Audi TT 46 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
Body Repairs
Audi TT 2007 ➤
Edition 09.2009
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.
Repair Group overview for Body Repairs
Re pa ir G ro up
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
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 A008JKI0120
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 ➤
Body Repairs - Edition 09.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Type plate and vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Expanded foam inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 General notes on repairs to aluminium parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 General notes on repairs to steel parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Body construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Aluminium panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.1 Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.2 Spot-welded/bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.3 Inspecting and repairing bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.4 Repair methods for replacing body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9.1 Body - front and centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.1 Floor group, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.2 Floor group, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10.3 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10.4 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10.5 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11 Straightening jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.2 Portal gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 Longitudinal member, upper part with console (Coupé and Roadster identical) . . . . . . . . 36
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2 Support, left-side - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . . . . . . . 43
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3 Support, right-side - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . . . . . . . 46
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Upper longitudinal member for wheel housing - Renewal (Coupé and Roadster identical)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5 Suspension strut mounting - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . 55
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6 Longitudinal member for wheel housing, upper, inner - Renewal (Coupé and Roadster
identical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7 Front longitudinal member - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . 65
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 2007 ➤
Body Repairs - Edition 09.2009
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8 Front longitudinal member - Partial renewal (Coupé and Roadster identical) . . . . . . . . . . 70
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9 Longitudinal member (front section) - Renewal (Coupé and Roadster identical) . . . . . . . . 73
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1 Roof - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2 Roof side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.3 Foam-filling roof side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3 Outer roof frame - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4 Front roof cross member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5 Rear roof frame - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6 Outer A-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7 Reinforcement tube and inner A-pillar - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . 122
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8 Inner A-pillar - Renewal (Coupé and Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9 Inner B-pillar - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
10 Outer side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
11 Inner side member - Partial renewal (old part section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
12 Inner side member - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
12.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
13 Floor panel - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1 Rear cross panel (top section) - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . 168
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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 2007 ➤
Body Repairs - Edition 09.2009
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2 Cross panel (inner section) - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . 173
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3 Rain channel - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4 Rear suspension strut mounting - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . 183
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5 Rear longitudinal member - Partial renewal (Coupé and Roadster identical) . . . . . . . . . . 186
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6 Side panel - Renewal (Coupé) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7 Side panel - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8 Inner side panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
9 Rear wheel housing - Partial renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . 217
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
9.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
10 Rear wheel housing - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . . . . . 222
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
10.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
11 Spare wheel well - Partial renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . . . 226
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
11.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
12 Spare wheel well - Renewal (Coupé and Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
12.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Contents iii
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
iv Contents
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00 – Technical data
1 General notes
This Manual describes only selected repair operations. A de‐
scription is given where the repair method differs from the original
manufacturing process.
Where the repair operation is not described: Separate the original
joint and repair using a replacement part.
If no description is given for any sub-parts supplied, these should
be matched up and butt welded with an SG continuous seam.
Please refer to the information in the Workshop Manual ⇒ General
Information; Body Repairs, General Body Repairs .
Audi TT 2007 ➤
Body Repairs - Edition 09.2009
1. General notes 1
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
2 Vehicle identification data
2.1 Type plate and vehicle identification number
The vehicle identification number -B- (chassis number) is stam‐
ped on the flange in the plenum chamber.
The type plate -A- is attached to the wing mounting flange (rightside).
2 Rep. Gr.00 - Technical data
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2.2 Vehicle data sticker
The vehicle data sticker is located in the spare wheel well at the
rear of the vehicle.
Audi TT 2007 ➤
Body Repairs - Edition 09.2009
2. Vehicle identification data 3
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
3 Expanded foam inserts
Various body cavities of the Audi TT 2007 are fitted with expanded
foam inserts.
The foam inserts reduce the noise transmitted to the interior when
driving.
These pre-moulded parts are fitted during body manufacture and
subsequently increase their volume in the paint shop drying oven
at approx. 180 °C after priming.
Caution
The replacement foam inserts expand only after reaching
about 180°C. For this reason, an additional filler foam is used
when performing repairs.
Filler foam required for repairs: D 506 KG1 A3.
As the required temperatures cannot be achieved under normal
workshop conditions, proceed as follows:
Remove residue of foam material on vehicle.
Restore paint coating; apply two coats (wet on wet) of glass/paint
primer D 009 200 02 if necessary, flash-off time approx.10 mi‐
nutes.
Requirement
Before continuing with this procedure, ensure that the replace‐
ment panel is ready for installation, i.e. cut to shape, matched up
to the vehicle, corrosion protection applied.
Renewing expanded foam insert
Fix expanded foam insert to vehicle.
Apply filler foam D 506 KG1 A3 to replacement panel.
Secure new part in position. Gently press in new part in vicinity of
expanded foam insert until it makes contact, and then weld into
place.
The foam hardens within 25 minutes.
Do not weld (SG) within 15 mm of the foam insert (on either side).
