Audi TT 5 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
Maintenance
Audi TT 1999 ➤
Edition 06.2007
Service Department. Technical Information
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Maintenance
He ad in g
1. Overview of engines
2. Delivery Inspection
3. LongLife Service
4. Oil Change Service
5. Inspection Service
6. Description of work
7. Type plate, vehicle identification number
8. Lifting the vehicle
9. Tow-starting/towing
10. Vehicle tests carried out as part of inspection services and maintenance
Service
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A0357015220
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Contents
1 Overview of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Delivery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 LongLife Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4 Oil Change Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Inspection Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Description of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 Battery: performing load test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Battery: checking "no load" voltage before starting the engine for the first time (only applies
to stock vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Battery: checking that battery cables are securely fitted . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.4 Battery: checking electrolyte level, topping up with distilled water if necessary . . . . . . . . . . 16
6.5 Lights, electrical equipment, switches, displays and other driver-operated controls: checking
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.6 Tyres: checking condition, wear pattern, tread depth and correcting inflation pressures. . . 21
6.7 Brake system: visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.8 Brake fluid level (depends on brake pad wear): checking . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.9 Brake fluid: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.10 Brake pads: checking thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.11 Direct shift gearbox (DSG): changing oil and renewing oil filter . . . . . . . . . . . . . . . . . . . . 30
6.12 Electric windows: checking positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.13 Vehicle keys: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.14 Interrogating fault memory for all systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.15 Noise insulation: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.16 Haldex coupling: changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.17 Haldex coupling: renewing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.18 Haldex coupling: checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.19 Hydraulic system: checking for leaks, checking hydraulic fluid level and topping up if
necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.20 Instrument cluster: setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.21 Air conditioner: checking operation and setting temperature to 22 °C . . . . . . . . . . . . . . . . 36
6.22 Cooling system: checking antifreeze and topping up with coolant if necessary . . . . . . . . . . 37
6.23 Poly V-belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.24 Air cleaner: cleaning housing and renewing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.25 Bonnet arrester hook: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.26 Engine cover panel: removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.27 Engine (from above and below) and engine compartment: visual check for leaks and
damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.28 Engine oil: draining or extracting, changing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.29 Engine oil: filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.30 Engine: checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.31 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.32 Wheel bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.33 Tyre repair kit: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.34 Radio (Chorus, Concert): switching off transport mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.35 Radio: activating anti-theft coding by entering fixed code number . . . . . . . . . . . . . . . . . . . . 49
6.36 Dust and pollen filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.37 Manual gearbox/final drive: checking oil level, topping up with oil if necessary . . . . . . . . . . 50
6.38 Windscreen wiper/washer system and headlight washer system: checking jet settings and
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.39 Windscreen wiper/washer system: checking jet settings, adjusting jets if necessary . . . . 50
6.40 Headlight washer system: checking jet settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.41 Headlights: checking settings and adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.42 Windscreen and headlight washer system: topping up with washer fluid . . . . . . . . . . . . . . 58
6.43 Wiper blades: checking park position and checking for damage . . . . . . . . . . . . . . . . . . . . 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 1999 ➤
Maintenance - Edition 06.2007
6.44 Service interval display: resetting Inspection Service (fixed intervals), up to chassis No. 8NY1
049 999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.45 Service interval display: resetting LongLife Service (from chassis No. 8NY1 050 000
onwards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.46 Service interval display: resetting Inspection Service (fixed intervals), from chassis No.
8NY1 050 000 onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.47 Track rod ball joints: checking play, security and boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.48 Door arresters and lock cylinders: lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.49 Transport locks: removing locking elements for front and rear axles . . . . . . . . . . . . . . . . . . 98
6.50 Underseal: visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.51 Plenum chamber: checking and cleaning water drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.52 Winter tyres (factory-fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.53 Toothed belt: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.54 Clock: setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.55 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7 Type plate, vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8 Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9 Tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10 Vehicle tests carried out as part of inspection services and maintenance . . . . . . . . . . . . . . 111
ii Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
1 Overview of engines
Petrol engines
Engine code AJQ APP AUQ ARY AUM BVP
kW at
rpm
rpm
EU II + D3 EU II + D3 EU IV EU III EU IV EU IV
4 / 5 4 / 5 4 / 5 4 / 5 4 / 5 4 / 5
132/
5500...6000
235/
2000...4600
132/
5500...6000
235/
2000...4600
132/
5500...6000
235/
1950...5000
132/
5500...600
0
235/
1950...500
0
110/
5500...570
0
210/
1750...460
0
1950...4700
9.5 9.5 9.5 9.0 9.5 9.3
Bosch
Motronic
1)
98
Super plus
Bosch
Motronic
1)
98
Super plus
Bosch
Motronic
1)
98
Super plus
Bosch
Motronic
1)
98
Super plus
Bosch
Motronic
2)
95
(unleaded)
Motronic
(unleaded)
120/
5700
225/
Bosch
95
Exhaust
emis‐
sions
standard
No. of cylinders /
valves per cylin‐
der
Capacity ltr. 1.781 1.781 1.781 1.781 1.781 1.781
Power
output
Torque Nm at
Bore ∅ mm 81.0 81.0 81.0 81.0 81.0 81.0
Stroke mm 86.4 86.4 86.4 86.4 86.4 86.4
Compression ra‐
tio
Fuel injection / ig‐
nition
RON min.
