Audi TT 47 User Manual

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Service

Workshop Manual

Audi TT 2007 ➤

General body repairs, exterior

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.

Service

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Re pa ir G ro up

00 - Technical data

50 - Body - front

55 - Bonnet, rear lid

57 - Front doors, door components, central locking

61 - Convertible roof, 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.

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 ➤

General body repairs, exterior - Edition 09.2009

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Routing and attaching pipes and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1 Removing and installing lock carrier with attachments - exploded view . . . . . . . . . . . . . . . . 3

1.2 Strut for engine mounting - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.3 Removing and installing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.4 Removing and installing front wing - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

55 - Bonnet, rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Bonnet - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.1 Removing and installing bonnet - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.2 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.3 Removing and installing gas strut - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.4 Removing and installing seal for bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.5 Removing and installing bonnet lock cable - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 18

2 Bonnet - TT RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.1 Bonnet - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.2 Removing and installing bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.3 Removing and installing bonnet hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.4 Removing and installing striker with arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.5 Removing and installing strikers (left and right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.6 Removing and installing impact guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.7 Gap widths at bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.8 Adjusting bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.9 Removing and installing gas strut and releasing gas from gas strut . . . . . . . . . . . . . . . . . . 31

3 Bonnet lock - TT RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.1 Bonnet lock - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.2 Removing and installing bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.3 Removing and installing bonnet lock (left and right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.4 Cable for bonnet and cable operating lever - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 36

3.5 Removing and installing mounting bracket for operating lever . . . . . . . . . . . . . . . . . . . . . . 37

3.6 Removing and installing cable for bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.7 Removing and installing cable for bonnet lock (left-side) . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.8 Removing and installing cable for bonnet lock (right-side) . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.9 Removing and installing mounting bracket for bonnet lock cables . . . . . . . . . . . . . . . . . . . . 41

3.10 Adjusting cables for bonnet lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 Rear lid - Coupé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.1 Removing and installing rear lid - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.2 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.3 Removing and installing rear lid hinge - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.4 Removing and installing gas strut - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.5 Removing and installing rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.6 Removing and installing seal for rear lid - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.7 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5 Rear lid - Roadster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.1 Removing and installing rear lid - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.2 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.3 Removing and installing rear lid hinge - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.4 Removing and installing gas strut - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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 ➤ General body repairs, exterior - Edition 09.2009

5.5 Removing and installing rear lid lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.6 Cable for rear lid lock - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.7 Removing and installing seal for rear lid - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 68

5.8 Adjusting rear lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6 Tank flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6.1 Removing and installing tank flap - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

57 - Front doors, door components, central locking . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1 Front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

1.1 Removing and installing door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1.2 Removing and installing window regulator - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 76

1.3 Adjusting door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1.4 Removing and installing door handle and door lock - exploded view . . . . . . . . . . . . . . . . . . 88

1.5 Removing and installing door handle - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

1.6 Removing and installing door lock - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

1.7 Door seals - Coupé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

1.8 Door seals - Roadster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

2 Servicing central locking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

2.1 Removing and installing bonnet contact switch F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.2 Removing and installing tank filler flap locking motor V 155 . . . . . . . . . . . . . . . . . . . . . . . . 97

61 - Convertible roof, hardtop, canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1 Repairing convertible roof (soft top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1.2 Convertible roof - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

1.3 Removing and installing convertible roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

1.4 Convertible roof compartment trim (front) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 105

1.5 Removing and installing convertible roof compartment trim (front) . . . . . . . . . . . . . . . . . . 105

1.6 Detaching tensioner at main mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

1.7 Adjusting convertible roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

1.8 Removing and installing seals for convertible roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1.9 Removing and installing flap for convertible roof frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1.10 Removing and installing trim for convertible roof storage compartment . . . . . . . . . . . . . . 116

1.11 Removing and installing locking mechanism for convertible roof . . . . . . . . . . . . . . . . . . . . 118

1.12 Removing and installing convertible roof cover - exploded view . . . . . . . . . . . . . . . . . . . . 124

1.13 Removing and installing headliner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

2 Repairing hydraulic system for convertible roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2.1 General information on hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2.3 Filling and bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

2.4 Hydraulic system - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

2.5 Removing hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

2.6 Renewing pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

2.7 Checking fluid level in hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

2.8 Hydraulic cylinder - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

63 - Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1 Bumper (front) - Audi TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1.1 Removing and installing bumper - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1.2 Removing bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

1.3 Removing and installing impact bar - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

2 Bumper (front) - Audi TT RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

2.1 Bumper (front) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

2.2 Removing and installing bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

2.3 Removing and installing guide for bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

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 ➤

General body repairs, exterior - Edition 09.2009

2.4 Removing and installing air intake grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

2.5 Removing and installing inner cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

2.6 Removing and installing spoiler (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

2.7 Removing and installing spoiler (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

2.8 Impact bar and impact absorber - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

2.9 Removing and installing impact absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

2.10 Removing and installing impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

3 Bumper (rear) - Audi TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

3.1 Removing and installing bumper (rear) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 162

3.2 Removing bumper (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

3.3 Removing and installing impact bar - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

4 Bumper (rear) - Audi TT RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

4.1 Bumper (rear) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

4.2 Removing and installing bumper (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

4.3 Removing and installing spoiler for bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

4.4 Removing and installing diffuser trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

4.5 Removing and installing exhaust trim panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

4.6 Impact bar, impact absorber and guide - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 175

4.7 Removing and installing impact absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

4.8 Removing and installing impact bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

4.9 Removing and installing bumper bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

4.10 Removing and installing guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

4.11 Removing and installing inner guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

64 - Glazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1 Flush-bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1.1 Removing and installing flush-bonded windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

1.2 Windscreen - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

1.3 Removing and installing windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

1.4 Side window - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1.5 Removing and installing side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

1.6 Rear window - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

1.7 Removing and installing rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

2 Windows secured by threaded fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

2.1 Removing and installing front door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

2.2 Adjusting door window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

66 - Exterior equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

1 Strips and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

1.1 Removing and installing roof trim strip - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

1.2 Renewing A-pillar trim - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

1.3 Removing and installing outer sill panel trim - exploded view . . . . . . . . . . . . . . . . . . . . . . 209

1.4 Removing and installing side member trim - exploded view . . . . . . . . . . . . . . . . . . . . . . . . 210

2 Exterior mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

2.2 Removing and installing exterior mirror - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 212

2.3 Removing and installing mirror glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

2.4 Removing and installing mirror housing - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 214

2.5 Removing and installing electric mirror adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

3 Radiator grille - Audi TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

3.1 Removing and installing radiator grille - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

4 Radiator grille - TT RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

4.1 Radiator grille and number plate holder - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 217

4.2 Removing and installing number plate holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

4.3 Removing and installing cover for radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Contents iii

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

4.4 Removing and installing radiator grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

5 Spoiler - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

5.1 Spoiler for rear lid - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

5.2 Wheel spoiler (front) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

5.3 Wheel spoiler (rear) - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

6 Spoiler - TT RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

6.1 Rear spoiler - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

6.2 Removing and installing spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

6.3 Assembling spoiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

7 Trim on underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

7.1 Removing and installing noise insulation - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . 232

7.2 Heat shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

8 Wheel housing liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

8.1 Removing and installing wheel housing liner (front) - exploded view . . . . . . . . . . . . . . . . . . 239

8.2 Removing and installing wheel housing liner (rear) - exploded view . . . . . . . . . . . . . . . . . . 240

9 Model emblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

iv Contents

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General body repairs, exterior - Edition 09.2009

00 – Technical data

1 Routing and attaching pipes and wir‐

ing

Make sketches or take photographs when unfastening or remov‐ ing and installing hydraulic and pneumatic pipes or wires. This ensures re-installation at the original location.

Audi TT 2007 ➤

1. Routing and attaching pipes and wiring 1

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

2 Contact corrosion

Contact corrosion can occur if unsuitable fasteners (bolts, nuts, washers etc.) are used on the vehicle.

For this reason, only fasteners with a special surface coating are fitted.

In addition, all rubber and plastic parts and all adhesives are made of non-conductive materials.

Always install new parts as listed in the Parts catalogue if you are not sure whether used parts can be reused.

Important:

♦ We recommend using genuine replacement parts only, as

these have been checked and are compatible with aluminium.

♦ We recommend using Audi Genuine Accessories.

♦ Damage caused by contact corrosion is not covered by the

warranty.

2 Rep. Gr.00 - Technical data

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Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

50 – Body - front

1 Body - front

1.1 Removing and installing lock carrier with attachments - exploded view

1 - Lock washer

❑ Used to secure impact

bar in position, does not have to be detached for removing lock carrier

2 - Bolt

❑ 30 Nm

3 - Impact bar

❑ Does not need to be de‐

tached from bumper brackets when remov‐ ing the lock carrier.

4 - Bolt

❑ 6 Nm

5 - Lock carrier

Note

❑ Removing:

– Remove bumper (front):

Audi TT ⇒ page 148 , Audi TT RS

⇒ page 156 .

– Remove headlight ⇒

Rep. Gr. 94 .

– Detach cable for bonnet

lock at coupling: Audi TT

⇒ page 18 , Audi TT

RS ⇒ page 41 .

