Audi TT 27 User Manual
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Service
Maintenance
Audi TT 2007 ➤
Edition 04.2010
Service Department. Technical Information
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.
Maintenance
He ad in g
1. Overview of engines
2. Delivery Service
3. Description of work
4. Type plate, vehicle identification number
5. Lifting the vehicle
6. Tow-starting/towing
7. Vehicle tests carried out as part of inspection services and maintenance
Service
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 precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A00IGTT0220
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.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
Contents
1 Overview of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Delivery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Description of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Cap for suspension strut protective tube: greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Reading out: measured value block 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Battery: checking "no load" voltage before engine is started for first time . . . . . . . . . . . . . . 6
3.4 Battery: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 Battery: checking that battery cables are securely fitted . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Battery: performing battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.7 Tyres: checking condition, wear pattern, tread depth and correcting tyre pressures . . . . . . 14
3.8 Brake system: visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.9 Lights: checking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.10 Brake pads: checking thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.11 Brake fluid level (depends on brake pad wear): checking . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.12 Brake fluid: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.13 S tronic gearbox: changing oil and renewing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.14 Electric windows: checking positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.15 G17 additive: adding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.16 Ignition keys: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.17 Diesel particulate filter: reading out ash deposit mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.18 Data memory: interrogating with vehicle diagnostic, testing and information system
VAS 5051/ 5052 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.19 Noise insulation: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.20 Haldex coupling: changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.21 Poly V-belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.22 Fuel filter: renewing (2.0 ltr. TDI CR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.23 Cooling system: checking coolant additive level and topping up with coolant if necessary
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.24 Instrument cluster: setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.25 Air cleaner: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.26 Bonnet arrester hook: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.27 Engine cover panel: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.28 Engine and engine compartment (from below): visual check for leaks and damage . . . . . . 38
3.29 Engine oil: draining or extracting, changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.30 Bonnet hinges: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.31 Engine oil: filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.32 Engine: checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.33 Navigation system: releasing eject button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.34 Radio: activating anti-theft coding by entering fixed code number . . . . . . . . . . . . . . . . . . . . 44
3.35 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.36 Wheel bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.37 Tyre pressure monitoring system: updating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.38 Manual gearbox/final drive: checking oil level, topping up with oil if necessary . . . . . . . . . . 47
3.39 Windscreen wiper/washer system: checking jet settings, adjusting jets if necessary . . . . 47
3.40 Headlight washer system: checking jet settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.41 Wiper blades: checking park position and checking for damage . . . . . . . . . . . . . . . . . . . . 50
3.42 Service interval display: resetting or adapting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.43 Fuse for headlight washer system: fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.44 Dust and pollen filter: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.45 Track rods, track control links, swivel joints, guide links and drive shafts on front and rear
axle: checking boots, play, and secure fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.46 Transport mode: deactivating (using vehicle diagnostic, testing and information system VAS
5051/5052 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.47 Door arresters, door hinges and lock cylinders: lubricating . . . . . . . . . . . . . . . . . . . . . . . . 57
Contents i
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
3.48 Transport locks: removing locking elements for front and rear suspension struts . . . . . . . . 57
3.49 Underseal: visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.50 Plenum chamber: checking and cleaning water drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.51 Winter tyres (factory-fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.52 Toothed belt for camshaft drive: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.53 Clock: setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.54 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4 Type plate, vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5 Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6 Tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7 Vehicle tests carried out as part of inspection services and maintenance . . . . . . . . . . . . . . 71
ii Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
1 Overview of engines
Petrol engines
Engines ⇒ Petrol engines
Engine code BWA CDLA CDLB BUB
Capacity 2.0 ltr. 2.0 ltr. 2.0 ltr. 3.2 ltr.
