Audi TT 56 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 ➤

Brake system

Edition 04.2009

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

45 - Anti-lock brake system

46 - Brakes - mechanism

47 - Brakes - hydraulics

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 ➤

Brake system - Edition 04.2009

Contents

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

1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Production code (PR No.) allocation: brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.4 Front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.5 Rear wheel brakes, front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.6 Rear wheel brakes, four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.7 Rear brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.2 Vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Four-wheel drive vehicles with Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.4 Testing four-wheel drive vehicles with Haldex coupling on a conventional brake

dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 General information on the anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.1 Notes for repair work on ABS Mark 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Connecting VAS 505x and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Components and fitting locations on brake system ABS/ESP Mark 60 . . . . . . . . . . . . . . . . 10

4 Removing and installing parts of ABS/ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.1 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.2 Removing and installing brake light switch (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.3 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.4 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.5 Removing and installing brake servo vacuum sender G483 . Only on vehicles with (OHBV)

optimised hydraulic brake assistance/vacuum sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 ABS/ESP Mark 60 control unit -J104- and hydraulic unit -N55- . . . . . . . . . . . . . . . . . . . . . . 19

5.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- . . . . . . . . 20

6 TFSI engine: ABS control unit -J104- and ABS hydraulic unit -N55- . . . . . . . . . . . . . . . . . . 25

6.1 Removing and installing control unit -J104- with hydraulic unit -N55- (TFSI) . . . . . . . . . . . . 25

6.2 Removing and installing control unit -J104- with hydraulic unit -N55- (TT RS) . . . . . . . . . . 29

7 Vehicles with diesel particulate filter: Control unit -J104- with hydraulic unit -N55- . . . . . . 34

7.1 Removing and installing control unit -J104- with hydraulic unit -N55- (TDI) . . . . . . . . . . . . 34

7.2 Basic setting of inlet valves and separating valves (Mark 60EC) . . . . . . . . . . . . . . . . . . . . 39

8 ABS/ESP system components on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8.2 Removing and installing speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

9 ABS/ESP system components on rear axle (front-wheel drive vehicles) . . . . . . . . . . . . . . 42

9.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

9.2 Removing and installing rear speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

10 ABS/ESP system components on rear axle (four-wheel drive vehicles) . . . . . . . . . . . . . . 44

10.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

10.2 Removing and installing rear speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1 Servicing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Contents i

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Audi TT 2007 ➤ Brake system - Edition 04.2009

1.1 Servicing front brakes 16" FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.2 Removing and installing brake pads - front brakes 16" FN3 . . . . . . . . . . . . . . . . . . . . . . . . 49

1.3 Removing and installing brake caliper - front brakes 16" FN3 . . . . . . . . . . . . . . . . . . . . . . 52

2 Servicing front brakes 17" FNR G57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.1 Removing and installing brake pads - front brakes 17" FNR G57 . . . . . . . . . . . . . . . . . . . . 57

2.2 Removing and installing brake caliper - front brakes 17" FNR G57 . . . . . . . . . . . . . . . . . . 60

3 Servicing front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.1 Removing and installing brake pads - front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . 64

3.2 Removing and installing brake caliper - front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . 67

3.3 Renewing brake caliper - front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

3.4 Removing and installing brake disc - front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . 71

4 Pressing back brake piston in front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5 Vibration damper on brake caliper - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

5.1 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

6 Servicing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6.1 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6.2 Removing and installing rear brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

6.3 Removing and installing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

6.4 Detaching and attaching handbrake cable from/to brake caliper . . . . . . . . . . . . . . . . . . . . 83

6.5 Pressing back piston in rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

7 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.1 Handbrake - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.2 Removing and installing handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.3 Removing and installing handbrake switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

7.4 Removing and installing handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.5 Removing and installing guide tubes for handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . 89

7.6 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

8.1 Brake pedal - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

8.2 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

8.3 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1 High-pressure and low-pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1.1 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

2 Servicing front brake caliper FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

2.1 Front brake caliper FN3 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

2.2 Removing and installing piston for front brake caliper FN3 . . . . . . . . . . . . . . . . . . . . . . . . 97

3 Servicing front brake caliper FNRG57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

3.1 Front brake caliper FNRG57 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

3.2 Removing and installing piston for front brake caliper FNRG57 . . . . . . . . . . . . . . . . . . . . 101

4 Servicing brake caliper (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

5 Servicing rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

5.1 Rear brake caliper - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

5.2 Removing and installing piston for rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

6 Bleeding brake system - ABS/ESP Mark 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6.1 Bleeding brake system with brake filling and bleeding equipment VAS 5234 or upgrade kit

and extraction unit V.A.G 1869/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

6.2 Bleeding brake system without brake filling and bleeding equipment . . . . . . . . . . . . . . . . 111

7 Brake servo/brake master cylinder - left-hand drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . 113

7.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

7.2 Checking non-return valve (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

7.3 Removing and installing non-return valve (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

7.4 Removing and installing brake fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

ii Contents

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Audi TT 2007 ➤

Brake system - Edition 04.2009

7.5 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

7.6 Removing and installing brake master cylinder (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . 119

7.7 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

7.8 Removing and installing brake servo (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

7.9 Removing and installing noise amplifier (TFSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

8 Exhauster pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

8.1 Removing and installing exhauster pump (TDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

8.2 Removing and installing exhauster pump (TFSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

8.3 Removing and installing exhauster pump (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

9 Brake lines and brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

9.1 Removing and installing brake lines and brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Contents iii

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Audi TT 2007 ➤ Brake system - Edition 04.2009

iv 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 ➤

Brake system - Edition 04.2009

00 – Technical data

1 Technical data

1.1 Production code (PR No.) allocation: brakes

Which brakes are fitted on the vehicle can be determined from the corresponding production code (PR No.) on the vehicle data sticker.

