Audi TT 51 User Manual

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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.

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

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Audi TT 2007 ➤ Fitting instructions: Filling roof side member with foam material - Edition 03.2008

ii Contents

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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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Audi TT 2007 ➤ Fitting instructions: Filling roof side member with foam material - Edition 03.2008

♦ Removal wedge -3409-

♦ Hand-cartridge gun -V.A.G 1628-

♦ Pop rivet pliers -VAS 5072-

Special tools and workshop equipment required

♦ Removal wedge -3409-

– 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.

2 Rep. Gr.51 - Body - centre

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Fitting instructions: Filling roof side member with foam material - Edition 03.2008

1 - 2-component structural foam cartridge

– Open cap.

2 - Static mixer

3 - Extension hose

4 - Adapter

Note

5 - Union nut

– Screw onto structural

foam cartridge -1- to‐ gether with static mixer

-2-.

Audi TT 2007 ➤

Removing A-pillar (top)

Removing

– Unclip C-pillar trim -1- at area adjoining upper A-pillar trim

-2-.

– Starting at top, unclip upper A-pillar trim -2- using removal

wedge -3409- .

– Lift out upper A-pillar trim -2-.

Installing

Install in reverse order of removal. Observe the following:

Note

♦

If clips for the trim have been left behind in the mounting points on the body, remove them and insert them in the trim.

♦

Check clips for damage or deformation and renew if neces‐ sary.

1. Filling roof side member with foam material 3

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Audi TT 2007 ➤ Fitting instructions: Filling roof side member with foam material - Edition 03.2008

– Start by inserting upper A-pillar trim -1- in ribbed section -2- of

dash panel in direction of -arrow-.

– Clip in upper A-pillar trim -2- and fold lip of door seal -3- over

upper A-pillar trim -2-.

Removing roof trim strip

Note

The side window can remain installed when removing the roof trim strip.

4 Rep. Gr.51 - Body - centre

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Fitting instructions: Filling roof side member with foam material - Edition 03.2008

1 - Roof trim strip

Note

– Detach door seals from

body flange in area of roof trim strip.

– Drill heads off pop riv‐

ets, knock out rivet stems and detach roof trim strip.

❑ Carefully prise roof trim

strip out of retaining clips and detach.

2 - Pop rivet

❑ 11x

3 - Side panel

4 - Retaining clip

❑ 4x

Audi TT 2007 ➤

End piece for roof trim strip

– When fitting, first slide roof trim strip -1- into moulded trim -2-

at side window and then press into retaining clip -2-.

1.2 Applying structural foam material

Note

Use 1 static mixer tube for all 4 holes.

Remove screw plugs -b- from roof side member.

Mask off adjacent rivet holes with commercially available adhe‐ sive tape -a-.

1. Filling roof side member with foam material 5

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Audi TT 2007 ➤ Fitting instructions: Filling roof side member with foam material - Edition 03.2008

6 Rep. Gr.51 - Body - centre

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Fitting instructions: Filling roof side member with foam material - Edition 03.2008

1 - Remove hose - 3 - (supplied with set) from nozzle

2 - Screw nozzle - 4 - into static mixer tube - 2 -

Audi TT 2007 ➤

– Apply hand-cartridge gun -V.A.G 1628- at right angles to roof

side member.

1. Filling roof side member with foam material 7

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Audi TT 2007 ➤ Fitting instructions: Filling roof side member with foam material - Edition 03.2008

– Inject the contents of one 2-component epoxy hard foam car‐

tridge into each hole.

8 Rep. Gr.51 - Body - centre

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Audi TT 2007 ➤

Fitting instructions: Filling roof side member with foam material - Edition 03.2008

1. Filling roof side member with foam material 9

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Audi TT 2007 ➤ Fitting instructions: Filling roof side member with foam material - Edition 03.2008

1 - Refit screw plugs immedi‐ ately after injecting foam ma‐ terial.

10 Rep. Gr.51 - Body - centre

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Fitting instructions: Filling roof side member with foam material - Edition 03.2008

1 - Rivet on roof trim strip using pop rivet pliers -VAS 5072- af‐ ter injecting foam material.

Audi TT 2007 ➤

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.

1. Filling roof side member with foam material 11