2)
1) Unleaded RON 95 can also be used, but will result in a slight loss of power.
2) Unleaded RON 91 can also be used, but will result in a slight loss of power.
Engine code BVR APX AMU BAM BFV BHE
Exhaust
EU IV EU II + D3 EU III EU III EU III EU IV
emis‐
sions
standard
No. of cylinders /
4/5 4 / 5 4 / 5 4/5 4/5 6/4
valves per cylin‐
der
Capacity ltr. 1.781 1.781 1.781 1.781 1.781 3.189
Power
output
kW at
rpm
140/
5700
165/
5500...6000
165/
5500...6000
165/
5500...600
176/
5700
184/
6300
0
Torque Nm at
rpm
240/
1980...5400
280/
2200...5500
280/
2200...5500
280/
2200...550
0
320/
2300...500
0
320/
2800...3200
Bore ∅ mm 81 81.0 81.0 81.0 81 84.0
Stroke mm 86.4 86.4 86.4 86.4 86.4 31.9
Compression ra‐
9.3 9.0 9.0 9.0 8.9 11.3
tio
Fuel injection / ig‐
nition
RON min.
Bosch
Motronic
3)
98
Super plus
Bosch
Motronic
3)
98
Super plus
Bosch
Motronic
3)
98
Super plus
Bosch
Motronic
3)
98
Super plus
Bosch
Motronic
3)
98
Super plus
Bosch
Motronic
98
Super plus
3)
1. Overview of engines 1
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
3) Unleaded RON 95 can also be used, but will result in a slight loss of power.
2 1. Overview of engines
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Maintenance - Edition 06.2007
2 Delivery Inspection
Work to be completed Page
In the case of stock vehicles: perform steps
specified in Technical Service Handbook; “In‐
spection and Maintenance”; Chapter 6
Battery: checking that battery cables are secure‐
ly fitted
Battery: performing load test ⇒ page 14
Engine (from above) and engine compartment:
visual check for leaks and damage
Cooling system: coolant must be filled to max.
level
Windscreen and headlight washer system: must
be filled to max. level
Engine: checking oil level and topping up if nec‐
essary
Brake system: brake fluid must be filled to max.
level
Hydraulic system: checking fluid level ⇒ page 34
Transport locks: removing locking elements for
front suspension struts
Please note: If there is a “warning” notice (orange
tag) attached to the interior mirror, the locking el‐
ements for rear suspension struts (on both sides)
must also be removed.
Underside of vehicle, mechanical units, steering,
boots, brake system, hoses, fluid reservoirs: vis‐
ual check for leaks and damage (without disman‐
tling noise insulation)
Underside of vehicle (underbody): visual check
for damage
Tyre pressure on all 4 wheels and spare wheel:
check (note: 3.5 bar when car leaves factory)
Wheel bolts: tightening to specified torque ⇒ page 46
Electric windows: checking positions ⇒ page 30
Clock: setting ⇒ page 100
Air conditioner: checking operation and setting
temperature to 22 °C
Radio or Radio/Navigation System Plus (Chorus,
Concert): Deactivating transport mode
Radio: sticking label with serial number and fixed
code number (see vehicle data sticker) onto radio
card
(included with radio operating instructions)
Radio: activating anti-theft coding by entering
fixed code number
Radio: storing local radio stations on station but‐
tons (on RDS radios, do not store until station
name appears on display)
Telephone: sticking label with serial number in
telephone operating instructions
Instrument cluster: setting the language ⇒ page 35
Service interval display: resetting ⇒ page 64
Passenger's airbag: checking key switch on / off,
must be set to “on”.
(see Owner's Manual)
⇒ page 16
⇒ page 41
⇒ page 37
⇒ page 51
⇒ page 51
⇒ page 45
⇒ page 22
⇒ page 98
⇒ page 98
⇒ page 22
⇒ page 36
⇒ page 46
⇒ page 49
Audi TT 1999 ➤
2. Delivery Inspection 3
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Work to be completed Page
All control units: interrogating fault memory
(Enter “00” for address word “Automatic test se‐
quence”)
Windscreen washer jets: adjusting height of
⇒ page 50
spray area
Protective seat covers and plastic sheeting for
carpet: removing
Floor mats: fitting
Cleanliness of vehicle interior: checking front and
rear seats, interior trim, carpeting/mats, windows
Fitting wheel covers/hub trim caps, roof aerial,
telephone aerial (components stored in luggage
compartment)
Transport protection: removing protective edge
strips on doors
Cleanliness of vehicle exterior: checking paint‐
work, trims, windows, wiper blades
Audi sticker: enter next service (and date for
brake fluid change) and affix sticker on left of
dash panel or on door post (B-pillar)
Service Schedule: removing vehicle data sticker
from spare wheel well or luggage compartment
floor and sticking into Service Schedule under
“Warranty entitlement record”. Entering Delivery
Inspection.
