Audi TT 28 User Manual
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.
Service
Workshop Manual
Audi TT 1999 ➤
General body repairs, exterior
Edition 07.2004
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.
Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
50 - Body - front
55 - Bonnet, rear lid
57 - Front doors, door components, central locking
61 - Convertible soft top, hardtop, canopy
63 - Bumpers
64 - Glazing
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 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 A0057005420
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 1999 ➤
General body repairs, exterior - Edition 07.2004
Contents
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Removing and installing lock carrier with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Wing panel (front) - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Noise insulation for vehicles with 4-cyl. engine - overview . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Removing and installing noise insulation for vehicles with 4-cyl. engine . . . . . . . . . . . . . . 4
1.5 Removing and installing noise insulation for vehicles with 6-cyl. engine . . . . . . . . . . . . . . 5
1.6 Body reinforcements (rear) for vehicles with 6-cyl. engine . . . . . . . . . . . . . . . . . . . . . . . . . . 7
55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Removing and installing bonnet, adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Removing and installing gas-filled strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Removing and installing bonnet lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Removing and installing bottom section of bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6 Removing and installing Bowden cable for bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Rear lid - Coupé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1 Removing and installing rear lid, adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Removing and installing gas-filled strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Removing and installing rear lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Removing and installing seal for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5 Removing and installing Bowden cable for rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Rear lid - Roadster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Removing and installing rear lid, adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Removing and installing gas-filled strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3 Removing and installing rear lid hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.4 Removing and installing seal for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5 Removing and installing Bowden cable for rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 Tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Removing and installing tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.1 Removing and installing front door and door subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2 Adapting and erasing force-resistance characteristic for window lifter motor . . . . . . . . . . 27
1.3 Adjusting door subframe - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4 Adjusting door subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.5 Removing and installing door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.6 Removing and installing window lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.7 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.8 Door handle and door lock - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.9 Removing and installing lock cylinder housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.10 Removing and installing door handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.11 Removing and installing door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.12 Removing and installing side impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.13 Removing and installing door seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2 Servicing central locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.1 Removing and installing actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.2 Removing and installing actuator for fuel tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
61 - Convertible soft top, hardtop, canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Contents i
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 1999 ➤
General body repairs, exterior - Edition 07.2004
1 Repairing convertible soft top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.2 Soft top - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3 Removing and installing soft top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.4 Adjusting soft top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.5 Removing and installing trim for soft top storage box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.6 Removing and installing tensioner and retainer for seal . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.7 Removing and installing soft top lock, adjusting soft top lock . . . . . . . . . . . . . . . . . . . . . . 53
1.8 Renewing soft top cover - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.9 Removing soft top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.10 Installing soft top cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.11 Installing seal for windscreen frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 Repairing hydraulic system for soft top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.2 Filling and bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3 Hydraulic system - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.4 Removing and installing hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.5 Removing and installing hydraulic cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3 Repairing hard top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.2 Hardtop - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.3 Removing and installing hard top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4 Adjusting hard top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.5 Removing and installing moulded headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1 Front bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.1 Bumper cover - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.2 Removing and installing bumper cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.3 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.4 Removing and installing air cowl (centre) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.5 Removing and installing air cowl (outer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.6 Removing and installing trim (side) on vehicles with 6-cyl. engine or S-line package . . . . 90