After painting the vehicle the repaired area must be cavity-sealed.
Location of expanded foam parts
4 Rep. Gr.00 - Technical data
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
3. Expanded foam inserts 5
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
4 General notes on repairs to alumini‐
um parts
The repair methods required for the purely aluminium body parts
are similar to the established procedures for the other Audi mod‐
els with aluminium body.
New joining technique
Flow-drill screws
Flow-drill screws can be easily released in the workshop and re‐
placed with new screws. Oversize screws are available for dam‐
aged threads. New panels have to be pre-drilled to take these
screws.
6 Rep. Gr.00 - Technical data
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5 General notes on repairs to steel
parts
Note
We recommend that repairs should be performed in a specialist
Audi workshop for aluminium.
These repairs are essentially the same as for vehicles with an allsteel body. However, special precautions are required due to the
risk of contact corrosion occurring on the aluminium parts of the
body. The dust produced when sanding or grinding steel parts,
and in particular sparks from cutting and welding operations, must
not be allowed to drop onto aluminium parts. This also applies to
painted aluminium panels. The glowing steel particles can dam‐
age the paint and come into contact with the aluminium, which
can cause contact corrosion on the undamaged aluminium body.
For these reasons, the entire body must be carefully protected
with suitable covers and masking while steel repairs are being
performed. Similarly, cutting operations may only be carried out
with mechanical tools (body saw or nibbler). Where sanding or
grinding is unavoidable, use non-sparking sanding/grinding discs
(or such that produce only a minimum amount of sparking).
Audi TT 2007 ➤
Body Repairs - Edition 09.2009
5. General notes on repairs to steel parts 7
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
6 Body construction
The Audi TT 2007 employs the ASF (Audi Space Frame) con‐
struction in an aluminium/steel body.
The repair methods are basically the same as the familiar alumi‐
nium repair methods, except that the combination of aluminium
and steel requires a number of new procedures.
This Workshop Manual describes standard repairs and repairs
carried out using repair methods which deviate from the original
manufacturing process.
Note the following for any repairs which are not described:
Separate at original joint; repair original joint using only genuine
replacement parts: see ⇒ General information; Body repairs,
General body repairs; Safety notes .
6.1 Aluminium panels
The areas of the body marked in grey - bonnet, plenum chamber,
front end and middle section - are made of aluminium.
⇒ Workshop Manual, General information; chapter on Work pro‐
cedures
Extra-high-strength body panels
Extra-high-strength body panels are used in the following areas:
The steel panels marked in yellow have a tensile strength of 340
– 500 N/mm2.
⇒ Workshop Manual, General information; chapter on Work pro‐
cedures
8 Rep. Gr.00 - Technical data
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
6. Body construction 9
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
7 Corrosion protection
The rear section of the body is manufactured from panels galvan‐
ised on both sides. Certain areas are cavity-sealed and have to
be re-sealed after completing repair work.
10 Rep. Gr.00 - Technical data
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8 Bonded joints
Bonded and spot-welded bonded joints are employed on the Audi
TT for increased body strength.
8.1 Bonded joints
In the case of adhesive-bonded joints, the joint between the sheet
metal parts is formed only by the adhesive.
8.2 Spot-welded/bonded joints
In spot welded bonded joints an electrically conductive adhesive
is used between the panels, which allows good root penetration
for spot welding.
The welding current must not be increased for spot-weld bonding
operations. The pre-press period must be extended to about 30
– 50 cycles because of the displacement of the adhesive. Always
use a fume extractor.
Spot-weld bonding is not carried out in the service sector.
8.3 Inspecting and repairing bonded joints
Audi TT 2007 ➤
Body Repairs - Edition 09.2009
Particular attention should be given to these joints when diag‐
nosing accident damage and performing body repairs.
Note the following points: Do not use a chisel to test the strength
of a joint or relieve stresses by hammering as this will damage or
destroy the bonded joint.
These joints should be inspected particularly closely when diag‐
nosing accident damage and after performing straightening work
on the body.
If the joint is not accessible with pop rivets, it must be repaired
with an arc-welded seam (SG). In this case the entire area of the
joint must be re-welded, as the heat produced by welding de‐
stroys the adhesive in the bonded joint. The SG seams should be
welded working from the thin to the thick panel. Always use a fume
extractor.
8.4 Repair methods for replacing body parts
When making repairs, welded joints can be used in place of all
spot-welded bonded joints and certain bonded joints if no suitable
body adhesive is available.
Do not make the repair with only the same spot welds or seams
as originally used in production. These alone are not adequate
for a proper joint.
The repair methods are shown in detail on the following pages.
Note
♦
If the instructions call for additional spot welds, these should
be applied in a single operation.
♦
Do not place new spot welds in-between the original spot
welds.
♦
SG plug welding should only be performed after spot welding.
♦
This avoids any increased shunt current when spot welding.
Ensure good root penetration at all joints.
Seal off repaired joint flanges and apply cavity sealing.