– Unscrew bolts -2- at lon‐

gitudinal member.

Note

– Unscrew bolts -6- at wing and unscrew bolts -4-.

– Detach lock carrier to front.

❑ Install in reverse sequence.

6 - Bolt

❑ 23 Nm

7 - Frame

❑ Removing ⇒ page 4

1. Body - front 3

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

Removing and installing bumper bracket

1 - Bumper bracket (right-side)

2 - Bolt

❑ 5 Nm

3 - Bumper bracket (left-side)

4 - Bumper

Frame for noise insulation

4 Rep. Gr.50 - Body - front

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1 - Frame

❑ Noise insulation re‐

moved

❑ Unscrew bolts -2- and

-3- and take out frame.

2 - Bolt

❑ 23 Nm

3 - Bolt

❑ 23 Nm

4 - Pop rivet nut

5 - Longitudinal member

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

1. Body - front 5

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1.2 Strut for engine mounting - exploded view

Only on Roadster; country-specific version

1 - Engine mounting

Removing ⇒ Rep. Gr. 10

2 - Strut for engine mounting

❑ Remove nut -5- and

bolts -3-

3 - Bolt

❑ 23 Nm

4 - Pop rivet nut

5 - Nut

❑ 10 Nm

6 - Special bolt

❑ Do not unscrew bolt

when removing strut

❑ Tightening torque ⇒

Rep. Gr. 10

Reinforcement for strut

6 Rep. Gr.50 - Body - front

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1 - Strut for engine mounting

❑ Remove bolts -2- if strut

has to be detached from bracket

WARNING

When installing, rein‐ forcement -3- must be pushed into strut -1-

2 - Bolt

❑ 23 Nm ❑

When tightening to specified torque, counterhold at nut -5with open-end spanner

3 - Reinforcement for strut

4 - Bracket

5 - Nut

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

1. Body - front 7

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1.3 Removing and installing plenum chamber cover

1 - Seal for bonnet

❑ When fitted correctly,

seal must be positioned over plenum chamber cover as shown in detail view

2 - Plenum chamber cover

❑ Wiper arms removed

Note

❑ Bonnet seal detached ❑ Pull trim panel out of re‐

taining strip, starting at side of windscreen and lifting it upwards verti‐ cally.

❑ Vehicles with bolts

⇒ page 9

Caution

Danger of smashing glass during installation

When installing, trim panel must not be knocked on with a ham‐ mer, etc.

Starting at the side, care‐ fully press trim into re‐ taining strip.

3 - Windscreen surround

❑ To facilitate removal / in‐

stallation, spray soap solution onto the windscreen surround.

❑ Not available as a separate replacement part

4 - Windscreen

5 - Plenum chamber

6 - Bulkhead trim

8 Rep. Gr.50 - Body - front

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General body repairs, exterior - Edition 09.2009

Plenum chamber cover with bolts

– Remove bolts -3- and -4-.

– Pull off rubber seal -1-.

– Starting at edge of windscreen, carefully pull plenum chamber

cover -2- vertically upwards out of retainer at windscreen

-arrows-.

1.4 Removing and installing front wing - exploded view

Audi TT 2007 ➤

1 - Bolt

❑ 11 Nm

2 - Bracket

3 - Wing panel

❑ Removing: ❑ Detach side member

trim in area of wing pan‐ el.

❑ Headlight removed ⇒

Rep. Gr. 94

– Remove bumper (front):

Audi TT ⇒ page 148 , Audi TT RS

⇒ page 156 .

– Remove wheel housing

liner ⇒ page 239 .

– Remove end plate

⇒ page 10 .

– Remove bolts and de‐

tach wing.

❑ Install in reverse se‐

quence.

4 - Brace

1. Body - front 9

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

Brace for wing panel

– Wing removed

– To remove, only loosen bolts -2- and slide brace forwards out

of elongated holes.

♦ Bolts -2- 23 Nm

Removing and installing end plate

1 - End plate

– Remove front wheel.

– Remove wheel housing

liner ⇒ page 239 .

❑ Detach reservoir.

– Pull out plug -3- and

slide out end plate -1downwards.

❑

2 - Plug

3 - Bolts

❑ 11 Nm

10 Rep. Gr.50 - Body - front

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General body repairs, exterior - Edition 09.2009

55 – Bonnet, rear lid

1 Bonnet - TT

1.1 Removing and installing bonnet - exploded view

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 strut

⇒ Item 5 (page 11)

from bonnet

⇒ page 16 .

– Unscrew nuts -4- at bon‐

net hinge at top.

Audi TT 2007 ➤

– Detach bonnet.

❑ Install in reverse se‐

quence.

❑ Adjusting:

– Align bonnet between

wings.

– Adjust height of bonnet

via bottom section of bonnet lock.

– Adjust position of bon‐

net to wings via bump stops ⇒ page 15 .

Note

2 - Bolts

❑ 32 Nm

3 - Bonnet hinge

• For removal and installa‐ tion, remove bonnet or support it securely.

❑ Removing:

– Remove gas strut ⇒ page 16 .

– Remove bolts -2- and nuts -4-.

❑ Install in reverse sequence.

4 - Nuts

❑ 25 Nm

5 - Gas strut

❑ Removing and installing ⇒ page 16 . ❑ The cylinder end of the gas strut must be installed on the bonnet side.

1. Bonnet - TT 11

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

6 - Ball stud

❑ 21 Nm

7 - Protective film

❑ Self-adhesive ❑ Peel off protective film before mounting.

8 - Nuts

❑ 9 Nm

9 - Arrester

Removing and installing arrester

– Unscrew nuts and detach arrester.

Removing and installing bonnet lock

12 Rep. Gr.55 - Bonnet, rear lid

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1 - Bolt

❑ 11 Nm

2 - Bolt

❑ 11 Nm

3 - Bonnet lock

❑ Unfasten bumper cover

(top) and press to side.

❑ Detach cable for bonnet

lock at coupling.

❑ Unplug electrical con‐

nector.

❑ Remove bolts -1- and

-2-.

Note

4 - Cover for bonnet lock

5 - Nut

❑ 11 Nm

6 - Brace

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

Removing and installing bonnet hinge

1. Bonnet - TT 13

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1 - Bonnet

2 - Gas strut

❑ Engage cylinder end of

gas strut on bonnet end

❑ Removing ⇒ page 16

3 - Nut

❑ 25 Nm

4 - Hinge for bonnet

– Before removing hinge,

support bonnet or se‐ cure it in position.

❑ Gas strut removed ❑ Remove bolts -3- and

nuts -5-.

❑ Detach bonnet when re‐

moving the two hinges.

5 - Nut

❑ 25 Nm

Adjusting bonnet hinge

♦ When renewing hinge, check dimension -a- = 12.5 mm; adjust

if necessary.

1.2 Adjusting bonnet

Special tools and workshop equipment required

14 Rep. Gr.55 - Bonnet, rear lid

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♦ Setting gauge -3371-

Gap widths at bonnet

• In area -A- = 3.5 mm ±0.5 mm

• In area -B- = 4.5 mm ± 0.5 mm

• In area -C- = 4.5 mm ± 0.5 mm

• In area -D- = 4.0 mm ... 2.5 mm (at corner radius)

• In area -E- = 3.5 mm ± 0.5 mm

• In area -F- = 3.5 mm ±0.5 mm

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

Adjusting height of bump stops

• With bonnet closed, adjusting buffers -1- must rest gently on lock carrier.

• Rubber buffers -2- are used as impact protection and should not make contact when bonnet is closed.

Note

The adjusting buffers are used to adjust the height of the bonnet.

Projection at bonnet

– When correctly set, the bonnet -1- must project in the area of

the headlights -2-.

• Dimension -a- = 3.5 mm ±0.5 mm

• Projection dimension -b- = 3 mm ±0.5 mm

1. Bonnet - TT 15

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1.3 Removing and installing gas strut - exploded view

1 - Gas strut

❑ To remove, lift locking

spring -arrow- slightly and detach gas strut from ball stud.

Note

2 - Bonnet

3 - Ball stud

❑ 21 Nm

Removing

– Support bonnet or secure it in position.

– Use small screwdriver to raise locking spring slightly and de‐

tach gas strut -1- from upper ball stud -2-.

– Repeat procedure at lower ball stud.

Installing

Note

If the gas strut has been completely removed make sure it is reinstalled in the correct position. The cylinder end of the gas strut must be engaged on the bonnet side.

– Press gas strut onto ball stud and engage.

16 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

Releasing gas from gas strut

– Clamp section -x = 50 mm- of gas 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 first third of cylinder part of gas strut (measured from

piston rod end of cylinder).

1.4 Removing and installing seal for bonnet

Audi TT 2007 ➤

1 - Lock carrier seal

❑ Slide centrally from rear

onto lock carrier.

2 - Profiled seal (right-side)

❑ Self-adhesive ❑ Pull off protective film

and press onto wing mounting flange.

3 - Seal for plenum chamber

❑ Starting at the side, slide

into profiled seal (with pre-tension).

❑ Gradually press on seal

as far as opposite side.

❑ When fitting, tension

seal at corners.

Caution

Squashing in corners is not permitted

❑ Insert seal in profiled

seal on opposite side in the same manner.

4 - Plenum chamber cover

❑ Must be inserted be‐

neath lip of plenum chamber seal.