1.7 Carrier and impact damper - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2 Rear bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.1 Removing and installing rear bumper - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.2 Removing and installing guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1 Flush-bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.1 Removing and installing flush-bonded windows - general comments . . . . . . . . . . . . . . . . 95
2 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.1 Windscreen - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.2 Removing and installing windscreen surround . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2.3 Removing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.4 Preparations before installing a new windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2.5 Installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Removing and installing side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.1 Side window - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.2 Removing undamaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.3 Removing damaged side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.4 Preparations before installing a new side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.5 Installing side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.1 Rear window - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
ii Contents
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 1999 ➤
General body repairs, exterior - Edition 07.2004
4.2 Removing an undamaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.3 Removing damaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.4 Preparations before installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.5 Installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5 Removing and installing rear window on hard top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.1 Removing an undamaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.2 Removing damaged rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.3 Preparations before installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.4 Installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1 Roof mouldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.1 Removing and installing roof joint moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.2 Converting attachment points for roof carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.3 Removing and installing roof trim moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2 Rear-view mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.1 Rear-view mirrors - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.2 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.3 Removing and installing housing for exterior mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.4 Removing and installing electric mirror adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.5 Removing and installing mirror base - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.6 Detaching cover from mirror base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3 Sill panel trim (outer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.1 Removing and installing sill panel trim (outer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4 Wheel housing liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.1 Removing and installing wheel housing liner (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.2 Removing and installing wheel housing liner (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5 Side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.1 Removing and installing side member trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6 Spoiler for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.1 Removing and installing spoiler for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.2 Removing spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.3 Installing spoiler (rear lid has holes for locating pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.4 Installing spoiler (rear lid without holes for locating pins) . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.5 Correcting panel gap at spoiler for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7 Spoiler for rear lid on vehicles with 6-cyl. engine or S-line package . . . . . . . . . . . . . . . . . . 143
7.1 Spoiler for rear lid - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.2 Removing and installing spoiler for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.3 Removing spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.4 Installing spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.5 Correcting panel gap at spoiler for rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
8 Trim cover panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
8.1 Removing and installing trim cover panel for soft top storage box . . . . . . . . . . . . . . . . . . . . 152
Contents iii
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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 1999 ➤
General body repairs, exterior - Edition 07.2004
iv Contents
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.
General body repairs, exterior - Edition 07.2004
50 – Body - front
1 Body - front
1.1 Removing and installing lock carrier with attachments
1 - Bolt with washer, 23 Nm
2 - Bumper
❑ Does not need to be de‐
tached from bumper
brackets when remov‐
ing the lock carrier.
3 - Hexagon bolt, 35 Nm
4 - Torx bolt T30, 6 Nm
5 - Wing panel
6 - Bolt with washer, 23 Nm
7 - Lock carrier
Audi TT 1999 ➤
Note
❑ Removing:
– Remove bumper cover
(front) ⇒ page 86 .
– Unplug electrical con‐
nectors for headlights.
– Remove bonnet lock
⇒ page 12 .
– Unscrew bolts
⇒ Item 3 (page 1) ,
⇒ Item 4 (page 1) and
⇒ Item 6 (page 1) .
Note
– Detach lock carrier to
front.
❑ Install in reverse sequence.
8 - Bolt, 4 Nm
9 - Hexagon nut, 23 Nm
1. Body - front 1
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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 1999 ➤
General body repairs, exterior - Edition 07.2004
1.2 Wing panel (front) - overview
1 - Bolt with washer, 10 Nm
2 - Brace
3 - Bolt with washer, 15 Nm
❑ Qty. 8
4 - Wing panel
❑ Removing:
– Remove bumper cover
(front) ⇒ page 86 .
– Remove wheel housing
liner ⇒ page 129 .
– Remove end plate
⇒ page 2 .
– Detach headlight.
– Unscrew bolts with
washers
⇒ Item 3 (page 2) and
detach wing.
❑ Install in reverse se‐
quence.
5 - Speed nuts
❑ Are inserted into wing
mounting flange.
Removing and installing end plate
– Remove front wheel.
– Remove wheel housing liner ⇒ page 129 .
– Remove bolts -1- from expanding clips -3- and remove end
plate -2- from wing.
2 Rep. Gr.50 - Body - front
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 1999 ➤
General body repairs, exterior - Edition 07.2004
1.3 Noise insulation for vehicles with 4-cyl. engine - overview
1 - Noise insulation (left-side)
❑ Removing:
– Remove noise insula‐
tion ⇒ page 4 .
– Unscrew lock washers
and detach noise insu‐
lation (left-side).
❑ To install, insert retain‐
ing pegs (front) into lock
carrier (bottom).
2 - Speed nuts
❑ Qty. 7
3 - Lock washers
– To remove, unscrew
with a suitable screw‐
driver.
– To install just press on.