Owner's literature: checking that it is complete
and preparing for handover to customer
Vehicle keys: checking operation ⇒ page 30
Road test ⇒ page 45
4 2. Delivery Inspection
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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.
3 LongLife Service
Vehicles built model year 2000 > -Y-
Note
♦
Belgium
♦
Denmark
♦
Germany
♦
Finland
♦
France
♦
Gibraltar
♦
Greece
♦
Great Britain
♦
Ireland
♦
Iceland
♦
Italy
♦
Canary Islands
♦
Luxembourg
♦
Malta
♦
Netherlands
♦
Norway
♦
Austria
♦
Portugal
♦
Sweden
♦
Switzerland/Liechtenstein
Audi TT 1999 ➤
Maintenance - Edition 06.2007
♦
Spain/Andorra
♦
Cyprus
♦
Japan (from August 2002)
♦
Czech Republic (from 2003)
Extended servicing intervals
♦ Vehicles with petrol engine/ turbocharged petrol engine: max.
30,000 km (20,000 miles) or max. 2 years, oil grade 2
♦ The oil grade must be entered in the instrument cluster.
LongLife engine oil
New VW standard (specially developed, resistant to ageing) ac‐
cording to specification:
-VW 503 00- or -VW 504 00- for petrol engines / turbocharged
petrol engines (110 / 120 / 132 / 140 / 184 kW)
-VW 503 01- or -VW 504 00- for turbocharged petrol engines
(165 / 176 kW)
3. LongLife Service 5
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Work to be completed
The order of the individual servicing operations is optimised
as a result of long-standing experience. It is therefore essen‐
tial to comply with the stated order to avoid unnecessary
delays.
The order in which operations are described here is based on
that specified for the Inspection Service, which is the type of
service performed most frequently.
Please inform the customer if any faults or defects which need
repairing are identified during an Inspection Service.
Interval Work to be completed
according to
All work to be completed except for jobs marked "XX"
service interval
display
every 60,000 km
All work to be completed including jobs marked "XX"
(40,000 miles)
every 30,000 km
(20,000 miles)
In addition to LongLife Service:
♦ Change oil for Haldex coupling
♦ Direct shift gearbox (DSG) tiptronic: changing oil and re‐
newing oil filter (only on vehicles with chassis no.
8N_41000189 to 8N_1009705)
every 60,000 km
(40,000 miles)
In addition to LongLife Service:
♦ Direct shift gearbox (DSG) tiptronic: changing oil and re‐
newing oil filter
♦ Haldex coupling: changing oil and renewing oil filter
every 120,000
km
(80,000 miles)
In addition to LongLife Service:
– Poly V-belt and toothed belt: renewing
♦ 1.8 ltr. 165 kW turbocharged engines from model year 2001
onwards
♦ 1.8 ltr. 176 kW turbocharged engines
every 180,000
km
(115,000 miles)
In addition to LongLife Service:
– Poly V-belt and toothed belt: renewing
♦ 1.8 ltr. 132 kW turbocharged engines from model year 2001
onwards
♦ 1.8 ltr. 110 kW turbocharged engines
♦ 1.8 ltr. 120 kW turbocharged engines
♦ 1.8 ltr. 140 kW turbocharged engines
⇒ page 33
⇒ page 30
⇒ page 30
⇒ page 99
⇒ page 99
every 180,000
km
(115,000 miles)
or every 5 years
In addition to LongLife Service:
– Poly V-belt and toothed belt: renewing
♦ 1.8 ltr. 132 kW turbocharged engines up to model year
2000
♦ 1.8 ltr. 165 kW turbocharged engines up to model year
2000
every 24 months In addition to LongLife Service:
– Brake fluid: changing
Work to be com‐
pleted B
Work to be completed Page
Electrical system
6 3. LongLife Service
⇒ page 99
⇒ page 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.
Maintenance - Edition 06.2007
Work to be completed Page
Front lighting - checking operation: side lights, dipped
headlights, main beam headlights, fog lights, turn sig‐
nals, hazard warning lights
Rear lighting - checking operation: brake lights (incl.