5 - Profiled seal (left-side)

❑ Self-adhesive ❑ Pull off protective film

and press onto wing mounting flange.

1. Bonnet - TT 17

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1.5 Removing and installing bonnet lock cable - exploded view

1 - Bonnet lock

❑ Removing and installing ❑ Slide upwards or down‐

wards to adjust bonnet.

2 - Cable for bonnet lock

❑ Removing: ❑ Disconnect cable at

coupling unit

⇒ page 19 .

– Disengage cable from

bracket -7-.

– Pull cable through to‐

wards engine compart‐ ment.

❑ Install in reverse se‐

quence.

3 - Foam sheath

❑ Attached to coupling

unit

4 - Coupling unit for cable

❑ Detach cable at this lo‐

cation before taking out lock carrier and when removing release lever.

5 - Grommet

❑ When installing, make

sure it is seated correct‐ ly.

6 - Cover for cable

❑ Attached to edge of pan‐

el

7 - Bracket for cable

❑ Disengaging cable ⇒ page 22

8 - Release lever for bonnet lock

❑ Removing cover for release lever ⇒ page 21

9 - Retaining clip

❑ Attached on side to body flange

10 - Clip

❑ Attached from front to lock carrier

Removing cover for cable

18 Rep. Gr.55 - Bonnet, rear lid

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1 - Cable

2 - Cover for cable

❑ To remove from body

flange, pull towards front and then detach upwards from wing mounting flange

❑ Unclip cable from cover.

3 - Body flange

4 - Wing mounting flange

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

Coupling unit for cable

1. Bonnet - TT 19

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1 - Cable (rear)

2 - Coupling unit for cable

❑ To release, detach foam

sheath and open cou‐ pling unit.

❑ Lift front cable with nip‐

ple out of coupling unit.

3 - Foam sheath

❑ After fitting cable, slide

sideways over coupling unit

4 - Cable (front)

Engaging cable in bonnet lock

20 Rep. Gr.55 - Bonnet, rear lid

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1 - Bonnet lock

2 - Nipple for cable

❑ Insert cable nipple in op‐

erating lever -5-.

❑ Insert cable in bottom

section of bonnet lock (in direction of arrow) and slide in until it en‐ gages.

3 - Cable (front)

4 - Guide

❑ Engage cable guide in

bottom section of bon‐ net lock.

5 - Operating lever

❑ Insert cable nipple at

this location

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

Removing cover for operating lever

1. Bonnet - TT 21

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1 - A-pillar trim (bottom)

2 - Cover for operating lever

❑ Before removing, disen‐

gage cable in coupling in engine compartment

⇒ page 19 .

❑ Raise operating lever by

approx. 90° and pull out of operating lever to‐ wards centre of vehicle.

3 - Operating lever

Removing operating lever

22 Rep. Gr.55 - Bonnet, rear lid

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1 - Bolts

❑ 12 Nm

2 - Mounting bracket for oper‐ ating lever

❑ Not available as a sepa‐

rate replacement part

3 - Cable

❑ If fitted correctly, cable

must run in idler roller

-arrow- in mounting bracket -2-.

4 - Operating lever

❑ Cover for operating lev‐

er removed

❑ A-pillar trim (bottom) re‐

moved

❑ Unscrew bolts -1- and

disengage cable -3-.

5 - Pop rivet nut

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

1. Bonnet - TT 23

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

2 Bonnet - TT RS

2.1 Bonnet - exploded view

1 - Locating element

❑ For striker ❑ Removing and installing

⇒ “2.5 Removing and in‐ stalling strikers (left and right)”, page 26

2 - Bolt

❑ 2 Nm

3 - Striker

❑ Removing and installing

⇒ page 26

❑ Adjusting

⇒ “2.8 Adjusting bon‐ net”, page 29

4 - Bonnet

❑ Removing and installing

⇒ page 25

5 - Nuts

❑ 9 Nm

6 - Striker with arrester

❑ Removing and installing

⇒ page 26

7 - Bump stop

8 - Adjusting buffer

❑ Adjusting

⇒ “2.8 Adjusting bon‐ net”, page 29

9 - Impact guard

❑ Removing and installing

⇒ page 26

10 - Bonnet hinge

❑ Removing and installing ⇒ page 25

11 - Bolt

❑ Note different lengths ❑ 34 Nm

12 - Gas strut

❑ Removing and installing ⇒ page 31

13 - Ball stud

❑ 23 Nm

14 - Nut

❑ 34 Nm

24 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

2.2 Removing and installing bonnet

Removing

– Remove washer jets ⇒ Rep. Gr. 92 .

– Pull sealing plug -2- out of bonnet.

– Guide electrical wiring harness -3- and washer fluid line -1- out

of bonnet.

WARNING

Risk of injury!

♦ A second mechanic is required to support and hold the

bonnet during removal and installation.

– Unscrew nuts -arrows- (left and right) at hinge.

– Detach bonnet -4-.

Installing

• Tightening torques ⇒ page 24

Installation is carried out in the reverse order; note the following:

– Adjust bonnet ⇒ page 29 .

Audi TT 2007 ➤

2.3 Removing and installing bonnet hinge

Removing

– Remove bonnet ⇒ page 25 .

– Disengage gas strut -2- at bonnet hinge ⇒ page 31 .

– Release retaining tabs and disengage duct -1- at bonnet

hinge.

– Use a felt-tip pen to mark installation position of bonnet hinge

-3- for re-installation.

– Remove bolts -4- and -5-.

Note

Bolts -4- and -5- have different lengths.

– Detach bonnet hinge.

Installing

• Tightening torques ⇒ page 24

Installation is carried out in the reverse order; note the following:

– Set stop bolt -1- for bonnet hinge to dimension -a-.

• Dimension -a- = 34 mm

– Install bonnet hinge according to markings made during re‐

moval.

– Adjust bonnet ⇒ page 29 .

2. Bonnet - TT RS 25

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

2.4 Removing and installing striker with ar‐ rester

Removing

– Unscrew cap nuts -3-.

– Detach striker -1- with arrester at bonnet -2-.

Installing

• Tightening torque ⇒ page 24

Install in reverse order of removal.

2.5 Removing and installing strikers (left and right)

Removing

– Open bonnet.

– Remove bolt -1- and detach locating element -2- for striker.

– Remove striker -3- for bonnet lock.

Installing

• Tightening torques ⇒ page 24

Installation is carried out in the reverse order; note the following:

– Adjust striker ⇒ “2.8 Adjusting bonnet”, page 29 .

2.6 Removing and installing impact guard

Special tools and workshop equipment required

♦ Hot-air blower -V.A.G 1416-

♦ Cleaning solution -D 009 401 04-

26 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

Removing

– Open bonnet.

– Carefully heat impact guard -1- with hot-air blower -V.A.G

1416- and pull impact guard off bonnet -2- in bonded area.

– Detach impact guard.

Installing

Installation is carried out in the reverse order; note the following:

– Remove any residual adhesive with adhesive strip remover -

VAS 6349- .

– Clean bonding surface on body with cleaning solution -D 009

401 04- .

– Peel off protective film and insert guide -2- on impact guard

-1- into mounting on bonnet -3-.

• Impact guard must be flush with outer edge of bonnet.

– Press on impact guard over entire length.

Audi TT 2007 ➤

2. Bonnet - TT RS 27

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

2.7 Gap widths at bonnet

Gap widths of bonnet to radiator grille, bumper and headlights

A - Bonnet to bumper

• Gap width -a- = 4.5 ±

0.5 mm

-1- Bonnet

-2- Bumper

❑ Adjusting ⇒ page 29

B - Bonnet to radiator grille (at side)

• Gap width -b- (from top to

bottom) = 4.0 … 2.5 ± 0.5 mm

-1- Bonnet

-3- Radiator grille

❑ Adjusting ⇒ page 29

C - Bonnet to radiator grille

• Gap width -c- = 4.4 ±

0.5 mm

• Projection -d- = 1.5 ± 0.5

mm

-1- Bonnet

-3- Radiator grille

❑ Adjusting ⇒ page 29

D - Bonnet to headlight

• Gap width -e- (from top to

bottom) = 3.0 … 1.6 ± 0.5 mm

• Projection -f- = 3.0 ± 0.5

mm

Gap widths of bonnet to wing and front door

28 Rep. Gr.55 - Bonnet, rear lid

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A - Bonnet to wing (in area of headlight)

• Gap width -a- = 2.5 ±

0.5 mm

-1- Bonnet

-2- Wing (front section)

❑ Adjusting ⇒ page 29

B - Bonnet to front door

• Gap width -b- = 3.5 ±

0.5 mm

• Projection -c- = 0.0 + 1.0 mm

-1- Bonnet

-3- Front door

❑ Adjusting ⇒ page 29

C - Bonnet to wing (in area of A-pillar)

• Gap width -d- = 3.5 ±

0.5 mm

• Projection -e- = 2.0 ± 0.5 mm

-1- Bonnet

-4- Wing (rear section)

❑ Adjusting ⇒ page 29

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

2.8 Adjusting bonnet

Special tools and workshop equipment required

♦ Setting gauge -3371-

2. Bonnet - TT RS 29

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

Procedure

• Gap widths ⇒ page 28

• Tightening torques ⇒ page 24

Lateral and longitudinal adjustment at hinge:

– Loosen nuts -A- at hinge -2- on both sides.