4 - Noise insulation (right-side)
❑ Removing:
– Remove noise insula‐
tion ⇒ page 4 .
– Unscrew lock washers
and detach noise insu‐
lation trim.
❑ To install, insert retain‐
ing pegs (front) into lock
carrier (bottom).
5 - Locking pin
❑ Qty. 4
6 - Noise insulation
❑ Removing and installing: ⇒ page 4 .
7 - Self-tapping screw, 2.2 Nm
1. Body - front 3
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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 1999 ➤
General body repairs, exterior - Edition 07.2004
1.4 Removing and installing noise insulation for vehicles with 4-cyl. engine
1 - Locking pin
❑ Qty. 4
2 - Noise insulation
– To remove, unscrew
self-tapping screws
⇒ Item 5 (page 4)
and detach noise insu‐
lation from lock carrier
towards the rear.
– To install, insert tabs on
noise insulation (front)
above -arrow A- and be‐
low -arrow B- the lock
carrier.
3 - Wheel housing liner
4 - Subframe
5 - Self-tapping screw, 2.2 Nm
6 - Bumper cover
7 - Lock carrier with attach‐
ments
8 - Noise insulation (left-side)
❑ Removing:
– Remove noise insula‐
tion.
– Unscrew lock washers
and detach noise insu‐
lation (left-side).
❑ To install, insert retain‐
ing pegs (front) into lock
carrier (bottom)
⇒ Item 7 (page 4) .
4 Rep. Gr.50 - Body - front
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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 1999 ➤
General body repairs, exterior - Edition 07.2004
1.5 Removing and installing noise insulation for vehicles with 6-cyl. engine
1 - Self-tapping screw, 2.2 Nm
2 - Edge trim
3 - Speed nut
4 - Noise insulation with rein‐
forcement plate
– To remove, unscrew
self-tapping screws
⇒ Item 1 (page 5) ,
⇒ Item 10 (page 5)
and
⇒ Item 14 (page 5)
and socket head bolts
⇒ Item 11 (page 5)
and
⇒ Item 12 (page 5) .
Pull noise insulation out
of lock carrier towards
rear.
5 - Noise insulation (right-side)
❑ Removing:
– Remove noise insula‐
tion with reinforcement
plate ⇒ Item 4 (page 5) .
– Unscrew lock washers
⇒ Item 7 (page 5)
and detach noise insu‐
lation (right-side).
❑ To install, insert retain‐
ing pegs (front) into lock
carrier (bottom).
6 - Speed nut
7 - Lock washers
8 - Noise insulation (left-side)
❑ Removing:
– Remove noise insulation with reinforcement plate ⇒ Item 4 (page 5) .
– Unscrew lock washers ⇒ Item 7 (page 5) and detach noise insulation (left-side).
❑ To install, insert retaining pegs (front) into lock carrier (bottom).
9 - Locking pin
❑ Qty. 4
10 - Self-tapping screw, 2.2 Nm
11 - Socket head bolt M8x18, 25 Nm
❑ Qty. 8
12 - Socket head bolt M12x1.5x30, 120 Nm
❑ Qty. 2
13 - Spring clip
1. Body - front 5
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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 1999 ➤
General body repairs, exterior - Edition 07.2004
14 - Self-tapping screw, 2.2 Nm
15 - Wheel spoiler (inner)
16 - Spreader rivet
Installing noise insulation
– Insert tabs on noise insulation (front) above -arrow A- and be‐
low -arrow B- the lock carrier.
– Loosely screw in 6 socket head bolts M8 -arrows 1- and hand-
tighten 2 socket head bolts M8 -arrows 2-.
– Loosely screw in 2 socket head bolts M12 -arrows 3-, then
centralise noise insulation.
– Tighten all socket head bolts.
– Tighten all self-tapping screws.
Removing and installing tubular cross member
– When installing, tighten bolts -1- for tubular cross member
-2- to 20 Nm.