3rd brake light), rear lights, reversing lights, rear fog
light, number plate lights, turn signals, hazard warn‐
ing lights, luggage compartment light
Interior lights and glove box lights, warning and indi‐
cator lamps, horn: checking operation
Self-diagnosis: interrogating fault memory with fault
⇒ page 31
reader -V.A.G 1551- or -VAS 5051Service interval display: resetting LongLife Service
⇒ page 64
(from chassis No. 8NY1 050 000 onwards)
Vehicle, from outside
Door arresters, lock cylinder and bonnet arrester
⇒ page 97
hook: lubricating
Windscreen wiper/washer system and headlight
⇒ page 50
washer system: checking jet settings and operation
Wiper blades in park position: checking ⇒ page 58
Only in the case of “juddering” wiper blades: checking
⇒ page 58
setting angle
Wiper blades: checking for damage
Tyres
Tyre on spare wheel: checking condition and wear
⇒ page 21
pattern; entering tread depth
Tyre (front left): checking condition and wear pattern;
⇒ page 21
entering tread depth
Tyre (rear left): checking condition and wear pattern;
entering tread depth
Tyre (rear right): checking condition and wear pattern;
entering tread depth
Tyre (front right): checking condition and wear pat‐
⇒ page 21
⇒ page 21
⇒ page 21
tern; entering tread depth
Tyre repair kit: checking expiry date ⇒ page 46
Vehicle, from below:
Engine, gearbox, final drive, steering and boots: vis‐
ual checks for leaks and damage
Engine oil: draining or extracting, changing oil filter ⇒ page 42
Manual gearbox/final drive: checking oil level, topping
⇒ page 50
up with oil if necessary
Haldex coupling: changing oil (four-wheel drive) / ad‐
⇒ page 33
ditional work
Haldex coupling: renewing oil filter (four-wheel drive) /
⇒ page 34
additional work
Brake system: visual check for leaks and damage ⇒ page 22
Brake pads: checking thickness ⇒ page 29
Underseal: visual check for damage ⇒ page 98
Exhaust system: visual check for leaks and damage,
check that parts are properly secured
Track rod ball joints: checking play, security and
⇒ page 97
boots
Swivel joints: checking play, checking boots for leaks
and damage
Engine compartment
Audi TT 1999 ➤
3. LongLife Service 7
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Work to be completed Page
Engine (from above) and engine compartment: visual
⇒ page 41
check for leaks and damage
Engine oil: filling up ⇒ page 44
Battery: checking electrolyte level, topping up with
⇒ page 16
distilled water if necessary
Battery with magic eye: checking display, topping up
with distilled water if necessary
Windscreen and headlight washer system: topping up
⇒ page 58
with washer fluid
Cooling system: checking antifreeze and coolant lev‐
⇒ page 37
el / antifreeze specified value -25°C; actual value
(measured value):
XXHydraulic system: checking for leaks, checking hy‐
⇒ page 34
draulic fluid level and topping up if necessary
XXAir cleaner: cleaning housing and renewing filter ele‐
⇒ page 40
ment
XXSpark plugs: renewing ⇒ page 100
Dust and pollen filter: renewing ⇒ page 49
Plenum chamber: checking water drain ⇒ page 99
Poly V-belt: renewing - additional work ⇒ page 39
Toothed belt: renewing - additional work ⇒ page 39
Brake fluid: changing (every two years) - additional
⇒ page 23
work
Note: Never remove strainer from brake fluid reser‐
voir
Final jobs
Tyre pressures on all 4 wheels and spare wheel:
⇒ page 22
checking
Headlights, ellipsoid headlights: checking settings
and adjusting if necessary
Gas discharge headlights: checking settings and ad‐
⇒ page 51
⇒ page 53
justing if necessary
Sticker: enter next service (and date for brake fluid
change) and affix sticker on left side of dash panel or
on door post (B-pillar)
Road test ⇒ page 45
8 3. LongLife Service
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
4 Oil Change Service
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Work required
Page
every 15,000 km
(10,000 miles)
or 12 months
Engine oil: draining or extracting, changing oil filter ⇒ page 42
Brake pads: checking thickness of disc brake pads ⇒ page 29
Engine oil: filling up ⇒ page 44
Service interval display: resetting (on vehicles up to chassis No.
⇒ page 59
8NY1 049 999)
Service interval display: resetting Inspection Service (from
⇒ page 81
chassis No. 8NY1 050 000 onwards)
4. Oil Change Service 9
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
5 Inspection Service
Fixed service interval
♦ Vehicles with petrol engine/ turbocharged petrol engine: max.
15,000 km (10,000 miles) or max. 1 year; oil grade 1.
♦ The oil grade must be entered in the instrument cluster.
Inspection Service
In the case of fixed service intervals the following engine oils ac‐
cording to VW standards must be used:
-VW 501 01- , -VW 502 00- or -VW 504 00- for petrol engines /
turbocharged petrol engines
Work to be completed
The order of the individual servicing operations is optimised
as a result of long-standing experience. It is therefore essen‐
tial to comply with the stated order to avoid unnecessary
delays.
The order in which operations are described here is based on
that specified for the Inspection Service, which is the type of
service performed most frequently.
Please inform the customer if any faults or defects which need
repairing are identified during an Inspection Service.
Interval Work to be completed
according to
All work to be completed except for jobs marked "XX"
service interval
display
every 60,000 km
All work to be completed including jobs marked "XX"
(40,000 miles)
every 30,000 km
(20,000 miles)
In addition to Inspection Service:
♦ Change oil for Haldex coupling
♦ Direct shift gearbox (DSG) tiptronic: changing oil and re‐
newing oil filter (only on vehicles with chassis no.