– Adjust bonnet -1- (lateral and longitudinal adjustment).

– Tighten nuts.

Height adjustment at hinge:

– Loosen bolts -B- and -C- at hinge on both sides.

– Adjust height of hinge -2- in area of bolt -B-.

– Tighten bolts.

Note

Check height adjustment of stop bolt for bonnet hinge

⇒ page 25 .

Height adjustment at bonnet lock:

• Tightening torque ⇒ page 33

– Loosen bolts -arrows-.

– Adjust height of bonnet lock -1- in lock carrier (front) -2-.

• The bonnet striker with arrester must engage vertically in the bonnet lock.

– Tighten bolts.

Height adjustment at bonnet lock (left and right):

• Tightening torque ⇒ page 24

– Remove bolt -1- and detach locating element -2- for striker.

– Screw striker -3- for bonnet lock as far as it will go into bonnet

and then screw out by 3 turns.

• Closing check for bonnet: Bonnet must fall into bonnet lock from neutral position and engage fully.

– If necessary, adjust height of striker.

– Fit locating element -2- onto striker -3-.

– Secure locating element with bolt.

30 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

Adjusting bump stop:

• Inner bump stops -1- are used as impact protection and should not make contact when bonnet is closed.

– Turn bump stops for bonnet to adjust height -arrows-.

2.9 Removing and installing gas strut and

releasing gas from gas strut

Note

Different gas struts are installed; the procedures for removal also differ.

Audi TT 2007 ➤

Removing gas strut with steel spring

WARNING

Risk of accident.

♦ Before removing a gas strut, support bonnet or secure it

in position.

– Disengage gas strut for bonnet; to do so, lift retaining spring

-2- -arrow- with a small screwdriver -1- and detach gas strut

-3- from ball stud.

Removing gas strut with plastic clip

– Using commercially available long-nose pliers, compress

plastic clip -1- as shown and pull gas strut -2- off ball stud.

Installing

Installation is carried out in the reverse order; note the following:

• The cylinder end of the gas strut must be installed on the bon‐ net side.

– Press gas strut onto ball stud until it engages audibly.

2. Bonnet - TT RS 31

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

Releasing gas from gas strut

– Clamp section -x = 50 mm- of gas strut in a vice.

WARNING

Risk of injury!

♦ It is important to only clamp this section.

♦ Always wear safety goggles while sawing.

Note

Cover area around saw notch with a cloth to catch any escaping fluid.

– Saw open first third of cylinder part of gas strut (measured from

piston rod end of cylinder).

32 Rep. Gr.55 - Bonnet, rear lid

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3 Bonnet lock - TT RS

3.1 Bonnet lock - exploded view

1 - Nut

❑ 9 Nm

2 - Brace

3 - Bolt

❑ 11 Nm

4 - Bolt

❑ 11 Nm

5 - Anti-theft bracket

6 - Bonnet lock (right-side)

❑ Removing and installing

⇒ page 35

7 - Mounting (right-side) for bonnet lock

8 - Bolt

❑ 3 Nm

9 - Mounting (left-side) for bon‐ net lock

10 - Bolt

❑ 10 Nm

11 - Bonnet lock (left-side)

❑ Removing and installing

⇒ page 35

12 - Bonnet lock

❑ With bonnet contact

switch -F266-

❑ Can be used to adjust

height of bonnet

⇒ page 29

❑ Removing and installing

⇒ page 34

13 - Bolt

❑ 11 Nm

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

3. Bonnet lock - TT RS 33

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

3.2 Removing and installing bonnet lock

Removing

– Detach bonnet contact switch -F266- only at bonnet lock

⇒ page 97 .

– Prise retaining clips -3- off cable guide -2-.

– Remove bolts -arrows-.

– Detach bonnet lock -1- from lock carrier.

– Press release lever at cable -1- in direction of -arrow A-.

– Swivel support bracket with cable in direction of -arrow B- and

disengage it at bonnet lock -2-.

Installing

• Tightening torque ⇒ page 33

Installation is carried out in the reverse order; note the following:

– Engage support bracket -5- with cable at bonnet lock -2-

-arrow- and swivel it forwards towards bonnet lock until catch

-1- engages. This causes cable nipple -4- to engage at oper‐ ating lever -3- for bonnet lock release.

– Install bonnet contact switch -F266- at bonnet lock

⇒ page 97 .

– Adjust bonnet ⇒ page 29 .

34 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

3.3 Removing and installing bonnet lock

(left and right)

Removing

– Remove bolts -arrows-.

– Take out bonnet lock -1- until cable is visible.

– Release retaining tab -1- -arrow A- and pull cable support

bracket out of mounting -2- -arrow B-.

– Pull cable nipple -3- out of release lever -4- at bonnet lock.

– Detach bonnet lock.

Installing

• Tightening torque ⇒ page 33

Installation is carried out in the reverse order; note the following:

– Adjust bonnet ⇒ page 29 .

Audi TT 2007 ➤

3. Bonnet lock - TT RS 35

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

3.4 Cable for bonnet and cable operating lever - exploded view

1 - Bonnet lock

2 - Cable (right-side)

❑ For bonnet lock (right-

side)

❑ Removing and installing

⇒ page 40

3 - Bonnet lock (right-side)

4 - Mounting bracket

❑ For cables leading to

bonnet locks (left and right)

❑ Removing and installing

⇒ page 41

5 - Cover

❑ For cable

6 - Grommet

❑ To seal off passenger

compartment

7 - Bolt

❑ 10 Nm

8 - Mounting bracket for oper‐ ating lever

❑ Removing and installing

⇒ page 37

9 - Operating lever

10 - Retaining clip

❑ For mounting bracket

with cable

11 - Bonnet lock (left-side)

❑ Removing and installing

⇒ page 35

12 - Cable (left-side)

❑ For bonnet lock (left-side) ❑ Removing and installing ⇒ page 39 ❑ Adjusting ⇒ page 43

13 - Cable

❑ For bonnet lock ❑ Removing and installing ⇒ page 37

36 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

3.5 Removing and installing mounting

bracket for operating lever

Removing

– Remove dash panel trim (driver side) ⇒ Rep. Gr. 70 .

– Remove A-pillar trim (bottom) ⇒ Rep. Gr. 70 .

– Remove bolts -1- and -2-.

– Pull cable -4- for bonnet out of support bracket and detach at

idler roller -arrow-.

– Disengage cable nipple -5- from operating lever -6-.

– Detach mounting bracket -3- for operating lever.

Installing

Installation is carried out in the reverse order; note the following:

• Tightening torque ⇒ page 36

– Cable nipple must be inserted correctly in operating lever.

– Insert cable in idler roller and press cable sleeve into support

bracket.

– Install A-pillar trim (bottom) ⇒ Rep. Gr. 70 .

– Install dash panel trim (driver side) ⇒ Rep. Gr. 70 .

Audi TT 2007 ➤

3.6 Removing and installing cable for bon‐

net lock

Removing

– Remove bumper ⇒ page 156 .

– Remove bolts -arrows-.

– Detach air duct -1-.

3. Bonnet lock - TT RS 37

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

– Unscrew nut -1- and bolts -3- and -4-.

– Detach brace -6-.

– Disengage anti-theft bracket -2- from bottom of lock carrier

-5- -arrows- and detach.

– Prise retaining clips -3- off cable guide -2-.

– Remove bolts -arrows-.

– Detach bonnet lock -1- from lock carrier.

– Press release lever at cable -1- in direction of -arrow A-.

– Swivel support bracket with cable in direction of -arrow B- and

disengage it at bonnet lock -2-.

38 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

– Slide both locking bars in direction of -arrows- and detach

cover for engine compartment electronics box.

– Push foam sleeve -7- at cable mounting bracket -6- to one

side.

– Cut through cable tie -arrow-.

– Release retaining clips and open cover.

– Take cable support bracket -4- out of cable mounting bracket

-1-.

– Disengage cable nipple for bonnet lock from connecting piece

-2-.

Audi TT 2007 ➤

Note

Ignore -items 3 and 5-.

– Guide cable out towards front through opening in lock carrier.

Installing

Installation is carried out in the reverse order; note the following:

Note

Re-attach all cable ties at the same locations when re-installing.

– Install cover for engine compartment electronics box ⇒ Rep.

Gr. 97 .

– Install bonnet lock ⇒ page 34 .

– Install bumper ⇒ page 156 .

3.7 Removing and installing cable for bon‐

net lock (left-side)

Removing

– Remove bonnet lock (left-side) ⇒ page 35 .

– Slide both locking bars in direction of -arrows- and detach

cover for engine compartment electronics box.

3. Bonnet lock - TT RS 39

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

– Push foam sleeve -7- at cable mounting bracket -6- to one

side.

– Cut through cable tie -arrow-.

– Release retaining clips and open cover.

– Take cable support bracket -3- out of cable mounting bracket

-1-.

– Disengage cable nipple for bonnet lock (left-side) from con‐

necting piece -2-.

Note

Ignore -items 4 and 5-.

– Cut open cable tie and detach cable for bonnet lock.

Installing

Installation is carried out in the reverse order; note the following:

Note

Re-attach all cable ties at the same locations when re-installing.