No. of cylinders /
valves per cylinder
Exhaust emissions
standard
Power output (kW at
147 / 5100 - 6000 195 / 6000 199 / 6000 184 / 6333
rpm)
Torque (Nm at rpm) 280 / 1800 - 5000 350 / 2500 … 5250 350 / 2500 … 5250 320 / 2500
Bore (∅ mm) 82.5 82.5 82.5 84.0
Stroke (mm) 92.8 92.8 92.8 95.5
Compression ratio 10.5:1 9.8:1 9.8:1 10.85:1
Fuel injection / ignition TFSI TFSI TFSI MPI
RON at least
4/4 4/4 4/4 6/4
EU IV EU IV EU IV EU IV
98 unleaded
1)
98 unleaded
1)
98 unleaded
1)
98 unleaded
1)
1)
Unleaded RON 95 can also be used, but will result in a slight
loss of power.
Engines ⇒ Petrol engines
Engine code CCZA CESA CDAA CDMA CEPA
Capacity 2.0 ltr. 2.0 ltr. 1.8 ltr. 2.0 ltr. 2.5 ltr.
No. of cylinders /
4/4 4/4 4/4 4/4 5/4
valves per cylinder
Exhaust
EU V EU V EU V EU IV EU V
emissions
standard
Power output (kW
at rpm)
Torque (Nm at
rpm)
147 / 5100 -
6000
280 / 1800 -
5000
155 / 4300 -
6000
350 / 1600 -
4200
118 / 4500 -
6200
250 / 1500 -
4500
195 / 6000 250 / 5400 -
6500
350 /
2500 … 5250
450 / 1600 -
5300
Bore (∅ mm) 82.5 82.5 82.5 82.5 82.5
Stroke (mm) 92.8 92.8 84.1 92.8 92.8
Compression ratio 9.8:1 9.8:1 9.8:1 9.8:1 10:1
Fuel injection / ig‐
TFSI TFSI TFSI TFSI TFSI
nition
RON at least
98 unleaded 1)98 unleaded
1)
95 unleaded
98 unleaded 1)98 unleaded
1)
1)
Unleaded RON 95 can also be used, but will result in a slight
loss of power.
Diesel engines
Engines ⇒ Diesel engines
Engine code CBBB CFGB
Capacity 2.0 ltr. 2.0 ltr.
No. of cylinders / valves per cylinder 4/4 4/4
1. Overview of engines 1
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Audi TT 2007 ➤
Maintenance - Edition 04.2010
Engines ⇒ Diesel engines
Engine code CBBB CFGB
Exhaust emissions stand‐
EU V EU V
ard
Power output (kW at rpm) 125 / 4200 125 / 4200
Torque (Nm at rpm) 350 / 1750 - 2500 350 / 1750 - 2500
Bore (∅ mm) 81 81
Stroke (mm) 95.5 95.5
Compression ratio 16.5 :1 16.5 :1
Fuel injection / ignition TDI
CR II
TDI
CR II
CN at least 51 51
Diesel particulate filter
1)
Unleaded RON 95 can also be used, but will result in a slight
X X
loss of power.
2 1. Overview of engines
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2 Delivery Service
Work to be completed Page
In the case of stock vehicles: performing steps
specified in maintenance table “stock vehicles”
Battery: checking that battery cables are se‐
curely fitted
Battery: checking no load voltage ⇒ page 6
Data memory: reading out ⇒ page 23
Service interval display: resetting ⇒ page 50
Instrument cluster: setting the language ⇒ page 28
Daytime running lights: activating (see MMI Op‐
erating Manual)
Fuse for headlight washer system: fitting ⇒ page 53
Transport mode: deactivating ⇒ page 56
Transport locks: removing locking elements for
suspension struts
Cap for suspension strut protective tube: greas‐
ing
G17 additive: adding into tank ⇒ page 21
Clock: setting ⇒ page 58
Front passenger's airbag: checking key switch
on / off, must be set to “on” (see Owner's Man‐
ual)
Ignition keys: checking operation. Enter the
number of ignition keys which have been
checked and handed over to the customer: ____
Service Schedule: removing vehicle data sticker
from supplied pack on front passenger's side
and sticking into Service Schedule under “War‐
ranty entitlement record”
Entering record of Delivery Service
Owner's literature: checking that it is complete
and preparing for handover to customer
Cooling system: coolant must be filled to max.