8N_41000189 to 8N_1009705)
every 60,000 km
(40,000 miles)
In addition to Inspection Service:
♦ Direct shift gearbox (DSG) tiptronic: changing oil and re‐
newing oil filter
♦ Haldex coupling: changing oil and renewing oil filter
every 120,000
km
(80,000 miles)
In addition to LongLife Service:
– Poly V-belt and toothed belt: renewing
♦ 1.8 ltr. 165 kW turbocharged engines from model year 2001
onwards
♦ 1.8 ltr. 176 kW turbocharged engines
every 180,000
km (115,000
miles)
In addition to LongLife Service:
– Poly V-belt and toothed belt: renewing
♦ 1.8 ltr. 132 kW turbocharged engines from model year 2001
onwards
♦ 1.8 ltr. 110 kW turbocharged engines
♦ 1.8 ltr. 120 kW turbocharged engines
♦ 1.8 ltr. 140 kW turbocharged engines
⇒ page 33
⇒ page 30
⇒ page 30
⇒ page 99
⇒ page 99
10 5. Inspection Service
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Interval Work to be completed
every
180,000 km
(115,000 miles)
/ every 5 years
In addition to LongLife Service:
– Poly V-belt and toothed belt: renewing
♦ 1.8 ltr. 132 kW turbocharged engines up to model year
2000
♦ 1.8 ltr. 165 kW turbocharged engines up to model year
2000
every 24 months In addition to Inspection Service:
– Brake fluid: changing
Work to be com‐
pleted B
Work to be completed Page
Electrical system
Front lighting - checking operation: side lights,
dipped headlights, main beam headlights, fog
lights, turn signals, hazard warning lights
Rear lighting - checking operation: brake lights
(incl. 3rd brake light), rear lights, reversing lights,
rear fog light, number plate lights, turn signals,
hazard warning lights, luggage compartment
light
Interior lights and glove box lights, warning and
indicator lamps, horn: checking operation
Self-diagnosis: interrogating fault memory with
fault reader -V.A.G 1551- or -VAS 5051-
Service interval display: resetting LongLife Serv‐
⇒ page 31
⇒ page 64
ice (from chassis No. 8NY1 050 000 onwards)
Vehicle, from outside
Door arresters, lock cylinder and bonnet arrester
⇒ page 97
hook: lubricating
Windscreen wiper/washer system and headlight
⇒ page 50
washer system: checking jet settings and opera‐
tion
Wiper blades in park position: checking ⇒ page 58
Only in the case of “juddering” wiper blades:
⇒ page 58
checking setting angle
Wiper blades: checking for damage
Tyres
Tyre on spare wheel: checking condition and
⇒ page 21
wear pattern; entering tread depth
Tyre (front left): checking condition and wear pat‐
⇒ page 21
tern; entering tread depth
Tyre (rear left): checking condition and wear pat‐
⇒ page 21
tern; entering tread depth
Tyre (rear right): checking condition and wear
⇒ page 21
pattern; entering tread depth
Tyre (front right): checking condition and wear
⇒ page 21
pattern; entering tread depth
Tyre repair kit: checking expiry date ⇒ page 46
Vehicle, from below:
Engine, gearbox, final drive, steering and boots:
visual checks for leaks and damage
⇒ page 99
⇒ page 23
5. Inspection Service 11
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Work to be completed Page
Engine oil: draining or extracting, changing oil fil‐
⇒ page 42
ter
Manual gearbox/final drive: checking oil level,
⇒ page 50
topping up with oil if necessary
Haldex coupling: changing oil (four-wheel drive) /
⇒ page 33
additional work
Haldex coupling: renewing oil filter (four-wheel
⇒ page 34
drive) / additional work
Brake system: visual check for leaks and dam‐
⇒ page 22
age
Brake pads: checking thickness ⇒ page 29
Underseal: visual check for damage ⇒ page 98
Exhaust system: visual check for leaks and dam‐
age, check that parts are properly secured
Track rod ball joints: checking play, security and
⇒ page 97
boots
Swivel joints: checking play, checking boots for
leaks and damage
Engine compartment
Engine (from above) and engine compartment:
⇒ page 41
visual check for leaks and damage
Engine oil: filling up ⇒ page 44
Battery: checking electrolyte level, topping up
⇒ page 16
with distilled water if necessary
Battery with magic eye: checking display, topping
up with distilled water if necessary
Windscreen and headlight washer system: top‐
⇒ page 58
ping up with washer fluid
Cooling system: checking antifreeze and coolant
⇒ page 37
level / antifreeze specified value -25°C; actual
value (measured value):
XXHydraulic system: checking for leaks, checking
⇒ page 34
hydraulic fluid level and topping up if necessary
XXAir cleaner: cleaning housing and renewing filter
⇒ page 40
element
XXSpark plugs: renewing ⇒ page 100
Dust and pollen filter: renewing ⇒ page 49
Plenum chamber: checking water drain ⇒ page 99
Poly V-belt: renewing - additional work ⇒ page 39
Toothed belt: renewing - additional work ⇒ page 39
Brake fluid: changing (every two years) - addi‐
⇒ page 23
tional work
Note: Never remove strainer from brake fluid res‐
ervoir
Final jobs
Tyre pressures on all 4 wheels and spare wheel:
checking
Headlights, ellipsoid headlights: checking set‐
⇒ page 22
⇒ page 51
tings and adjusting if necessary
Gas discharge headlights: checking settings and
⇒ page 53
adjusting if necessary
Sticker: enter next service (and date for brake
fluid change) and affix sticker on left side of dash
panel or on door post (B-pillar)
12 5. Inspection Service
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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.
