Specification Book May 2009 Rear Coupe Dimensions Component mm A 4 5 mm 0 5 mm B 3 5 mm 0 5 mm C 4 0 mm 0 5 mm D 2 0 mm 0 5 mm E 2 0 mm 0 5 mm...

Page 106: ...Body Audi TT Quick Reference Specification Book May 2009 97 Component mm A 4 0 mm 0 5 mm B 4 5 mm 0 5 mm C 3 5 mm 0 5 mm D 2 mm all around...

Page 107: ...m 0 5 mm D 2 mm all around E 2 0 mm 0 5 mm Body Exterior Lock Carrier Service Position Tightening Torques Component Nm Lock carrier bolts upper 8 Lock carrier bolts lower 60 Side impact member screws...

Page 108: ...ody bolts 2 Front Hood Tightening Torques Component Nm Hood hex nut 22 Gas filled strut ball studs 21 Hood hinge bolts 25 Hood hinge nuts 32 Hood catch nuts 9 Release lever bracket bolts 2 0 Hood lock...

Page 109: ...Tightening Torques Component Nm Spring glider bolts always replace 1 8 Electrical drive motor bolts 3 5 Slotted guide rail Torx bolts 5 Installation unit bolts 8 Front Bumper Tightening Torques Compo...

Page 110: ...adiator Grille Tightening Torques Component Nm Radiator grille bolts 2 Strips and Trim Tightening Torques Component Nm Sill panel extension bolts 2 Retaining strip to sill panel bolts 1 2 Body Interio...

Page 111: ...ing crash sensor bolts 7 Interior Trim Tightening Torques Component Nm Instrument panel bolts 3 Instrument panel above tunnel bolts 8 Instrument panel aligning bolts 2 Footwell trim bolts 1 5 Instrume...

Page 112: ...elside side trim on front seat 2 Seat bracket and operation lever bolts 3 5 Front seat backrest bolts always replace 34 5 Bucket seat pan bolts 24 Rear seat center backrest bolt 9 Rear seat belt buckl...

Page 113: ...ng Part No 7SEU17C Denso G 052 300 A2 PXE16 Sanden G 052 154 A2 DSC17E Zexel G 052 200 A2 Refrigerant PAG Oil Capacities Model Production Total capacity cm3 1K0 820 803 G Sanden from 10 04 110 10 1K0...

Page 114: ...Pressure Table Temperature in C Pressure in bar positive pressure of R134a 45 0 61 40 0 49 35 0 34 30 0 16 25 0 06 20 0 32 15 0 63 10 1 00 5 1 43 0 1 92 5 2 49 10 3 13 15 3 90 20 4 70 25 5 63 30 6 70...

Page 115: ...sembly carrier bracket bolts 8 Heating and ventilation unit bracket bolts 10 A C System Tightening Torques Component Nm Shielding plate nut 6 Refrigerant lines to engine compartment bolts 12 Assembly...

Page 116: ...retainer to generator M5 3 Voltage regulator to generator screw M4 2 Protective cap to generator M5 4 Ribbed belt pulley with freewheel to generator nut M10 80 Ribbed belt pulley without freewheel to...

Page 117: ...t 23 Front Wiper Motor Tightening Torques Component Nm Wiper arm to wiper frame shaft nuts 17 Wiper frame with linkage and wiper motor to plenum panel bolts 8 Headlamp washer system spray nozzle to fr...

Page 118: ...housing screws 2 0 Side mirror housing to door screw 6 5 Rear lamp to body bolt 3 5 Rear lamp bulb carrier to rear lamp screws 1 7 Rear fog lamp to rear bumper screws 1 2 High mount brake lamp to rea...

Page 119: ...Audi TT Quick Spec 09...

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