6 Rep. Gr.50 - Body - front
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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 1999 ➤
General body repairs, exterior - Edition 07.2004
1.6 Body reinforcements (rear) for vehicles with 6-cyl. engine
1 - Self-tapping screw, 1.5 Nm
❑ Qty. 6
2 - Wheel spoiler (rear)
3 - Speed nut
❑ Qty. 6
4 - Self-tapping screw, 1.5 Nm
❑ Qty. 4
5 - Expanding nut
❑ Qty. 4
6 - Floor trim for fuel tank
7 - Pan-head bolt, 65 Nm
❑ Qty. 5
❑ Tighten in sequence:
“A”, “B”, “C”.
8 - Diagonal strut
9 - Pan-head bolt, 65 Nm
❑ Qty. 5
❑ Tighten in sequence:
“A”, “B”, “C”.
10 - Pan-head bolt, 65 Nm
❑ Qty. 5
❑ Tighten in sequence:
“A”, “B”, “C”.
11 - Lock washers
❑ Qty. 6
– To remove, unscrew
with a suitable screw‐
driver.
– To install just press on.
12 - Hexagon flange nut, 2.5 Nm
1. Body - front 7
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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 1999 ➤
General body repairs, exterior - Edition 07.2004
55 – Bonnet, rear lid
1 Bonnet
1.1 Contact corrosion
Contact corrosion can occur if unsuitable fasteners are used on
the vehicle (bolts, nuts, washers etc.).
For this reason, only fasteners with a special surface coating
(Dachromet) have been fitted on the vehicle. These fasteners can
be identified by their greenish colour.
In addition, all rubber and plastic parts and all adhesives are made
of non-conductive materials.
Always renew parts if you are in any doubt as to whether the old
part can be used again.
Please note the following:
♦ Always use genuine replacement parts (same as original
equipment). These have been tested and are aluminium-com‐
patible.
♦ Accessories must be approved by AUDI AG.
♦ Damage resulting from contact corrosion is not covered by the
warranty.
8 Rep. Gr.55 - Bonnet, rear lid
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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.
General body repairs, exterior - Edition 07.2004
1.2 Removing and installing bonnet, adjusting bonnet
Note
The bonnet is made of aluminium. Please observe the notes on corrosion ⇒ page 8 .
1 - Bonnet
• When removing or instal‐
ling the bonnet, a 2nd me‐
chanic is required to sup‐
port and hold the bonnet.
❑ Removing:
– Detach gas-filled strut
⇒ Item 6 (page 9)
from bonnet
⇒ page 11 .
– Unscrew hexagon bolts
⇒ Item 5 (page 9) .
Audi TT 1999 ➤
– Detach bonnet.
❑ Install in reverse se‐
quence.
❑ Adjusting:
– Centralise bonnet be‐
tween the wings.
– Adjust height of bonnet
via bottom section of
bonnet lock
⇒ page 12 .
– Adjust position of bon‐
net to wings via the stop
buffers ⇒ page 10 .
❑ Panel gaps
⇒ page 10
❑ Removing and installing
bonnet lining
⇒ page 11 .
2 - Protective film
❑ Self-adhesive
❑ Peel off protective film before mounting.
3 - Bonnet hinge
• When installing or removing the bonnet hinge, the bonnet ⇒ Item 1 (page 9) must be removed or properly
secured.
❑ Removing:
– Unscrew bolts ⇒ Item 4 (page 9) and ⇒ Item 5 (page 9) .
– Remove gas-filled strut ⇒ page 11 .
❑ Install in reverse sequence.
4 - Hexagon bolt, 21 Nm
5 - Hexagon bolt, 21 Nm
1. Bonnet 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 1999 ➤
General body repairs, exterior - Edition 07.2004
6 - Gas-filled strut
❑ Removing and installing: ⇒ page 11 .
❑ The cylinder end of the gas-filled strut must be installed on the bonnet side.
7 - Hexagon nut, 8 Nm
8 - Arrester
❑ Removing:
– Open bonnet.
– Unscrew hexagon nuts ⇒ Item 7 (page 10) and remove arrester.
❑ Install in reverse sequence.
Adjusting height of stop buffers
• When bonnet -4- is closed, stop buffers -2- and -3- must rest
lightly on lock carrier.
• Rubber buffer -1- is used as impact protection and should not
make contact when bonnet is closed.