level
Engine: checking oil level and topping up if nec‐
essary
Headlight washer system: fitting fuse ⇒ page 53
Navigation system: releasing eject button ⇒ page 44
Brake system: brake fluid must be filled to max.
level
Wheel bolts: tightening to specified torque ⇒ page 46
Radio or radio/navigation system: disposing of
label with serial number and fixed code number
(supplied pack on front passenger's side) after
entering fixed code number
Radio and radio/navigation system: activating
anti-theft coding by entering fixed code number
Tyre pressure on all 4 wheels and spare wheel:
checking (note: 3.5 bar when car leaves factory)
Saving pressures in tyre pressure monitoring
system
ELSA mainte‐
nance table
⇒ page 9
⇒ page 57
⇒ page 5
⇒ page 22
⇒ page 26
⇒ page 44
⇒ page 18
⇒ page 44
⇒ page 14
⇒ page 46
Audi TT 2007 ➤
Maintenance - Edition 04.2010
2. Delivery Service 3
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Audi TT 2007 ➤
Maintenance - Edition 04.2010
Work to be completed Page
Accessories: installing (components stored in
luggage compartment, glove box, supplied
pack); keep puller or plastic clip in vehicle tool
kit.
Vehicle (from below): checking for damage
(without removing noise insulation)
Protective seat covers, plastic sheeting for car‐
pet: removing
Floor mats: fitting
Cleanliness of vehicle interior: checking front
and rear seats, interior trim, carpeting/mats,
windows
Cleanliness of vehicle exterior: checking paint‐
work, trims, windows, wiper blades
Transport protection: removing protective edge
strips on doors
Interior mirror with compass: calibrating (if “C” is
⇒ Rep. Gr. 68
displayed on mirror)
Road test and reset DIS ⇒ page 45
4 2. Delivery Service
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3 Description of work
The following chapters describe the work steps necessary for
performing the services listed in the maintenance tables.
Please refer to the relevant maintenance table for information on
when a service is due.
3.1 Cap for suspension strut protective tube: greasing
Special tools and workshop equipment required
♦ Lubricant G 000 405 A2
Audi TT 2007 ➤
Maintenance - Edition 04.2010
♦ Brush
Coat contact surface -arrow- of plastic cap at suspension strut
protective tube with G 000 405 A2.
Note
After removing the spring inserts/spacers and greasing the cap
for the suspension strut protective tube, make sure that the boot
is correctly seated in the suspension strut mounting and at the
shock absorber tube.
3.2 Reading out: measured value block 32
Note
Only applies in certain countries. For the countries affected, refer
to maintenance table.
3. Description of work 5
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
– Carry out the following steps, one after the other.
♦ Connect -VAS 5051/5052-
♦ Self-diagnosis
♦ Engine electronics
♦ Measured value blocks
♦ Select measured value block 32
♦ Display zone 2 (4-cyl. engines)
♦ Display zones 2 and 4 (V6 and V8 engines)
Note
Add four times as much G17 additive ⇒ page 21 if there is a
deviation of > 15% in the values.
3.3 Battery: checking "no load" voltage be‐
fore engine is started for first time
3.3.1 Special tools and workshop equipment
required
♦ Hand-held multimeter -V.A.G 1526C-
– Ensure that the following rules are observed, otherwise correct
measurements cannot be guaranteed.
6 3. Description of work
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♦ The battery must not be placed under load from connected
electrical equipment for at least 12 hours before the test.
♦ The battery must not be charged for at least 12 hours before
test.
Remove rear moulded insert -3- for tools below luggage com‐
partment floor covering.
– Detach cover -arrow- for battery compartment.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
– Detach moulded insert above battery.