Maintenance - Edition 06.2007
Work to be completed Page
Road test ⇒ page 45
Audi TT 1999 ➤
5. Inspection Service 13
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
6 Description of work
6.1 Battery: performing load test
The battery load test provides information on the condition of the
battery.
Special tools and workshop equipment required
♦ Battery tester -VAS 5097 A-
Note
It is not necessary to remove the battery when using battery tester
-VAS 5097 A- . The battery does not have to be disconnected.
Carrying out load test
– Switch off ignition.
– Read operating instructions for battery tester.
– Connect the clamps of the test leads to battery terminals as
described in operating instructions for the tester.
The clamps must make good contact with the battery terminals.
– As the load current differs depending on the battery, the cur‐
rent must be set on the tester according to battery capacity ⇒
Operating instructions for battery test equipment.
– Perform a battery load test as described in the operating in‐
structions.
Test equipment display during load test
Please note the test results shown on the display of the tester.
Table:
Display on bat‐
tery tester
Battery Very
Delivery Inspection Inspection Service
LongLife Service
Battery OK Battery OK
Good
Battery Good
Battery Not Good
Charge battery
Charge battery
Battery Faulty Renew battery
1)
1)
Battery OK
Charge battery
Renew battery
1)
2)
1) - Perform battery load test again after recharging the battery.
If tester shows “Battery Good” after charging battery, battery is
OK. However, if tester still shows “Battery Not Good”, battery must
be renewed.
14 6. Description of work
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2) - Agree battery replacement with customer.
– Renewing the battery ⇒ Electrical system; Repair group 27;
Removing and installing battery .
Notes on battery load test:
The battery voltage will decrease during the test due to the high
load (high current flow).
If a battery is in working order battery voltage will only drop to
minimum voltage.
If the battery is defective or only insufficiently charged, battery
voltage will very quickly drop below minimum voltage.
After carrying out the load test the voltage will remain at this low
level for quite a while; voltage will only rise again slowly.
6.2 Battery: checking "no load" voltage be‐
fore starting the engine for the first time
(only applies to stock vehicles)
Special tools and workshop equipment required
♦ Digital multimeter -V.A.G 1715-
♦ or
♦ Hand-held multimeter -V.A.G 1526 B-
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Note
♦
The vehicle must not be driven or started with the battery that
is to be tested for at least 2 hours before performing test.
♦
The battery must not be placed under load from connected
electrical equipment for at least 2 hours before the test.
♦
The battery must not be charged for at least 2 hours before
the test.
– Open the protective cover on the battery -A- (velcro fastener).
– Open lid -B- of main fuse box towards front of vehicle.
– Check voltage between battery terminals with the ignition
switched off.
♦ If the tester indicates 12.5 V or more, then the battery is OK.
♦ If the voltage is less than 12.5 V, locate the source of the
problem (repair measure).
6. Description of work 15
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
6.3 Battery: checking that battery cables are securely fitted
– Open the protective cover on the battery -A- (velcro fastener).
– Open lid -B- of main fuse box towards front of vehicle.
– Check that the battery terminal clamps are securely fitted. If
necessary, tighten nuts -1- and -3-.
WARNING
If the battery terminal clamp on the positive terminal is not fitted
securely, disconnect the battery earth strap from the battery
negative terminal first to avoid possible accidents.
– After connecting battery earth strap, enter anti-theft code for
radio ⇒ page 49 .
– Activate the automatic one-touch function for opening and
closing the electric windows ⇒ page 30 .
– Set the clock ⇒ page 100 .
– Check that battery is securely installed. If necessary tighten
securing bolt -3- on retainer plate -2-.
Tightening torque Nm
Battery terminal clamp to battery terminal 5
Bolt on retainer plate 22
6.4 Battery: checking electrolyte level, top‐
ping up with distilled water if necessary
The battery is located in the engine compartment (front left).
16 6. Description of work
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– Open the protective cover on the battery -A- (velcro fastener)
and push slightly downwards.
♦ The electrolyte level must be between min. and max. marks
Note
♦
For batteries with clearly visible min. and max. mark, a visual
check of the battery is sufficient.
♦
If the external min. and max. marks on the battery are not
clearly visible or if the electrolyte level cannot be checked
properly due to an opaque battery housing, the sealing plugs
must be unscrewed ⇒ Topping up with distilled water.
♦
The electrolyte level must align with the marking inside the
battery (plastic moulding). This corresponds to the max mark‐
ing on the outside.
– If necessary, top up battery cells to max. mark with distilled
water.
Topping up with distilled water
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Note
The centre sealing plugs on the battery are concealed by the
bracket for the main fuse box. To unscrew these sealing plugs
you must first remove the main fuse box.
– In the case of vehicles with anti-theft code you will require the
correct code; if necessary obtain the code beforehand.
– Open lid -B- of main fuse box towards front of vehicle.