– Install bonnet lock (left-side) ⇒ page 35 .

– Install cover for engine compartment electronics box ⇒ Rep.

Gr. 97 .

3.8 Removing and installing cable for bon‐ net lock (right-side)

Removing

– Slide both locking bars in direction of -arrows- and detach

cover for engine compartment electronics box.

40 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

– Push foam sleeve -7- at cable mounting bracket -6- to one

side.

– Cut through cable tie -arrow-.

– Release retaining clips and open cover.

– Take cable support bracket -5- out of cable mounting bracket

-1-.

– Disengage cable nipple for bonnet lock (right-side) from con‐

necting piece -2-.

Note

Ignore -items 3 and 4-.

– Unscrew bolts -arrows- and detach air duct.

– Remove bonnet lock (right-side) ⇒ page 35 .

– Cut open cable tie and detach cable for bonnet lock.

Installing

Installation is carried out in the reverse order; note the following:

Audi TT 2007 ➤

Note

Re-attach all cable ties at the same locations when re-installing.

– Install bonnet lock (right-side) ⇒ page 35 .

– Install cover for engine compartment electronics box ⇒ Rep.

Gr. 97 .

3.9 Removing and installing mounting bracket for bonnet lock cables

Removing

– Slide both locking bars in direction of -arrows- and detach

cover for engine compartment electronics box.

3. Bonnet lock - TT RS 41

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

– Push foam sleeve -7- at cable mounting bracket -6- to one

side.

– Cut through cable tie -arrow-.

– Release retaining clips and open cover.

– Take cable support brackets -3, 4, 5- out of cable mounting

bracket -1-.

– Disengage cable nipple for bonnet lock from connecting piece

-2-.

– Remove dash panel trim (driver side) ⇒ Rep. Gr. 70 .

– Remove A-pillar trim (bottom) ⇒ Rep. Gr. 70 .

– Pull cable -2- for bonnet out of support bracket -1- and detach

at idler roller -arrow-.

– Disengage cable nipple -3- from operating lever -4-.

– Remove wiper arms ⇒ Rep. Gr. 92 .

– Remove bolts -3- and -4-.

– Pull off rubber seal -1-.

Caution

Risk of damage to plenum chamber cover.

♦ Coat transition between windscreen and plenum chamber

cover with a small amount of soap solution.

– Starting at edge of windscreen, carefully pull plenum chamber

cover -2- vertically upwards out of retainer at windscreen

-arrows-.

42 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

– Detach cover -4- and take cable out of retaining clip -3-.

– Pull sealing grommet -1- with cable -2- out of opening in body.

– Remove cable mounting bracket for bonnet lock.

Installing

Installation is carried out in the reverse order; note the following:

– Install plenum chamber cover ⇒ page 8 .

– Install cover for engine compartment electronics box ⇒ Rep.

Gr. 97 .

– Engage cable nipple -3- in operating lever -4-.

– Guide cable -2- for bonnet over idler roller -arrow- and press

it into support bracket -1-.

– Install A-pillar trim (bottom) ⇒ Rep. Gr. 70 .

– Install dash panel trim (driver side) ⇒ Rep. Gr. 70 .

Audi TT 2007 ➤

3.10 Adjusting cables for bonnet lock

Procedure

When the release lever is operated, the bonnet locks (left and right) should be operated simultaneously.

– Set bonnet locks (left and right) to “closed” position:

• The operating cables should allow the catches on the bonnet

locks to engage fully.

• The operating cables -1- and -2- should then be slack.

– If necessary, turn operating cable adjuster -3- accordingly

-arrows-.

3. Bonnet lock - TT RS 43

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

4 Rear lid - Coupé

4.1 Removing and installing rear lid - exploded view

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 ⇒

Rep. Gr. 70 .

– Disconnect wiring and

pull out of rear lid.

– Remove gas struts (left

and right) ⇒ page 48 .

– Unscrew bolts connect‐

ing rear lid hinges to rear lid ⇒ page 47 .

– Detach rear lid.

❑ Install in reverse se‐

quence.

❑ Adjusting:

• Gas struts must be fitted 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 gap widths ⇒ page 46 .

– Adjust bump stops ⇒ Item 2 (page 44) .

❑ Removing and installing seal for rear lid ⇒ page 53 .

2 - Bump stop

❑ With the rear lid correctly adjusted and closed, the adjusting buffers must rest lightly against the body. ❑ Adjusting ⇒ page 45 .

3 - Pop rivet

❑ To remove, drill out rivet heads and knock out rivet stems.

4 - Rear lid lock

❑ To remove, unscrew bolts with washers and disengage cable.

5 - Nuts

❑ 21 Nm

44 Rep. Gr.55 - Bonnet, rear lid

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Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

6 - Cable for manual release

7 - Striker plate

❑ Adjusting:

– Hand-tighten bolts with washers ⇒ Item 5 (page 44) (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 ⇒ Item 5 (page 44) .

8 - Nuts

❑ 21 Nm

9 - Protective film

❑ Self-adhesive ❑ Peel off protective film before mounting.

10 - Rear lid hinge

❑ Removing and installing ⇒ page 47 .

Adjusting bump stops

– Close rear lid.

Note

With the rear lid correctly adjusted and closed, the adjusting buf‐ fers must rest lightly against the body.

– Replacement buffers are pre-adjusted and should only be

screwed in or out as and when required.

– Check gap widths ⇒ page 46 .

Note

To remove bump stop, drill rivet head off pop rivet -1-, knock out rivet stem and detach bump stop.

4. Rear lid - Coupé 45

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

4.2 Adjusting rear lid

Special tools and work‐ shop equipment re‐ quired

♦ Setting gauge -3371-

Gap widths

The gap widths can be checked using setting gauge -3371- .

• In area -A- = 4.5 mm ± 0.5 mm

• In area -B- = 3.5 mm ± 0.5 mm

• In area -C- = 4.0 mm ± 0.5 mm

• In area -D- = 2.0 mm ± 0.5 mm

• In area -E- = 2.0 mm ± 0.5 mm

46 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

4.3 Removing and installing rear lid hinge - exploded view

1 - Rear lid hinge

❑ To remove rear lid, only

unscrew bolts -3-.

❑ Unfasten headliner in

area of nut -4-.

❑ To remove, take out

cover ⇒ page 47 and unscrew nut -4-.

2 - Rear lid

3 - Bolt

❑ 21 Nm

4 - Nut

❑ 21 Nm

Audi TT 2007 ➤

Removing cover for rear lid hinge

4. Rear lid - Coupé 47

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1 - Cover for rear lid hinge

❑ To detach cover for rear

lid hinge, start by prising out at bottom

❑ When installing, engage

at top and then allow to engage at bottom.

4.4 Removing and installing gas strut - ex‐

ploded view

WARNING

Risk of accident.

♦ Before removing a gas strut, support rear lid or secure it

in position.

48 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.

1 - Rear lid

2 - Gas strut

❑ Observe installation po‐

sition and engage gas strut on body end.

❑ Note different versions.

3 - Ball stud

❑ 21 Nm

4 - Retaining clip

❑ To release, lift slightly

with a small screwdriv‐ er.

❑ Note different versions.

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

Note

Different gas struts are installed; the procedures for removal also differ.

Note

Removing gas strut with steel spring

– Disengage gas strut for rear lid; to do so, lift retaining spring

-2- -arrow- with a small screwdriver -1- and detach gas strut

-3- from ball stud.

4. Rear lid - Coupé 49

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 ➤ General body repairs, exterior - Edition 09.2009

Removing gas strut with plastic clip

– Using commercially available long-nose pliers, compress

plastic clip -1- as shown and pull gas strut -2- off ball stud.

Installing

Note

♦

Following complete removal, pay attention to correct position of gas strut when installing.

♦

The gas strut cylinder must be engaged on the body end.

– Start by pressing on gas strut at bottom and then onto ball

studs at top.

Releasing gas from gas strut

– Clamp section -x = 50 mm- of gas 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 first third of cylinder part of gas strut (measured from

piston rod end of cylinder).

50 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

4.5 Removing and installing rear lid lock

1 - Rear lid

2 - Rear lid lock

❑ Rear lid trim removed ⇒

Rep. Gr. 70

❑ Before removing, de‐

tach cover for rear lid lock.

❑ Disengage manual re‐

lease cable.

❑ Unscrew nuts and de‐

tach rear lid lock.

3 - Cover for rear lid lock

❑ Cover should engage

audibly in rear lid lock on installation.

4 - Nut

❑ 21 Nm

5 - Anti-theft cover

Audi TT 2007 ➤

Manual release for rear lid lock

4. Rear lid - Coupé 51

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1 - Cable

❑ Before removing, unclip

anti-theft cover

❑ Cable secured with clips

-arrows-.

2 - Rear lid lock

3 - Rear lid

4 - Operating lever for manual release mechanism

❑ Clipped into rear lid trim.

5 - Cap for rear lid trim

52 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

4.6 Removing and installing seal for rear lid - exploded view

1 - Seal for rear lid

❑ To remove, pull seal off

body flange.

❑ When fitting, align seal

with joint -arrow- at left ball stud and press onto body flange all round.