– With ignition switched off, measure voltage between battery
clamps -2- and -3-.
1 - If the tester indicates 12.5 V or more, then the battery is OK.
2 - If the tester indicates 12.2 to 12.5 V the battery must be
charged ⇒ Rep. Gr. 27 .
3 - If the tester indicates between 11.6 and 12.2 V proceed as
follows: Charge battery ⇒ Rep. Gr. 27 . After charging bat‐
tery allow to stand with no load for 24 hours. Then carry out
battery test / battery load test ⇒ page 9 .
4 - If tester indicates 11.6 V or less the battery must be renewed
⇒ Rep. Gr. 27 .
WARNING
Always adhere to correct procedure, otherwise measurements
will be falsified.
3. Description of work 7
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Audi TT 2007 ➤
Maintenance - Edition 04.2010
3.4 Battery: checking
3.4.1 Batteries with “magic eye”
The battery is located in the luggage compartment (rear right).
– Switch off the ignition and remove the ignition key from the
lock.
– Remove rear moulded insert -3- for tools below luggage com‐
partment floor covering.
Note
-Item 1- and -item 2- can be disregarded.
– Detach cover -arrow- for battery compartment.
– Detach moulded insert above battery.
♦ The magic eye -arrow- indicates the electrolyte level and the
charge level of the battery to be checked.
♦ Three different colours are used as indicators:
– Green → the battery is sufficiently charged.
– Black → no charge or charge too low
– Colourless or yellow → critical electrolyte level has been
reached. Battery must be renewed.
3.4.2 Battery with sealing plugs
♦ A visual check of the battery is sufficient for batteries with
clearly visible external min. and max. marks.
♦ The electrolyte level must be above the minimum marking, but
must not exceed the maximum marking.
♦ If the external min. and max. marks on the battery are not
clearly visible or if the electrolyte level cannot be checked
properly due to an opaque battery housing, the sealing plugs
must be unscrewed. It is then possible to visually check the
electrolyte level from the inside.
♦ The electrolyte level must align with the marking inside the
battery (plastic moulding). This corresponds to the max. mark‐
ing on the outside.
8 3. Description of work
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
If electrolyte level is too low, the cell plates dry out, resulting in a
loss of battery capacity (loss of power). The cell plates must be
fully covered by electrolyte (sulphuric acid) in order to prevent
corrosion of plates, plate bridges and cell connectors. Corrosion
of these parts will impair battery function and make it unreliable.
It will be rendered unusable.
WARNING
If the electrolyte level is below the min. marking the battery
must be renewed! ⇒ Rep. Gr. 27
3.5 Battery: checking that battery cables are securely fitted
– Check that battery clamps are securely fitted. If necessary,
tighten nuts -1- and -4-.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
WARNING
If the battery clamp on the positive terminal is not fitted se‐
curely, disconnect the battery earth strap from the battery
negative terminal first to avoid possible accidents.
– Check that battery is securely installed. If necessary tighten
securing bolt -2- on retainer plate -3-.
Tightening torque Nm
Battery clamps to battery terminals 5
Bolt on retainer plate 22
3.6 Battery: performing battery test
Special tools and workshop equipment required
3. Description of work 9
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
♦ Battery tester -VAS 6161- (with printer)
♦ Battery tester -VAS 5097 A-
Note
♦
During battery test with battery tester -VAS 6161- (with print‐
er), battery earth wire does not have to be disconnected.
♦
It is not necessary to remove the battery when using battery
tester -VAS 5097A- . The battery does not have to be discon‐
nected.
3.6.1 Performing battery test using battery tester -VAS 6161- (with printer)
♦ The battery tester with printer -VAS 6161- no longer puts the
battery under load, but works by measuring the dynamic con‐
ductivity. For this reason it is possible to perform several
measurements without re-charging the battery.
♦ "No-load" voltage measurement can be performed without de‐
lay.
♦ All battery types are stored in the tester. These data can be
updated.