The vehicle data sticker can be found in the spare wheel well and in the Service Schedule.

The corresponding PR numbers are listed in the following tables. They indicate the required combination of brake discs/calipers/ drums ⇒ Electronic parts catalogue (ETKA)

1.2 Brakes

Brake system

Diagonal dual-circuit brake system, anti-lock brake system (ABS) with electronic brake pressure distribution (EBPD). Certain equipment versions or model production dates additionally feature electronic differential lock (EDL), traction control system (ASR) and electronic stabilisation program (ESP).

1.3 Front brakes

Front axle

Brake caliper (PR No.) Front brake caliper Piston

Brake disc (PR No.) Front brake disc ∅ mm Brake disc thickness

(ventilated) Brake disc, wear limit

Brake pad Pad thickness (new,

without backplate) Pad wear limit (without

backplate)

1LJ 1LL 1LK 1LM 1LN

FN3 FN3 FNR-G-57 FNR-G-57 FNR-G-57

∅ mm 54 54 57 57 57

1LJ 1LJ 1LK 1LK 1LK

312 (16“) 312 (16“) 340 (17“) 340 (17“) 340 (17“)

mm 25 25 30 30 30

mm 21 21 27 27 27

mm

mm 2 2 2 2 2

14 14 14 14 14

1.4 Front brakes (TT RS)

Front axle, TT RS

Brakes (PR No.) 1LA Front brake caliper Piston

Brake disc (PR No.) 1LK Front brake disc Brake disc thickness (ventilated) Brake disc, wear limit

Brembo (M4)

∅ 40 / 44 mm

∅ 370 mm

32 mm 30 mm

1. Technical data 1

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Audi TT 2007 ➤ Brake system - Edition 04.2009

Front axle, TT RS

Pad wear limit (without backplate) 2 mm

1.5 Rear wheel brakes, front-wheel drive

Rear wheel brakes, front-wheel drive

Brake caliper (PR No.) Rear brake caliper Piston

Brake disc (PR No.) Rear brake disc ∅ mm Brake disc thickness (non-ventilated) Brake disc thickness (ventilated) Brake disc wear limit

Brake pad Pad thickness (new, without backplate) mm Pad wear limit (without backplate)

∅ mm 38 38

mm 12 12 mm ------ -----mm 9 9

mm 2 2

2ED 1KZ

CII 38HR CII 38HR

2ED, 2EE 1KZ, 1KJ,

286 (16“) 286 (16“)

12 12

1.6 Rear wheel brakes, four-wheel drive

Rear wheel brakes, four-wheel drive

Brake caliper (PR No.) Rear brake caliper Piston

Brake disc (PR No.) Rear brake disc ∅ mm Brake disc thickness

(non-ventilated) Brake disc thickness

(ventilated) Brake disc,

wear limit Pad wear limit (without

backplate)

∅ mm 41 41 41 41 41

mm 12 12 ------ ------ ------

mm ------ ------ 22 22 22

mm 9 9 19 19 19

mm 2 2 2 2 2

1KJ 2EE 2EA 2EF 2EG

CII 41HR CII 41HR CII 41HR CII 41HR CII 41HR

1KJ, 1KZ 2EE, 2ED 2EA 2EF 2EG 286 (16“) 286 (16“) 310 (17“) 310 (17“) 310 (17“)

1.7 Rear brakes (TT RS)

Rear brakes (TT RS)

Rear brake caliper CII 41 HR Piston ∅ mm 41 Rear brake disc Brake disc thickness (ventilated

brake disc) Brake disc,

wear limit Pad wear limit (without back‐

plate)

∅ mm 312

mm 22

mm 19

mm 2

2 Rep. Gr.00 - Technical data

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2 Brake test

2.1 General notes

The wheels are driven by the test rollers.

During the test the gearbox must be in neutral on manual gear‐ boxes or

in position N on automatic gearboxes.

Follow the instructions provided by the manufacturer of the brake test equipment when performing the test.

Note

Electronic brake control systems are inoperative when the ignition is switched off.

2.2 Vehicles with front-wheel drive

Audi TT 2007 ➤

Brake system - Edition 04.2009

Testing on a single-axle brake dynamometer

Perform brake test on a single-axle brake dynamometer.

The EDL control can activate the brakes if the rollers start at dif‐ ferent points in time.

Test speed must not exceed 6 km/h.

All brake test equipment approved by Audi meets these require‐ ments.

