Audi TT 47 User Manual
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service
Workshop Manual
Audi TT 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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT00220
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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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
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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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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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 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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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
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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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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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
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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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ 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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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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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 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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