♦ The battery bar code can be directly read off with the optionally
available 2D scanner.
♦ The integrated temperature sensor improves the quality of
measurements.
♦ The data can be stored on an SD card.
Note
For more information on the battery tester -VAS 6161- (with print‐
er), refer to the tester's ⇒ operating instructions .
10 3. Description of work
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Special tools and workshop equipment required
♦ Battery tester (with printer) -VAS 6161-
Note
For instructions on how to use the battery tester -VAS 6161- refer
to its ⇒ operating instructions .
Procedure:
• The battery temperature must be at least +10 °C.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
WARNING
Risk of injury due to electrolyte.
♦ The accident prevention procedures must be observed
when handling electrolyte.
♦ Wear eye protection and protective clothing.
♦ Sealing plugs of batteries which are not maintenance-free
must be firmly screwed in when measuring voltage under
load.
Risk of explosion due to a discharged battery with “magic eye”.
♦ If the “magic eye” is colourless or light yellow, do not test
or charge the battery. Do not attempt to jump-start the ve‐
hicle! There is a danger of explosion if you test or charge
the battery or jump-start the vehicle! The battery must be
renewed.
– Switch off ignition and all electrical equipment.
– On vehicles with “magic eye” check colour of “magic eye”.
– Switch on battery tester -VAS 6161- (with printer).
– Connect red test clamp “+” of battery tester to positive battery
terminal or jump start terminal in engine compartment.
– Connect black test clamp “–” of battery tester to negative bat‐
tery terminal or jump start terminal in engine compartment.
Note
Make sure the test clamps make proper contact.
– Select one of the following functions:
♦ Maintenance test
3. Description of work 11
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
♦ Service test
♦ Warranty test
Maintenance test
– Select “Maintenance test” from the menu.
– Connect scanner and scan in vehicle identification number.
– Select connection point: “at battery post” or “at jump start
post”.
– Select vehicle model.
– Scan in battery's bar code.
– Determine temperature by holding temperature sensor at a
distance of approx. 5 cm over battery or jump start post until
a constant temperature is displayed.
– Start test.
– If required, print out test log.
Service test
– Select “Service test” from the menu.
– Select vehicle model.
– Determine temperature by holding temperature sensor at a
distance of approx. 5 cm over battery until a constant temper‐
ature is displayed.
– Select battery type: “Regular”, “AGM”, “2*6V” or “Gel”.
– Select rating units: “CCA”, “JIS”, “DIN”, “SAE”, “IEC” or “EN”.
– Start test.
– If required, print out test log.
Warranty test
– Select “Warranty test” from the menu.
– Select fitting location: “in vehicle” or “out of vehicle”.
– Select vehicle model.
– Determine temperature by holding temperature sensor at a
distance of approx. 5 cm over battery until a constant temper‐
ature is displayed.
– Select battery type: “Regular”, “AGM”, “2*6V” or “Gel”.
– Select corresponding rating using arrow buttons.
– Start test.
– If required, print out test log.
Note
The test log is required for warranty processing.
– Switch off battery tester.
– Detach test clamps.
12 3. Description of work
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Test result on printout:
1 - Test mode
2 - Test result
3 - Measured voltage
4 - Measured nominal value of battery
5 - Nominal value of battery set on tester
6 - Temperature measured above battery
7 - Fitting location of battery
8 - Position of battery clamp set on tester
9 - Selected battery type
Result of maintenance test Measures
Battery good Battery OK
Charge battery Charge battery
Charge battery instantly Charge battery completely and
repeat test. Faults can occur if
battery is not completely charg‐
ed when test is repeated
Mark as defect Mark as “defect” and remove
from vehicle
Check tester connection Remove battery and repeat test
Battery frozen Thaw battery and repeat test
Check connection Connect cable directly to bat‐
tery and not to jump-start termi‐
nal
Audi TT 2007 ➤
Maintenance - Edition 04.2010
Result of service test and war‐
Measures
ranty test
Battery good Battery OK
Battery good - recharge Charge battery completely
Replace battery Remove battery and repeat
test. Result "Replace battery"
can arise if cables do not make
proper contact
Bad cell - replace Renew battery
Battery frozen Thaw battery and repeat test
Check connection Connect cable directly to bat‐
tery and not to jump-start termi‐
nal
– Renew battery ⇒ Rep. Gr. 27 .