Note
The stop buffers can be used for adjusting the height of the bon‐
net.
Panel gaps
The panel gaps can be checked using setting gauge -3371- .
•
In section -A- = 4.0 mm
•
In section -B- = 4.0 mm
•
In section -C- = 4.0 mm
•
In section -D- = 4.0 mm
+ 1 mm
+ 1 mm
+ 1 mm
+ 1 mm
10 Rep. Gr.55 - Bonnet, rear lid
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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.
General body repairs, exterior - Edition 07.2004
1.3 Removing and installing gas-filled strut
Removing
– Prop up and secure bonnet in open position.
– Use a small screwdriver to lift retaining clip slightly and pull
gas-filled strut -1- off ball stud (top) -2-.
– Perform same steps at ball stud (bottom).
Installing
Note
If gas-filled strut has been completely removed make sure it is reinstalled in the correct position. The cylinder end of the gas-filled
strut must be engaged on the bonnet side.
– Press gas-filled strut onto ball stud and make sure it engages.
Releasing gas from gas-filled strut
– Clamp section -x = 50 mm- of gas-filled strut in a vice.
Audi TT 1999 ➤
WARNING
♦ Only the section indicated may be clamped in the vice
(accident risk!).
♦ Always wear safety goggles while sawing.
Note
Cover area around saw cut with a cloth to catch any fluid which
may escape.
– Saw open the first third of the cylinder part of the gas-filled strut
(measured from the strut rod end of the cylinder).
1.4 Removing and installing bonnet lining
Removing
– Disengage clips -3- (18x) at bonnet -1- and detach lining -2-.
Installing
Install in reverse order.
1. Bonnet 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 1999 ➤
General body repairs, exterior - Edition 07.2004
1.5 Removing and installing bottom section
of bonnet lock
Removing
– Disengage Bowden cable for bonnet ⇒ page 12 .
– Unscrew bolts -2- (Qty. 4). Tightening torque: 10 Nm.
– Take out bottom section of bonnet lock -1-.
Note
To adjust bonnet, move bottom section of bonnet lock up or down
as required.
Installing
Install in reverse order.
1.6 Removing and installing Bowden cable for bonnet lock
1 - Bowden cable for bonnet
lock
❑ Removing:
– Remove storage com‐
partment on driver's
side ⇒ General body re‐
pairs, interior; Rep. Gr.
68 .
– Unscrew bolts.
– Disengage Bowden ca‐
ble from support bracket
-arrow B- and eyelet
-arrow A- on bonnet lock
(bottom section)
⇒ Item 3 (page 12) .
– Detach retaining clip
⇒ Item 2 (page 12) .
– Disengage Bowden ca‐
ble from bracket
⇒ Item 4 (page 12) .
– Pull Bowden cable to‐
wards passenger com‐
partment of vehicle to
remove.
❑ Install in reverse se‐
quence.
2 - Retaining clip
3 - Bonnet lock (bottom sec‐
tion)
❑ Removing and instal‐
ling: ⇒ page 12 .
❑ Move up or down to ad‐
just bonnet.
12 Rep. Gr.55 - Bonnet, rear lid
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4 - Bracket for Bowden cable
5 - Release lever for bonnet lock
6 - Expanding nut
7 - Fillister head self-tapping screw, 1.5 Nm
8 - Grommet
❑ When installing, make sure it is seated correctly.
9 - Edge protection
❑ Must be pushed onto edge of metal panel.
Audi TT 1999 ➤
General body repairs, exterior - Edition 07.2004
1. Bonnet 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 1999 ➤
General body repairs, exterior - Edition 07.2004
2 Rear lid - Coupé
2.1 Removing and installing rear lid, adjusting rear lid
1 - Rear lid
• When removing or instal‐
ling the rear lid, a 2nd me‐
chanic is required to sup‐
port and hold the rear lid.
❑ Removing:
– Remove rear lid lining.
– Detach electrical wiring
and pull completely out
of rear lid.
– Remove gas-filled struts
(left and right)
⇒ page 16 .