6. Description of work 17
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
– Slacken hexagon nut -1- and disconnect battery earth strap.
– Remove the hexagon nut -2- and detach retaining brackets for
main fuse box from battery housing.
– Remove the sealing plugs.
– Only top up the electrolyte level with distilled water.
Note
The use of distilled water prevents contamination of the electro‐
lyte and any associated increase in self discharge.
– After connecting battery earth strap, enter anti-theft code for
radio ⇒ page 49 .
– Activate the automatic one-touch function for opening and
closing the electric windows ⇒ page 30 .
– Set the clock ⇒ page 100 .
Batteries with magic eye
18 6. Description of work
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
– In the case of batteries (lead-calcium batteries) with magic eye
-arrow- please carry out check as follows:
The magic eye indicates the electrolyte level and the charge level
of the battery. Three different colours are used as indicators:
Green → the battery is sufficiently charged.
Black → no charge or charge too low (repair measure).
Colourless or yellow → critical electrolyte level has been reached.
It is essential to top up with distilled water:
– Remove the foil covering the sealing plug.
Note
♦
Sealed starter batteries have been fitted from week 01, model
year 2001.
♦
On these batteries it is not possible to measure relative density
or top up with distilled water.
– Unscrew sealing plug from battery.
– Use battery filler bottle -VAS 5045- to top up with distilled water
to max. mark.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Note
The neck of filler bottle -VAS 5045- is designed to prevent over‐
filling of the battery cells and spillage of battery acid. When the
"max." level is reached, the flow of distilled water into the cells is
cut off.
– Screw the sealing plug back onto battery.
Electrolyte level too high
Note
If the electrolyte level is too high (above the max. marking) the
leaking electrolyte (sulphuric acid/water mixture) will cause dam‐
age outside the battery, e. g. to components in engine compart‐
ment.
– The foil covering the sealing plug must be pulled off on bat‐
teries with magic eye -arrow-.
Note
♦
Sealed starter batteries have been fitted from week 01, model
year 2001.
♦
On these batteries it is not possible to measure relative density
or top up with distilled water.
– Unscrew sealing plug from battery.
If the electrolyte level is too high (over-filled), e.g. is above inner
mark for electrolyte level (plastic moulding) or above the exterior
max. marking:
6. Description of work 19
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
– Draw off electrolyte with a hydrometer (⇒ illustration) until the
electrolyte level reaches the plastic moulding or the max.
marking.
Note
Observe disposal regulations.
– Screw the sealing plug back onto battery.
6.5 Lights, electrical equipment, switches,
displays and other driver-operated con‐
trols: checking operation
– The following components must be checked:
♦ Lighting, headlights, fog lights, turn signals, hazard warning
lights, rear lights, rear fog light, reversing lights, brake lights,
parking light function
♦ Interior lights and reading lights (automatic switch-off function
for front interior light), glove box lighting, ashtray light, luggage
compartment lighting, ignition key light
♦ Warning buzzer indicating that lights and/or radio have been
left on
♦ All switches on console
♦ Driver Information System (DIS)
♦ Instrument cluster including all displays, counters, lights and
illumination
♦ Dual-tone horn
♦ Windscreen wiper/washer system, headlight washer system
♦ Cigarette lighter
♦ Electric exterior mirrors (heated, adjustable)
♦ Electric window lifters
♦ Central locking, remote control (radio-operated), convenience
close function
♦ Seat heating
♦ Radio
20 6. Description of work
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
6.6 Tyres: checking condition, wear pattern, tread depth and correcting inflation pressures.
Note
In the interest of driving safety, only tyres of the same type and
tread pattern should be fitted on a vehicle.
6.6.1 Checking tyres
Delivery Inspection
– Check tyre tread surfaces and sidewalls for damage and re‐
move any foreign bodies.
Inspection Service
– Check tyres for scuffing, one-sided wear, porous sidewalls,
cuts and fractures.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
WARNING
Any defects must be reported to the customer.
6.6.2 Checking tyre wear pattern
– The wear pattern of the front tyres indicates, for example,
whether the toe and camber have to be checked.
♦ Feathering on tread indicates incorrect toe setting.
♦ One-sided tread wear is usually due to incorrect camber.
Note
If the above types of wear are found, check wheel alignment to
determine the cause (repair measure).
6.6.3 Checking tyre tread depth
– Checking tyre tread depth
♦ Minimum depth: 1.6 mm
Note
♦
This figure may vary for individual countries due to different
legislation.
♦
The minimum tread depth is reached when the tyres have
worn down level with the 1.6 mm high tread wear indicators
positioned at intervals around the tyre.
♦
If the tread depth is approaching the minimum permissible
tread depth, the customer must be informed.
6. Description of work 21
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
6.6.4 Inflating to correct pressures
The correct inflation pressures for summer tyres are listed on the
sticker on the inside of the tank flap.
Note
♦
Please note that the inflation pressures listed on the sticker
apply to cold tyres. When the tyres are warm, the actual pres‐
sures will be higher, but must not be reduced.
♦
When using winter tyres, pressures should be increased by
0.2 bar.