Note
If the battery has to be renewed, observe disposal regulations.
3.6.2 Performing battery load test using VAS 5097 A
– Switch off ignition.
– Read operating instructions for battery tester.
3. Description of work 13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
– Connect the clamps of the test leads to battery terminals as
described in operating instructions for the tester.
The clamps must make good contact with the battery terminals.
– As the load current differs depending on the battery, the cur‐
rent must be set on the tester according to battery capacity ⇒
Operating instructions for battery test equipment.
– Perform a battery load test as described in the operating in‐
structions.
Please note the test results shown on the display of the tester.
Display on bat‐
tery tester
Battery Very
Delivery Inspection Inspection Service
LongLife Service
Battery OK Battery OK
Good
Battery Good Battery OK Battery OK
Battery Sufficient Renew battery
Battery Not Good Renew battery
Battery Faulty Renew battery
Cannot be tested Renew battery
Charge battery
Charge battery
Renew battery
Renew battery
1)
1)
2)
2)
1) - Perform battery load test again after recharging the battery.
If tester shows “Battery Good” after charging, battery is OK. How‐
ever, if tester still shows “Battery Not Good”, battery must be
renewed.
2) - Agree battery replacement with customer.
– Renew battery ⇒ Rep. Gr. 27 .
Notes on battery load test:
The battery voltage will decrease during the test due to the high
load (high current flow).
If a battery is in working order battery voltage will only drop to
minimum voltage.
If the battery is defective or only insufficiently charged, battery
voltage will very quickly drop below minimum voltage.
After carrying out the load test the voltage will remain at this low
level for quite a while; voltage will only rise again slowly.
3.7 Tyres: checking condition, wear pattern,
tread depth and correcting tyre pres‐
sures
Note
All tyres and wheels (front and rear) must be of same type and
size. On four-wheel drive vehicles you must also ensure that all
tyres are made by the same manufacturer and have the same
tread pattern.
Delivery Inspection
– Check tyre tread surfaces and sidewalls for damage and re‐
move any foreign bodies.
Inspection Service
– Check tyres for scuffing, one-sided wear, porous sidewalls,
cuts and fractures.
14 3. Description of work
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
WARNING
Any defects must be reported to the customer.
Checking tyre wear pattern
– The wear pattern of the front tyres indicates, for example,
whether the toe and camber have to be checked.
♦ Feathering on tread indicates incorrect toe setting.
♦ One-sided tread wear is usually due to incorrect camber.
Note
If the above types of wear are found, check wheel alignment to
determine the cause (repair measure).
Checking tyre tread depth
♦ Minimum depth: 1.6 mm
Audi TT 2007 ➤
Maintenance - Edition 04.2010
Note
♦
This figure may vary for individual countries due to different
legislation.
♦
If the tread depth is approaching the minimum permissible
tread depth, the customer must be informed.
3.7.1 Inflating to correct pressures
The correct inflation pressures are listed on the sticker inside the
B-pillar.
Note
Please note that the tyre pressures listed on the sticker apply to
cold tyres. When the tyres are warm, the actual pressures will be
higher, but must not be reduced.
3.7.2 Spare wheel
• Collapsible spare wheel
The correct tyre pressure is indicated on the sidewall.
3.8 Brake system: visual check for leaks and damage
– Check following components for leaks and damage:
♦ Brake master cylinder
♦ Brake servo
♦ ABS hydraulic unit
♦ Brake calipers
3. Description of work 15
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
– Ensure that brake hoses are not twisted.
– Make sure that brake hoses do not touch any components
when steering is on full lock.