– Unscrew hexagon bolts
securing hinges to rear
lid ⇒ page 16 .
– Detach rear lid.
❑ Install in reverse se‐
quence.
❑ Adjusting:
• Gas-filled struts must be fit‐
ted before adjusting new
rear lid.
– Height and longitudinal
adjustments at top of
rear lid must be made
via rear lid hinge.
– Height adjustments at
bottom of rear lid must
be made via rear lid
lock.
– Align rear lid centrally according to specified panel gaps ⇒ page 15 .
– Adjust stop buffers ⇒ Item 2 (page 14) .
❑ Removing and installing seal for rear lid ⇒ page 17 .
2 - Stop buffers (2x)
❑ Adjusting ⇒ page 15 .
3 - Pop rivet
❑ To remove, drill out rivet heads and knock out rivet stems.
4 - Cover
❑ Unclip
5 - Bolt with washer, 12 Nm
6 - Striker plate
❑ Adjusting:
– Hand-tighten bolts with washers ⇒ Item 5 (page 14) (it must still be possible to move striker plate).
14 Rep. Gr.55 - Bonnet, rear lid
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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 1999 ➤
General body repairs, exterior - Edition 07.2004
– Carefully close rear lid until it is flush with rear side panels.
– Carefully open rear lid and tighten bolts with washers ⇒ Item 5 (page 14) .
7 - Rear lid hinge
❑ Removing and installing: ⇒ page 16 .
8 - Bolt with washer, 8 Nm
9 - Rear lid lock
❑ To remove, unscrew bolts with washers ⇒ Item 8 (page 15) and disengage Bowden cable.
10 - Bowden cable for rear lid lock
❑ Removing and installing: ⇒ page 18 .
11 - Protective film
❑ Self-adhesive
❑ Peel off protective film before mounting.
Adjusting stop buffers
– Loosen clamping bolt -2- and pull stop buffer out slightly.
– Close rear lid -4- and align with body; at the same time, rear
lid lock must engage in 2nd stop of striker plate.
• This will push stop buffers -3- into correct position.
– Open rear lid and pull stop buffers out one stop.
– Tighten clamping bolt -2- to 2 Nm.
– Close rear lid.
– Check panel gaps ⇒ page 15 .
Note
To remove stop buffer drill rivet head off pop rivet -1-, knock out
rivet stem and detach buffer stop.
Panel gaps
The panel gaps can be checked using setting gauge -3371- .
•
In section -A- = 4.5 mm
•
In section -B- = 3.5 mm
•
In section -C- = 5.0 mm
+ 1 mm
+ 1 mm
+ 1 mm
2. Rear lid - Coupé 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 1999 ➤
General body repairs, exterior - Edition 07.2004
2.2 Removing and installing gas-filled strut
Removing
Note
When removing or installing gas-filled strut, push back open rear
lid -3- slightly, taking care not to damage any components.
– Use a screwdriver to slightly push back retaining springs -4-
at ends of gas-filled strut -1- and detach gas-filled strut from
ball studs -2-.
Installing
Note
If gas-filled strut has been completely removed make sure it is reinstalled in the correct position. The cylinder end of the gas-filled
strut must be engaged on the body side.
– Press gas-filled strut onto ball studs, first at bottom, then at
top.
•
Tightening torque for ball studs -2-: 15 Nm
Releasing gas from gas-filled strut
– Clamp section -x = 50 mm- of gas-filled strut in a vice.
WARNING
– 1 Nm
♦ Only the section indicated may be clamped in the vice
(accident risk!).
♦ Always wear safety goggles while sawing.
Note
Cover area around saw cut with a cloth to catch any fluid which
may escape.
– Saw open the first third of the cylinder part of the gas-filled strut
(measured from the strut rod end of the cylinder).
2.3 Removing and installing rear lid hinge
Removing
– First lever out cover -1- for rear lid hinge at bottom, then detach
from rear lid -2-.
– Remove roof frame trim ⇒ General body repairs, interior; Rep.
Gr. 70 .
16 Rep. Gr.55 - Bonnet, rear lid
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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.
General body repairs, exterior - Edition 07.2004
– Unscrew hexagon bolts -4- and remove rear lid -1-.