Audi TT 2007 ➤

4.7 Adjusting rear lid

Special tools and workshop equipment required

♦ Setting gauge -3371-

Gap widths

4. Rear lid - Coupé 53

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

♦ Dimension -A- = 4.0 mm ± 0.5 mm

♦ Dimension -B- = 4.5 mm ± 0.5 mm

♦ Dimension -C- = 3.5 mm ± 0.5 mm

♦ Dimension -D- = 2 mm all round

54 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

5 Rear lid - Roadster

5.1 Removing and installing rear lid - exploded view

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 ⇒

Rep. Gr. 70 .

– Disconnect wiring and

pull out of rear lid.

– Remove gas struts (left

and right) ⇒ page 58 .

Audi TT 2007 ➤

– Unscrew bolts connect‐

ing rear lid hinges to rear lid ⇒ page 58 .

– Detach rear lid.

❑ Install in reverse se‐

quence.

❑ Adjusting:

• Gas struts must be fitted 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 gap widths ⇒ page 57 .

– Adjust bump stops ⇒ Item 2 (page 55) .

❑ Removing and installing seal for rear lid ⇒ page 68 .

2 - Bump stop

❑ With the rear lid correctly adjusted and closed, the adjusting buffers must rest lightly against the body. ❑ Adjusting ⇒ page 56 .

3 - Pop rivet

❑ To remove, drill out rivet heads and knock out rivet stems.

4 - Rear lid lock

❑ To remove, unscrew bolts with washers and disengage cable.

5 - Nuts

❑ 21 Nm

5. Rear lid - Roadster 55

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

6 - Cable for manual release

7 - Striker plate

❑ Adjusting:

– Hand-tighten bolts with washers ⇒ Item 5 (page 55) (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 ⇒ Item 5 (page 55) .

8 - Nuts

❑ 21 Nm

9 - Protective film

❑ Self-adhesive ❑ Peel off protective film before mounting.

10 - Rear lid hinge

❑ Removing and installing ⇒ page 58 .

Adjusting bump stops

– Close rear lid.

Note

With the rear lid correctly adjusted and closed, the adjusting buf‐ fers must rest lightly against the body.

– Replacement buffers are pre-adjusted and should only be

screwed in or out as and when required.

– Check gap widths ⇒ page 57 .

Note

To remove bump stop, drill rivet head off pop rivet -1-, knock out rivet stem and detach bump stop.

56 Rep. Gr.55 - Bonnet, rear lid

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5.2 Adjusting rear lid

Special tools and work‐ shop equipment re‐ quired

♦ Setting gauge -3371-

Gap widths

The gap widths can be checked using setting gauge -3371- .

• In area -A- = 4.5 mm ± 0.5 mm

• In area -B- = 3.5 mm ± 0.5 mm

• In area -C- = 4.0 mm ± 0.5 mm

• In area -D- = 2.0 mm ± 0.5 mm

• In area -E- = 2.0 mm ± 0.5 mm

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

5. Rear lid - Roadster 57

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

5.3 Removing and installing rear lid hinge - exploded view

1 - Bolt

❑ 21 Nm

2 - Bolt

❑ 21 Nm

3 - Rear lid hinge

❑ To remove rear lid, only

unscrew nuts -6-.

❑ To remove, remove cov‐

er and unscrew bolts

-1- and -2-.

4 - Rear lid

5 - Gas strut

❑ Note different versions.

6 - Nut

❑ 21 Nm

5.4 Removing and installing gas strut - ex‐ ploded view

WARNING

Risk of accident.

♦ Before removing a gas strut, support rear lid or secure it

in position.

58 Rep. Gr.55 - Bonnet, rear lid

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1 - Rear lid

2 - Gas strut

❑ Observe correct instal‐

lation position

❑ Note different versions

3 - Ball stud

❑ 21 Nm

4 - Retaining clip

❑ Note different versions.

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

Note

Different gas struts are installed; the procedures for removal also differ.

Removing gas strut with steel spring

– Disengage gas strut for rear lid; to do so, lift retaining spring

-2- -arrow- with a small screwdriver -1- and detach gas strut

-3- from ball stud.

5. Rear lid - Roadster 59

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

Removing gas strut with plastic clip

– Using commercially available long-nose pliers, compress

plastic clip -1- as shown and pull gas strut -2- off ball stud.

Installing

Note

♦

Following complete removal, pay attention to correct position of gas strut when installing.

♦

Gas strut cylinder must be engaged at rear lid end.

– Start by pressing on gas strut at bottom and then onto ball

studs at top.

Releasing gas from gas strut

– Clamp section -x = 50 mm- of gas 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 first third of cylinder part of gas strut (measured from

piston rod end of cylinder).

60 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

5.5 Removing and installing rear lid lock

1 - Rear lid

2 - Rear lid lock

❑ Rear lid trim removed ⇒

Rep. Gr. 70

❑ Before removing, de‐

tach cover for rear lid lock.

❑ Disengage manual re‐

lease cable.

❑ Unscrew nuts and de‐

tach rear lid lock.

3 - Cover for rear lid lock

❑ Cover should engage

audibly in rear lid lock on installation.

4 - Nut

❑ 21 Nm

5 - Anti-theft cover

Audi TT 2007 ➤

5. Rear lid - Roadster 61

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

5.6 Cable for rear lid lock - exploded view

Manual release for rear lid lock

1 - Manual release handle

2 - Grommet

3 - Bowden cable

❑ When installing, engage

rear lid end of cable with coupling unit -8- in rear lid lock ⇒ page 62 .

❑ Clip coupling unit into in‐

ner part of rear lid

⇒ page 63 .

❑ With rear lid open, run

handle end of Bowden cable through hinge into luggage compartment and engage grommet

-6- onto hinge

⇒ page 64 .

❑ Clip cover -5- onto

hinge.

❑ Take hold of Bowden

cable in luggage com‐ partment and run cable through bottom hole in rear roof frame -10-.

❑ Engage Bowden cable

in end plate -11- in cen‐ tre of convertible roof compartment

⇒ page 65 .

❑ Engage Bowden cable

in handle.

4 - Grommet for rear lid

5 - Cover

❑ Push onto hinge

6 - Grommet for hinge

❑ Clipped into hinge

7 - Guide piece

8 - Coupling unit

9 - Rear lid lock

10 - Rear roof frame

11 - End plate, convertible roof compartment

Attaching Bowden cable to rear lid lock

62 Rep. Gr.55 - Bonnet, rear lid

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1 - Rear lid lock

2 - Cover

❑ After attaching Bowden

cable, fit cover on lock.

3 - Actuator for rear lid lock

4 - Bowden cable

❑ Engage in actuator as

shown and secure Bow‐ den cable to rear lid lock.

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

Coupling unit for Bowden cable

5. Rear lid - Roadster 63

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1 - Coupling unit for Bowden cable

❑ Coupling unit is clipped

into inside of rear lid.

❑ Pull out locking element

from the side and fold open coupling unit.

❑ Push locking element

back into coupling unit when installing.

2 - Cable

❑ Fit ball on cable into

coupling unit, close flap and push in locking ele‐ ment.

3 - Locking element

Routing of Bowden cable at hinge

64 Rep. Gr.55 - Bonnet, rear lid

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1 - Cover

❑ Press cover onto side of

hinge.

2 - Bowden cable

3 - Grommet for hinge

❑ Press grommet into

hinge so it snaps into place.

4 - Hinge for rear lid

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

Attaching Bowden cable to handle

5. Rear lid - Roadster 65

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1 - Bowden cable

❑ Engage ball -1- on Bow‐

den cable in handle -2-.

Caution

To ensure correct func‐ tion, the cable must run behind the retaining lug as shown.

2 - Manual release handle

3 - Grommet

❑ Push into end plate and

secure by moving to‐ ward one side.

Manual release mechanism (different version for some countries)

66 Rep. Gr.55 - Bonnet, rear lid

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1 - Retainer for Bowden cable

❑ Riveted to rear lid

2 - Bowden cable

3 - Rear lid

4 - Rear lid lock

❑ Engage Bowden cable

in rear lid lock as shown in detail illustration

-arrow-.

❑ Attaching Bowden cable

to operating lever ⇒ Rep. Gr. 70 .

5 - Rivet

❑ 3x

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

5. Rear lid - Roadster 67

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

5.7 Removing and installing seal for rear lid - exploded view

1 - Seal for rear lid

❑ To remove, pull seal off

body flange.

❑ When fitting, align seal

with joint -arrow- at left ball stud and press onto body flange all round.

5.8 Adjusting rear lid

Special tools and workshop equipment required

♦ Setting gauge -3371-

Gap widths

68 Rep. Gr.55 - Bonnet, rear lid

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Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

♦ Dimension -A- = 4.0 mm ± 0.5 mm

♦ Dimension -B- = 4.5 mm ± 0.5 mm

♦ Dimension -C- = 3.5 mm ± 0.5 mm

♦ Dimension -D- = 2 mm all round

5. Rear lid - Roadster 69

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

6 Tank flap

Special tools and workshop equipment required

♦ Front-end hook -3370-

6.1 Removing and installing tank flap - exploded view

1 - Cable for tank flap

2 - Bolts

❑ 4 Nm

3 - Retaining hook

❑ Retaining hook must be

flush with bottom part of tank flap.

4 - Tank flap

❑ When removing, unbolt

cable -1- at tank flap.