6.6.5 Spare wheel
• Temporary (compact) spare wheel
The correct inflation pressure is indicated on the sidewall.
Note
Check the valve extensions for damage and dirt which could
cause leaks. Renew if necessary.
6.7 Brake system: visual check for leaks and damage
– Check following components for leaks and damage:
♦ Brake master cylinder
♦ Brake servo
♦ ABS hydraulic unit
♦ Brake calipers
– Ensure that brake hoses are not twisted.
– Make sure that brake hoses do not touch any components
when steering is on full lock.
– Check brake hoses for porosity, blistering and brittleness.
– Check brake hoses and pipes for chafing.
– Check brake pipe connections and mountings for correct seat‐
ing, leaks and corrosion.
WARNING
Any faults found must be rectified (repair measure).
6.8 Brake fluid level (depends on brake pad wear): checking
Only use new genuine VW/Audi brake fluid in accordance with
US standard FMVSS 116 DOT 4.
22 6. Description of work
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
WARNING
♦ Brake fluid is poisonous. It also has caustic properties and
must therefore not be allowed to come into contact with
paintwork.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air. It must therefore always be stored in airtight containers.
– Note the following:
Delivery Inspection
♦ The fluid level must be at the MAX mark.
Note
The fluid level must not exceed the MAX marking, otherwise the
fluid will overflow.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
Inspection Service
When the vehicle is driven, the brake fluid level will drop slightly
with use and as a result of the automatic adjustment of the brake
pads.
– When checking the brake fluid level, always take into account
the amount of wear on the brake pads:
♦ If the brake pads are new or a long way from reaching the wear
limit, the fluid level should be between the MIN and MAX
marks.
♦ If the brake fluid level is at or slightly above the MIN marking
and the brake pads have almost reached the wear limit, top‐
ping up is not required.
WARNING
If the fluid level has fallen below the MIN mark, check the brake
system (repair measure) before adding brake fluid.
6.9 Brake fluid: changing
Note
Only use new genuine VW/Audi brake fluid, refer to ⇒ ETKA .
6. Description of work 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 1999 ➤
Maintenance - Edition 06.2007
Changing the brake fluid with brake filling and bleeding equipment
-VAS 5234- ⇒ page 26
Changing the brake fluid with brake filling and bleeding equipment
-V.A.G 1869- ⇒ page 24
WARNING
♦ Brake fluid must on no account come into contact with liq‐
uids containing mineral oils (oil, petrol, cleaning agents).
Mineral oils damage the plugs and sleeves in the brake
system.
♦ Brake fluid is poisonous and must under no circumstances
be sucked through a tube using the mouth. Because of its
caustic properties it must also not come into contact with
paintwork.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air. It must therefore always be stored in airtight containers.
♦ Always observe the relevant environmental regulations for
disposal.
6.9.1 Changing brake fluid with brake filling and bleeding equipment -V.A.G 1869-
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -V.A.G 1869-
♦ Container for collecting used fluid
24 6. Description of work
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.
Note
♦
The brake fluid reservoir must always be adequately filled to
ensure that no air can enter the brake system from the reser‐
voir.
♦
The strainer in the brake fluid reservoir must not be removed.
♦
Observe the instructions given in the operating manual for the
brake filling and bleeding equipment -V.A.G. 1869- .
WARNING
Do not reuse the old brake fluid that has been extracted.
– Open brake fluid reservoir.
– Open the bleeder screw on brake caliper (rear right).
– Get a suitable container ready to catch the used brake fluid.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
6. Description of work 25
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 1999 ➤
Maintenance - Edition 06.2007
– With engine running, use brake pedal to pump out brake fluid
until fluid level goes down as far as the connection -arrow- on
the reservoir.
– Close bleeder screw.
On vehicles with manual gearbox the clutch slave cylinder must
also be “flushed out” with new brake fluid. When doing so, note
the following:
– Connect brake filling and bleeding equipment -V.A.G 1869- ,
but do not switch on yet.
– Open bleeder screw on clutch slave cylinder.
– Fit bleeder hose leading to brake fluid collector onto bleeder
screw on clutch slave cylinder.
–
Then switch on bleeder appliance and allow about 100 cm3 of
brake fluid to drain out.
– Close bleeder screw.
Sequence for changing brake fluid in brake calipers:
1 - Front left-hand brake caliper
2 - Front right-hand brake caliper
3 - Rear left-hand brake caliper
4 - Rear right-hand brake caliper
– Fit bleeder hose leading to brake fluid collector onto bleeder
screw for relevant brake caliper.
–
Open bleeder screw and allow about 200 cm3 of brake fluid to
drain out.
Used brake fluid is pushed out of the system when new fluid is
pumped in.
– Close bleeder screw.
– Disconnect hose from brake fluid reservoir.
– Check pedal pressure and free play of brake pedal.
♦
Free play: no more than 1/3 of pedal travel
– During the final test drive, make sure that at least one ABS-
controlled brake application is carried out (with noticeable
pulsing of brake pedal).
6.9.2 Changing brake fluid with brake filling and bleeding equipment -VAS 5234-
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234-
26 6. Description of work
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