– Unscrew hexagon bolt -3- and hexagon nut -5-. Then detach
rear lid hinge -2-.
Installing
– Install and adjust rear lid hinge and rear lid.
– Tighten hexagon nut -5- and hexagon bolts -3- and -4- to
21 Nm.
– First engage cover with notches -arrow- at top in roof flange.
Audi TT 1999 ➤
2.4 Removing and installing seal for rear lid
Removing
– Open rear lid and pull off seal -1-.
Installing
• Butt joint -arrow- of seal for rear lid must be aligned with ball
socket of hinge (left-side).
– When installing seal, start in bottom corners (left and right).
– Press seal onto body as shown in illustration.
2. Rear lid - Coupé 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 1999 ➤
General body repairs, exterior - Edition 07.2004
2.5 Removing and installing Bowden cable for rear lid lock
1 - Retaining bracket for Bow‐
den cable
2 - Hexagon nut, 5 Nm
3 - Rear lid lock
❑ Removing and instal‐
ling:
⇒ Item 9 (page 15) .
4 - Bowden cable for rear lid
lock
❑ Engage in retaining
bracket as illustrated.
Engaging and disengaging Bowden cable for rear lid lock
• Rear lid lock -1- removed.
– Lift Bowden cable -2- out of support bracket -arrow B-.
– Pivot Bowden cable 90° -arrow A- and take out of rear lid lock.
18 Rep. Gr.55 - Bonnet, rear lid
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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.
General body repairs, exterior - Edition 07.2004
3 Rear lid - Roadster
3.1 Removing and installing rear lid, adjusting rear lid
1 - Rear lid
• When removing or instal‐
ling the rear lid, a 2nd me‐
chanic is required to sup‐
port and hold the rear lid.
❑ Removing:
– Remove gas-filled struts
(left and right)
⇒ page 21 .
– Unscrew hexagon bolts
securing hinges to rear
lid ⇒ page 22 .
– Detach rear lid.
❑ Install in reverse se‐
quence.
❑ Adjusting:
• Gas-filled struts must be fit‐
ted before adjusting new
rear lid.
– Height and longitudinal
adjustments at top of
rear lid must be made
via rear lid hinge.
Audi TT 1999 ➤
– Height adjustments at
bottom of rear lid must
be made via rear lid
lock.
– Align rear lid centrally
according to specified
panel gaps
⇒ page 20 .
– Adjust stop buffers
⇒ Item 2 (page 19) .
2 - Stop buffers (2x)
❑ Adjusting ⇒ page 20 .
3 - Pop rivet
❑ To remove, drill out rivet heads and knock out rivet stems.
4 - Cover
❑ Unclip
5 - Bolt with washer, 12 Nm
6 - Striker plate
❑ Adjusting:
– Hand-tighten bolts with washers ⇒ Item 5 (page 19) (it must still be possible to move striker plate).
– Carefully close rear lid until it is flush with rear side panels.
– Carefully open rear lid and tighten bolts with washers ⇒ Item 5 (page 19) .
3. Rear lid - Roadster 19
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 1999 ➤
General body repairs, exterior - Edition 07.2004
7 - Rear lid hinge
❑ Removing and installing: ⇒ page 22 .
8 - Bolt with washer, 8 Nm
9 - Rear lid lock
❑ To remove, unscrew bolts with washers ⇒ Item 8 (page 20) and disengage Bowden cable.
10 - Bowden cable for rear lid lock
❑ Removing and installing: ⇒ page 23 .
11 - Protective film
❑ Self-adhesive
❑ Peel off protective film before mounting.
Adjusting stop buffers
– Loosen clamping bolt -2- and pull stop buffer out slightly.
– Close rear lid -4- and align with body; at the same time, rear
lid lock must engage in 2nd stop of striker plate.
• This will push stop buffers -3- into correct position.
– Open rear lid and pull stop buffers out one stop.
– Tighten clamping bolt -2- to 2 Nm.
– Close rear lid.
– Check panel gaps ⇒ page 20 .