❑ When installing a new

tank flap, proceed as fol‐ lows:

– Guide cable through

opening in tank flap cup.

– Insert tank flap at an an‐

gle until retaining tabs engage at flange in side panel.

– Press down the tank flap

against the pre-tension of the tank flap cup until the adjustable retaining hook engages visibly.

– Secure tank flap with

bolts (3x).

5 - Tank flap cup

6 - Drain hose

70 Rep. Gr.55 - Bonnet, rear lid

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General body repairs, exterior - Edition 09.2009

Removing

– Remove the three bolts -arrows-.

– Release catch -arrow- with hook -T40207- (or make an im‐

provised hook with e.g. a piece of welding wire).

Audi TT 2007 ➤

– Use front-end hook -3370- to pull tank flap vertically upwards

out of body opening.

– Remove bolts -arrows- at cable.

6. Tank flap 71

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

Installing

Installation is carried out in reverse order; note the following:

– The tank flap cup must be installed as follows to be able to lay

the overflow hose without kinking:

• As shown in the illustration, the edge of the drain hole in the

tank flap cup must coincide with the edge of the hole in the body -arrows-.

Installation position of tank flap

1 - Lid for tank flap

❑ Set an even distance

-A- from the side panel.

2 - Tank cap

3 - Tank flap

4 - Tank flap cup

❑ Fit onto body flange all

around (as shown).

5 - Drain hose

Drain hose for tank flap

72 Rep. Gr.55 - Bonnet, rear lid

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1 - Drain hose

– Press drain hose into

clips -3- beneath wheel housing liner and fit onto body pins (as shown).

2 - Tank flap

3 - Clip

❑ Attached to body pins as

shown.

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

6. Tank flap 73

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

57 – Front doors, door components, central locking

1 Front door

Special tools and workshop equipment required

♦ Multi-point socket screwdriver -T10011-

♦ Bit insert -3320/2-

♦ Socket -3410-

74 Rep. Gr.57 - Front doors, door components, central locking

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Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

1.1 Removing and installing door

Note

♦

For various assembly operations, the door can be lifted out of the door hinges completely after unplugging the electrical connectors at the A-pillar (bottom).

♦

No adjustment work is required after fitting.

1 - Door panel

– Pull bellows out of A-pil‐

lar (bottom).

– Unplug electrical con‐

nectors at A-pillar (bot‐ tom).

– Loosen bolt -4- at door

hinge (top).

– Unscrew lower bolt with

washer -9- at door hinge (bottom).

– Pull trim cap off hinge

pin.

Caution

Protect the painted sur‐ faces on the door and wing panel from dam‐ age.

– Carefully lift the door up

and off the hinges.

2 - Upper section of door hinge (top)

❑ Not available as a sepa‐

rate replacement part

❑ Remains bolted to the

door.

3 - Lower section of door hinge (top)

❑ Not available as a sepa‐

rate replacement part

❑ Remains bolted to A-pillar.

4 - Locking nut

❑ 25 Nm

5 - Cap

❑ Attach to locking nut

6 - Retaining clip

❑ Only fitted on replacement part. ❑ Pull off after fitting a new hinge.

1. Front door 75

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

7 - Upper section of door hinge (bottom)

– If necessary, slacken any tension between upper and lower section of door hinge (bottom) using a

screwdriver.

❑ Not available as a separate replacement part ❑ Remains bolted to the door.

8 - Lower section of door hinge (bottom)

❑ Not available as a separate replacement part ❑ Remains bolted to A-pillar.

9 - Bolt with washer

❑ 32 Nm

1.2 Removing and installing window regulator - exploded view

1 - Door window

❑ Removing and installing

⇒ page 201

2 - Window regulator

❑ Door trim removed ⇒

Rep. Gr. 70

– Window glass removed

– Cover for inner door

panel removed

⇒ page 79

– Disconnect/unclip elec‐

trical wiring.

– Window regulator motor

removed

– Remove nuts -4- and

-7-.

– Lift window regulator to

side through opening and out of door.

3 - Door

4 - Nut

❑ 8 Nm

5 - Bolt

❑ 3.5 Nm

6 - Window regulator motor

Note

7 - Nut

❑ 8 Nm

Lateral adjustment of window regulator

76 Rep. Gr.57 - Front doors, door components, central locking

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1 - Window regulator

2 - Door

3 - Nut

❑ 8 Nm

4 - Nut

❑ 8 Nm

5 - Adjuster screw

❑ For lateral adjustment,

the position of the win‐ dow regulator can be al‐ tered via the adjuster screws.

– Loosen nuts -3- and

screw adjuster screws in or out to align with door seal at roof or rear window.

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

Height adjustment of window regulator

Note

The height of the window regulator can be adjusted without removing the door trim.

1. Front door 77

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1 - Window regulator

❑ To adjust, move window

regulator down as far as it will go

❑ Apply 5 mm Allen key to

adjuster screws from underneath (through door panel) and perform adjustment -arrows- ac‐ cordingly.

2 - Driver (rear)

❑ Adjuster screw (rear)

-arrow-

3 - Driver (front)

❑ Adjuster screw (front)

-arrow-

Removing window regulator motor

– Door trim removed ⇒ Rep. Gr. 70 .

78 Rep. Gr.57 - Front doors, door components, central locking

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General body repairs, exterior - Edition 09.2009

– Bolt -2- 3.5 Nm

Note

♦

Window regulator motor can be removed or installed with mo‐ tor or side window in any position.

♦

Unplug connectors before removing motor.

– Unscrew bolts -2- and detach motor -1- from threaded pins.

Installing

– When installing, make sure threaded pins -3- engage with

catches in inner door panel.

– Push window regulator motor -1- onto threaded studs -3- and

secure with bolts -2-.

Note

♦

After installing the electric motor and attached wiring, first turn the ignition on.

♦

Then raise door window as far as it will go and keep window regulator switch pulled for approx. 2 seconds.

♦

The window regulator is now in the basic setting and the open‐ ing/closing function is activated.

Audi TT 2007 ➤

Removing and installing rear cover for inner door panel

1. Front door 79

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1 - Cable for interior door han‐ dle

2 - Grommet

❑ Must be completely

pressed into cover -4-.

3 - Inner door panel

4 - Cover

❑ To remove, gradually

release retaining tabs on cover using a thin ob‐ ject.

❑ Position of retaining

tabs

5 -

Cover fasteners

– Use a thin tool to gradually release fasteners -arrows- of cover

-1- from inner door panel -2-.

– Renew seal -3- if necessary.

80 Rep. Gr.57 - Front doors, door components, central locking

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General body repairs, exterior - Edition 09.2009

Removing and installing front covers for inner door panel

– Insert centring pin -arrow- of cover -1- in inner door panel -4-

and press on.

– Renew seal -2- of cover -3- if necessary.

Removing A-pillar trim

Audi TT 2007 ➤

1 - Trim

❑ Attach trim from above

as shown -arrow- and secure with bolt -4-.

2 - Door

3 - Outer window slot trim strip

❑ Trim -1- detached for re‐

moval

4 - Bolt

❑ 2.5 Nm

1. Front door 81

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

Side impact bar for Coupé

– The side impact bar is removed and installed through the elon‐

gated hole for the bellows.

– When installing, slide impact bar -1- through elongated hole in

door -2- and tighten bolts -3- to 12 Nm.

Side impact bar for Roadster

– The side impact bar is removed and installed through the elon‐

gated hole for the bellows.

– When installing, slide impact bar through elongated hole in

door.

– Fit impact bar in hole in A-pillar and then secure hand-tight

with bolt -1-.

– Then secure impact bar -2- with bolt -1-.

– Tighten bolts to 12 Nm, starting at the B-pillar and working

forwards.

Protective side strip

– Bolt -1- 3.5 Nm

– Insert protective side strip in door and secure with bolts.

82 Rep. Gr.57 - Front doors, door components, central locking

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General body repairs, exterior - Edition 09.2009

Reinforcement for door trim

To remove, drill off rivet heads and knock out rivet stems.

Removing and installing outer window slot trim strip

Audi TT 2007 ➤

1 - Door

2 - Speed nut

❑ Pressed into door flange

3 - Window slot trim strip

❑ Door trim ⇒ Rep. Gr. 70

and door window re‐ moved

– Remove A-pillar trim.

❑ Unscrew bolts and de‐

tach window slot trim strip.

❑ When installing, align

slot trim strip at B-pillar and secure with bolts

-4-.

4 - Bolt

❑ 1.5 Nm

Removing and installing inner window slot trim strip

1. Front door 83

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1 - Door

2 - Inner window slot trim strip

❑ Door trim removed. ❑ Door window removed.

– To install, insert in guide

rail at A-pillar.

– Insert slot trim strip at A-

pillar -arrow-.

– Then clip into door at B-

pillar.

– Press slot trim strip onto

door flange from above.

3 - Door window

4 - A-pillar trim

1.3 Adjusting door

Special tools and workshop equipment required

♦ Setting gauge -3371-

84 Rep. Gr.57 - Front doors, door components, central locking

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General body repairs, exterior - Edition 09.2009

♦ Template -T40038/7-

Adjustment using template -T40038/7-

– The template can be used to check the lateral position and

height of the door as well as its position with respect to the rear window.

Audi TT 2007 ➤

– The distance from the side window can be checked with the

graduation for dimension -a-.

