Audi TT 51 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 ➤
Fitting instructions: Filling roof side member with foam
material
Edition 03.2008
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
51 - Body - centre
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 A005TT01920
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 ➤
Fitting instructions: Filling roof side member with foam material - Edition 03.2008
Contents
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Filling roof side member with foam material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Applying structural foam material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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 ➤
Fitting instructions: Filling roof side member with foam material - Edition 03.2008
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.
Fitting instructions: Filling roof side member with foam material - Edition 03.2008
51 – Body - centre
1 Filling roof side member with foam
material
1.1 Procedure
Enter the repair in the Service Schedule under Service Record /
Workshop Remarks after filling the roof side member with foam
material.
Roof side member (left-side) filled with foam material: yes / no
Roof side member (right-side) filled with foam material: yes / no
Note
♦
After the rivets have been fitted, the vehicle must be left stand‐
ing on a level surface for 24 hours at a room temperature of
15° C to allow the adhesive components to harden.
♦
Do not continue working on the vehicle until this time has
elapsed.
Audi TT 2007 ➤
Note
The instructions given here apply to the left side of the vehicle.
The procedure for the right side of the vehicle is the same.
It is important to keep exactly to the procedure as described.
Heat the cartridge of structural foam material for 30 minutes in a
water bath at a constant temperature of approx. 60 °C.
The cartridge can also be heated at 60° C in a suitable oven, if
available.
Remove A-pillar.
Remove roof trim strips.
Mask off rivet holes with commercially available adhesive tape.
Prepare static mixer for foaming operation.
Inject foam into holes and then refit screw plugs immediately.
Install A-pillar.
Install roof trim strips.
Replacement parts
♦ 4x 2-component epoxy hard foam -D 506 110 A2-
♦ 22x Pop rivet N 910 197 01
Special tools and workshop equipment required
♦ Drill -VAS 5830-
1. Filling roof side member with foam material 1
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