Note
To remove stop buffer drill rivet head off pop rivet -1-, knock out
rivet stem and detach buffer stop.
Panel gaps
The panel gaps can be checked using setting gauge -3371- .
•
In section -A- = 3.5 mm
•
In section -B- = 3.5 mm
•
In section -C- = 5.0 mm
+ 1 mm
+ 1 mm
+ 1 mm
20 Rep. Gr.55 - Bonnet, rear lid
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.
General body repairs, exterior - Edition 07.2004
3.2 Removing and installing gas-filled strut
Removing
Note
When removing or installing gas-filled strut, push back open rear
lid slightly, taking care not to damage any components.
– Use a screwdriver to slightly push back retaining springs -5-
at ends of gas-filled strut and detach gas-filled strut -2- from
ball studs.
3 - Stop for rear lid
4 - Rear lid hinge
Installing
Note
If gas-filled strut has been completely removed make sure it is reinstalled in the correct position. The cylinder end of the gas-filled
strut must be engaged on the bonnet side.
Audi TT 1999 ➤
– Press gas-filled strut onto ball studs, first at bottom, then at
top.
•
Tightening torque for ball head stud: 15 Nm
- 1 Nm
.
Releasing gas from gas-filled strut
– Clamp section -x = 50 mm- of gas-filled strut in a vice.
WARNING
♦ Only the section indicated may be clamped in the vice
(accident risk!).
♦ Always wear safety goggles while sawing.
Note
Cover area around saw cut with a cloth to catch any fluid which
may escape.
– Saw open the first third of the cylinder part of the gas-filled strut
(measured from the strut rod end of the cylinder).
3. Rear lid - Roadster 21
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 1999 ➤
General body repairs, exterior - Edition 07.2004
3.3 Removing and installing rear lid hinge
Removing
– Unscrew hexagon nuts -3- and remove rear lid -4-.
– Unscrew hexagon bolts -2- and remove rear lid hinge -1-.
Installing
– Install and adjust rear lid hinge and rear lid.
– Tighten hexagon nuts -3- and hexagon bolts -2- to 21 Nm.
3.4 Removing and installing seal for rear lid
Removing
– Open rear lid and pull off seal -1-.
Installing
• Butt joint -arrow- of seal must be aligned with ball socket of
hinge (left-side).
– When installing seal, start in bottom corners (left and right).
– Press seal onto body all around.
22 Rep. Gr.55 - Bonnet, rear lid
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.
General body repairs, exterior - Edition 07.2004
3.5 Removing and installing Bowden cable for rear lid lock
1 - Fastener
2 - Release lever for rear lid
lock
3 - Fillister head self-tapping
screw, 1.5 Nm
4 - Noise insulation (bottom
section)
❑ Can only be removed af‐
ter disassembling the
hydraulic pump.
5 - Bowden cable for rear lid
lock
❑ Disengaging
⇒ page 23
❑ Position in retaining
clips
⇒ Item 7 (page 23) as
illustrated.
6 - Rear lid lock
❑ Removing and instal‐
ling:
⇒ Item 9 (page 20) .
7 - Retaining clip for Bowden
cable
Audi TT 1999 ➤
Engaging and disengaging Bowden cable for rear lid lock
• Rear lid lock removed.
– Lift Bowden cable -2- out of support bracket -arrow B-.
– Pivot Bowden cable 90° -arrow A- and take out of rear lid lock.
3. Rear lid - Roadster 23
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 1999 ➤
General body repairs, exterior - Edition 07.2004
4 Tank flap
4.1 Removing and installing tank flap
Special tools and workshop equipment required
♦ Front-end hook -3370-
Removing
– Remove the three bolts -arrows-. Tightening torque: 4 Nm.
– Use front-end hook -3370- to pull fuel tank flap vertically up‐
wards out of body opening.
– Unscrew bolts -arrows- on release cable.
Installing
Installation is carried out in reverse order; note the following:
– To ensure overflow hose can be routed without kinking the
rubber cup must be installed as follows:
• The edge of drain hole must align with edge of square hole
-arrows- as shown in illustration.
24 Rep. Gr.55 - Bonnet, rear lid
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