– The projection of the wing with respect to the door or of the

door with respect to the side panel can be checked with the graduations for dimensions -b- and -c-.

– Template must be applied at a distance (-a- = 100 mm) from

rear edge of door window or at front as extension of top edge of windscreen -arrow- to roof trim strip.

1. Front door 85

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

– In illustration shown (min. mark on window), window is cor‐

rectly set if two resting surfaces -a- and -b- make contact with door window and there is a small gap at contact surface of roof trim strip.

– If the upper resting surface -a- does not make contact with the

door window, the door window is too far inwards.

– In illustration shown (max. mark on window), window is cor‐

rectly set if contact surface makes contact with roof trim strip and there is a small gap at contact surface -a- of upper tem‐ plate.

– If contact surface of template does not make contact with roof

trim strip, door window is set too far outwards.

Height adjustment

– At a distance of -a- = 17 mm measured from the top edge of

the door window, make a mark on adhesive strip -2-.

– Apply template as shown and slide it upwards until it makes

contact with roof trim strip -1-.

– When correctly adjusted, the mark must be in the area of the

small graduation as shown.

86 Rep. Gr.57 - Front doors, door components, central locking

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General body repairs, exterior - Edition 09.2009

Setting with respect to side window

– Insert the template as shown in the door seal -3- between the

mounting rail -4- of the side window -1- and the door window

-2-.

– The door window must be in the area of the small groove.

Gap widths

The gap widths can be checked using setting gauge -3371- .

• Dimension -A- = 3.5 mm ± 0.5 mm

• Dimension -B- = 3.5 mm ± 0.5 mm

• Dimension -C- = 0 mm ... –1 mm

• Dimension -D- = 0 mm ... +1 mm

Audi TT 2007 ➤

Adjusting door at striker plate

– Loosen bolts -2-.

– Move striker plate -1- until door shell is flush with body contour.

– Tighten bolts to 20 Nm.

Note

The striker plate must only be adjusted towards the centre of the vehicle and not in height, as otherwise the lock could become damaged.

1. Front door 87

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1.4 Removing and installing door handle and door lock - exploded view

1 - Door lock

• Door trim removed ⇒ Rep.

Gr. 70

❑ The door lock can be re‐

moved without taking out the window regula‐ tor.

❑ Removing ⇒ page 92

2 - Bolt

❑ 20 Nm

3 - Anti-theft cover

❑ Attached to door panel

⇒ page 89

4 - Mounting bracket

• Remove and install with

door handle and lock cylin‐ der housing removed.

• Disengage cable at door

lock.

❑ To remove, unscrew

cross-head bolt -11-, slide mounting bracket slightly to rear and take out of door.

5 - Operating cable

❑ Engage in door lock

⇒ Item 3 (page 90)

6 - Backing plate (rear)

❑ Insert in door panel

7 - Lock cylinder housing

❑ Removing:

– Unclip cap on end face of door.

– Pull out door handle.

– Use socket wrench (width across flats T20) to unscrew bolt as far as it will go.

– Whilst pressing gently on the bolt, release the lock cylinder and pull it sideways out of the door.

❑ Installing:

– Fit cap -8- before installing.

8 - Cap

❑ Attached to lock cylinder

9 - Door handle

10 - Backing plate (front)

❑ Attach to door handle

11 - Bolt

❑ 2.5 Nm

88 Rep. Gr.57 - Front doors, door components, central locking

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General body repairs, exterior - Edition 09.2009

Removing anti-theft cover

– The anti-theft cover -1- is attached as shown to the door panel

-4- between the door lock -2- and the mounting bracket -3-.

Removing and installing lock cylinder

– Prise off cover -1-.

– Pull and hold door handle.

– Use a socket wrench (width across flats T20) to unscrew bolt

-2- as far as it will go.

– Slight pressure on the socket wrench or bolt is required to

completely release the lock cylinder housing.

– Pull lock cylinder housing -2- sideways out of door or mounting

bracket.

Installing

Install in reverse order.

Audi TT 2007 ➤

1. Front door 89

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1.5 Removing and installing door handle - exploded view

1 - Door handle

❑ Before detaching, re‐

move lock cylinder with cover at driver's door or housing

❑ To remove, slide door

handle towards rear and disengage from operat‐ ing lever on mounting bracket.

❑ Pull door handle out to‐

wards the side at rear end.

❑ Pull door handle out of

mounting bracket and door by pulling it to‐ wards the rear in diago‐ nal direction.

2 - Mounting bracket

3 - Operating cable

❑ Door lock removed. ❑ Engage operating cable

in operating lever of door lock -arrow-.

Caution

♦The Bowden cable must NOT be kinked during in‐ stallation. This can cause malfunctions.

♦Check function after in‐ stalling.

❑ Insert operating cable

sideways in door lock, then turn through 90° to lock in position.

4 - Door lock

❑ Removing ⇒ page 92

5 - Striker

6 - Operating lever

❑ Engage operating cable in operating lever at door handle, as shown.

Inserting door handle in mounting bracket

90 Rep. Gr.57 - Front doors, door components, central locking

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1 - Backing plate (rear)

❑ Clip into door panel

2 - Door handle

– Backing plates -2- and

-5- must be fitted prior to installation.

– Insert door handle in

front door opening until it engages in web at mounting bracket

-arrow-.

– Press door handle at

rear lock cylinder into mounting bracket.

– Insert lock cylinder with

cap.

– To secure lock cylinder,

completely screw in bolt

⇒ page 89

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

3 - Mounting bracket

4 - Backing plate (front)

❑ Attach to door handle.

5 - Door

– When installing door handle -1-, rear end must be inserted in

mounting bracket in direction of -arrow- (as shown).

1. Front door 91

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

1.6 Removing and installing door lock - exploded view

1 - Cap

❑ Pressed into door ❑ When removing, unclip

from lock cylinder and unscrew bolt beneath.

2 - Bolt

❑ 20 Nm

3 - Door

4 - Door lock

❑ Removing: ❑ Door trim removed ⇒

Rep. Gr. 70

❑ Rear cover at inner door

panel removed

⇒ page 79

– Run door window to top

position.

– Lock cylinder removed.

– Unscrew bolts -2- and

slide door lock down‐ wards.

– Disengage cable for in‐

terior handle -7- from door lock.

❑ Install in reverse order

or removal.

5 - Shaft for lock cylinder

❑ When installing, the so-

called “paddle” must slide into groove

-arrow- in door lock.

6 - Lock cylinder

7 - Cable for interior door handle

Engaging cable for interior handle in door lock

– To install, first insert Bowden cable -2- vertically into release

lever -3- as shown in detail view, then swivel 90° and clip into door lock -1- to secure.

92 Rep. Gr.57 - Front doors, door components, central locking

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1.7 Door seals - Coupé

Removing and installing inner door seal

1 - Door seal

• Remove and install with Apillar trim (bottom), sill pan‐ el trim and B-pillar trim removed ⇒ Rep. Gr. 70 .

❑ Removing:

– Detach door seal from

door flange all round or pull out of seal rails at top and side window.

❑ Installing:

– Start by pressing door

seal into seal rail at Bpillar (top) -arrow-.

– Then press door seal in‐

to seal rail at A-pillar (top) -arrow-.

Audi TT 2007 ➤

General body repairs, exterior - Edition 09.2009

– At roof frame, first press

door seal in at centre, then along entire length of seal rail.

– Push door seal into seal

rail at bottom of side window.

– Then push seal fully into

seal rail in area of side window, starting from the centre.

– Press door seal onto

door flange at B-pillar (bottom).

– Then push door seal on

between side window and B-pillar (bottom), starting in centre.

– Press door seal onto door flange at A-pillar (bottom).

– Then press door seal onto door flange between A-pillar and B-pillar (bottom), starting in centre.

– Press door seal on completely between A-pillar (bottom) and A-pillar (top), starting in centre.

2 - Seal for roof frame

❑ Pressed in on flange in roof frame

3 - Roof trim strip

1.8 Door seals - Roadster

Special tools and workshop equipment required

1. Front door 93

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Audi TT 2007 ➤ General body repairs, exterior - Edition 09.2009

♦ Roller -3356-

Removing and installing inner door seal

1 - Seal (front)

Note

❑ A-pillar trim (top) and

roof frame trim removed ⇒ Rep. Gr. 70

– Unscrew bolts and pull

off seal (front) starting at A-pillar.

– Remove any residual

adhesive at points where seal was attach‐ ed with adhesive strip.

– Bonding surfaces must

be free of dust and grease; clean with cleaning solution D 009 401 04.

– Attach seal at top cor‐

ners (left and right) of roof flange.

– Slide seal onto roof

frame.

– Attach seal downwards

onto flange of A-pillar.

– Secure seal at top with

bolts (left and right).

– Grasp tab and gradually

pull out protective film between roof frame and seal and press seal onto roof frame with a roller

-3356- .

2 - Inner door seal

❑ A-pillar trim (bottom), sill panel trim and back panel trim removed ⇒ Rep. Gr. 70

– Pull door seal off body flange all around and pull out from underneath seal (front).

– Remove any residual adhesive at points where seal was attached with adhesive strip.

– Bonding surfaces must be free of dust and grease; clean with cleaning solution D 009 401 04.

94 Rep. Gr.57 - Front doors, door components, central locking