– Check brake hoses for porosity, blistering and brittleness.
– Check brake hoses and pipes for chafing.
– Check brake pipe connections and mountings for correct seat‐
ing, leaks and corrosion.
WARNING
Any faults found must be rectified (repair measure).
3.9 Lights: checking function
– The following components must be checked:
♦ Front lights: side lights, dipped beam, main beam, front fog
lights, turn signals, hazard warning lights
♦ Tail light cluster: brake lights (incl. 3rd brake light), rear lights,
reversing lights, rear fog light, number plate light, turn signals,
hazard warning lights
♦ Horn, glove box light and luggage compartment light
3.10 Brake pads: checking thickness
Special tools and workshop equipment required
♦ Test pin T40139
Test pin
Before using the test gauge to check the pad thickness, push the
sliding ring towards the tip of the gauge as far as it will go.
Then insert the test gauge through the wheel rim and bring the tip
of the gauge into contact with the brake disc. Then slide the body
of the gauge uniformly towards the brake pad until the gauge
makes contact with the backplate of the brake pad.
Then take out the test pin and read off the value on the scale
marked with the brake symbol.
Note
♦
When removing the test pin, take care not to move the sliding
ring. This would give an incorrect measurement.
♦
The second scale on the test pin (with the tyre symbol) can be
used for checking tread depth.
16 3. Description of work
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Front disc brake pads:
a - Pad thickness including backplate
- Wear limit: 7
Rear disc brake pads:
a - Pad thickness including backplate
- Wear limit: 7
WARNING
When brake pad thickness (including backplate) is down to 7,
the brake pads have reached their wear limit and must be re‐
newed (repair measure). The customer must be informed.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
Note
♦
On some vehicles (fitted with aftermarket rims) it may not be
possible to insert the test pin through the wheel rim and bring
it into contact with the brake disc or the brake pad, due to the
shape of the rim. In this case proceed as follows:
♦
Determine thickness of outer pads by checking visually (using
electric torch through cut-out in rim).
♦
Determine thickness of inner pads by checking visually (with
help of electric torch and mirror).
3.11 Brake fluid level (depends on brake pad wear): checking
Note
Only use new genuine VW/Audi brake fluid, refer to ETKA.
WARNING
♦ Brake fluid is poisonous. It also has caustic properties and
must therefore not be allowed to come into contact with
paintwork.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air. It must therefore always be stored in airtight containers.
– Note the following:
3. Description of work 17
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Maintenance - Edition 04.2010
3.11.1 Delivery Inspection
♦ The fluid level must be at the MAX mark.
Note
The fluid level must not exceed the MAX marking, otherwise the
fluid will overflow.
3.12 Brake fluid: changing
Note
Only use new genuine VW/Audi brake fluid, refer to ETKA.
Changing brake fluid with brake filling and bleeding equipment VAS 5234-
WARNING
♦ Brake fluid must on no account come into contact with liq‐
uids containing mineral oils (oil, petrol, cleaning agents).
Mineral oils damage the plugs and sleeves in the brake
system.
♦ Brake fluid is poisonous and must under no circumstances
be sucked through a tube using the mouth. Because of its
caustic properties it must also not come into contact with
paintwork.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air. It must therefore always be stored in airtight containers.
♦ Always observe the relevant environmental regulations for
disposal.
3.12.1 Changing brake fluid with brake filling and bleeding equipment -VAS 5234-
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234-
18 3. Description of work
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with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Container for collecting used fluid
Audi TT 2007 ➤
Maintenance - Edition 04.2010
Note
♦
The brake fluid reservoir must always be adequately filled to
ensure that no air can enter the brake system from the reser‐
voir.
♦
The strainer in the brake fluid reservoir must not be removed.
♦
Observe the instructions given in the operating manual for the
brake filling and bleeding equipment -VAS 5234- .
– Unscrew cap -1- from brake fluid reservoir.
3. Description of work 19
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