8. Bonded joints 11
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
9 Body panel gaps/shut lines
Special tools and workshop equipment required
♦ Setting gauge -3371-
9.1 Body - front and centre
♦ Dimension A = 4.5 mm ± 0.5 mm
♦ Dimension B = 4.5 mm ± 0.5 mm
♦ Dimension C = 3.5 mm ± 0.5 mm
♦ Dimension D = 3.5 mm ± 0.5 mm
♦ Dimension E = 3.5 mm ± 0.5 mm
♦ Dimension F = 3.5 mm ± 0.5 mm
12 Rep. Gr.00 - Technical data
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♦ Check that panel gaps are parallel with body lines
Audi TT 2007 ➤
Body Repairs - Edition 09.2009
9.1.1 Body - rear
♦ Dimension A = 4.0 mm ± 0.5 mm
♦ Dimension B = 4.5 mm ± 0.5 mm
♦ Dimension C = 3.5 mm ± 0.5 mm
♦ Dimension D = 2.0 mm ± 0.5 mm
9. Body panel gaps/shut lines 13
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
♦ Check that panel gaps are parallel with body lines
14 Rep. Gr.00 - Technical data
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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.
10 Body dimensions
10.1 Floor group, front
Distance between rear attachment points of front suspension
-a- 836 ± 2 mm
Distance between front longitudinal members (front)
-b- 899 ± 2 mm
Distance between front attachment points of front suspension
-c- 873 ± 2 mm
Diagonal distance between front longitudinal member and attach‐
ment points of front suspension
-d- 1084 ± 2 mm
Audi TT 2007 ➤
Body Repairs - Edition 09.2009
10. Body dimensions 15
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with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 2007 ➤
Body Repairs - Edition 09.2009
10.2 Floor group, rear
Distance between rear longitudinal members (rear)
-a- 978 ± 2 mm
Distance between rear longitudinal members (front)
-b- 980 ± 2 mm
Diagonal distance between longitudinal member (front) and lon‐
gitudinal member (rear)
-c- 1049 ± 2 mm
16 Rep. Gr.00 - Technical data
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10.3 Body - front
Distance between front longitudinal members
-a- 1018 ± 2 mm
Audi TT 2007 ➤
Body Repairs - Edition 09.2009
Distance between suspension strut mountings
-b- 1129 ± 2 mm
Distance between wing panel mountings
-c- 1271 ± 2 mm
Diagonal distance between suspension strut mounting and wing
panel mounting
-d- 1317 ± 2 mm
10. Body dimensions 17
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Body Repairs - Edition 09.2009
18 Rep. Gr.00 - Technical data
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10.4 Body - centre
Distance between A-pillars
-a- 1534 ± 2 mm
Height of door opening
-b- 935 ± 2 mm
Audi TT 2007 ➤
Body Repairs - Edition 09.2009
10. Body dimensions 19
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
10.5 Body - rear
Distance between rear longitudinal members
-a- 1044 ± 2 mm
Distance between side panels
-b- 913 ± 2 mm
Distance between rear cross panel flange and roof flange
-c- 1269 ± 2 mm
20 Rep. Gr.00 - Technical data
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11 Straightening jig
11.1 Overview
Audi TT 2007 ➤
Body Repairs - Edition 09.2009
Note
♦
The item numbers in the illustrations are identical with the end
numbers on the alignment bracket mountings.
♦
The item numbers of the alignment bracket mountings marked
with a circle are for checking the body with mechanical units
installed.
♦
Check the clearance of the alignment brackets before placing
them on the straightening jig. Any obstructing components
should be detached or removed.
♦
The required basic set size is given for the alignment bracket
mountings.
Alignment bracket set Audi TT -VAS 6384-
11. Straightening jig 21
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
2 - MZ 142 and TV 400
3 - Spacer
4 - MZ 142 and alignment bracket mounting
6 - MZ 260
8 - MZ 602
10 - Spacer
12 - MZ 260
14 - MZ 140
16 - Left and right centring piece identical
18 - Bracket without MZ and alignment bracket
20 - MZ 140
22 - MZ 080
24 - MZ 080 and 22
25 - Spacer
26 - MZ 200
28 - MZ 602
30 - MZ 260
32 - MZ 200
Overview of alignment bracket positions with MZ elements for
vehicles with mechanical units installed
Overview of front alignment brackets
22 Rep. Gr.00 - Technical data
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
2 - Front longitudinal member
When checking, bolt on MZ last, as the longitudinal position of the
impact absorber mounting can vary by several mm due to pro‐
duction tolerances - if necessary do not bolt down.
3 - Front longitudinal member / top of wheel housing
Overview of front alignment brackets
6 - Engine carrier mounting
7 - Engine carrier mounting
11. Straightening jig 23
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Audi TT 2007 ➤
Body Repairs - Edition 09.2009
Overview of front alignment brackets
24 Rep. Gr.00 - Technical data
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