2.3 Four-wheel drive vehicles with Haldex coupling

Testing on a single-axle brake dynamometer for four-wheel drive vehicles

The rollers drive the wheels of one axle in opposite directions to avoid transmitting torque to the other axle.

The EDL control can activate the brakes if the rollers start at dif‐ ferent points in time.

Test speed must not exceed 6 km/h.

All brake test equipment approved by Audi meets these require‐ ments.

2.4 Testing four-wheel drive vehicles with Haldex coupling on a conventional brake dynamometer

Proceed as follows to test brakes on a conventional brake dyna‐ mometer.

– Drive vehicle forward until front wheels are standing on rollers.

– Switch off engine and wait for 3 seconds.

– Perform brake test on front wheels.

– Allow engine to run for approx. 5 seconds after performing

brake test to build up sufficient vacuum in the servo.

– Drive vehicle forward until rear wheels are standing on rollers.

2. Brake test 3

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Switch off engine and wait for 3 seconds.

– Perform brake test on rear wheels.

WARNING

The engine must not run and the ignition must be switched off during the brake test, otherwise the rear wheels will be driven by the Haldex coupling.

4 Rep. Gr.00 - Technical data

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3 Brake fluid

3.1 General notes

Brake fluid is hygroscopic, i.e. it has the tendency to absorb water and moisture from the atmosphere

The boiling point decreases as the water content increases, which means a considerable rise in brake fluid temperature can lead to formation of vapour bubbles and reduced braking effect.

The colour of the brake fluid becomes darker over the course of time. This is caused by a normal chemical reaction and is not an indication of the condition of the fluid.

WARNING

Rubber parts of brake system (sleeves, seals) are not com‐ patible with mineral oil, fuel and cleaning agents. Even minute quantities coming into contact with a sleeve or seal will affect the component and could impair brake operation.

Audi TT 2007 ➤

Brake system - Edition 04.2009

3. Brake fluid 5

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Audi TT 2007 ➤ Brake system - Edition 04.2009

45 – Anti-lock brake system

1 General information on the anti-lock

brake system

1.1 Notes for repair work on ABS Mark 60

WARNING

The anti-lock brake system is basically maintenance-free.

Testing, removing, installing and repair work may only be per‐ formed by qualified personnel.

Failure to observe the information described in this Workshop Manual may result in damage to the system and could make the vehicle unsafe.

Note

Malfunctions in the ABS system do not influence the brake system itself. However, a change in braking behaviour must be reckoned with.

Vehicles equipped with the ABS Mark 60 do not have a mechan‐ ical brake pressure regulator. A specially matched software in the control unit controls the rear axle brake pressure regulation.

♦ Before carrying out repair work on the anti-lock brake system,

determine the cause of the problem using self-diagnosis.

♦ Always switch off ignition before unplugging the connector at

hydraulic control unit.

♦ If a new hydraulic control unit has been fitted, it must be en‐

coded. Vehicle diagnostic, testing and information system VAS 505x-

♦ Bleed brake system after performing work involving opening

of brake system: ABS/ESP Mark 60 ⇒ page 109 . To do so, use for example the brake filling and bleeding equipment V.A.G 1869- or brake filling and bleeding equipment -VAS 5234- .

♦ Absolute cleanliness is required when working on the anti-lock

brake system; avoid any products that contain mineral oil, such as oil, grease, etc.

♦ Thoroughly clean all connections and the adjacent areas be‐

fore loosening; do not use harsh cleaning agents such as brake cleaner, fuel, thinners or similar.

♦ Place removed parts on a clean surface and cover them up.

♦ Carefully cover or seal open components if repairs are not to

be carried out immediately. Use plugs from repair kit; Part No. ⇒ ETKA .

♦ When the brake system is open do not work with compressed

air and do not move the vehicle.

♦ Only use lint-free cloths.

♦ Only use genuine spare parts from original packaging.

6 Rep. Gr.45 - Anti-lock brake system

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♦ Only remove replacement parts from packaging immediately

prior to installation.

♦ During the final road test, ensure that at least one ABS-con‐

trolled braking operation is performed (pulsations must be felt at the brake pedal).

♦ During painting operations, the electronic control unit can be

exposed to a maximum temperature of 95 °C for only a short period, and to a maximum of 85 °C for longer periods (approx. 2 hours).

♦ Before carrying out welding work with an electric welding unit,

refer to ⇒ General notes; Body repairs; Safety notes .

Audi TT 2007 ➤

Brake system - Edition 04.2009

1. General information on the anti-lock brake system 7

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Audi TT 2007 ➤ Brake system - Edition 04.2009

2 Connecting -VAS 505x- and select‐

ing functions

Special tools and workshop equipment required

♦ Vehicle diagnostic, testing and information system -VAS 505x-

WARNING

♦ Test equipment must always be secured to the rear seat

when road-testing the vehicle.

♦ While the vehicle is moving this equipment must be oper‐

ated by a second person; NOT by the driver.

– Attach the diagnosis cable connector to the diagnosis con‐

nection.

8 Rep. Gr.45 - Anti-lock brake system

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– Switch on tester -arrow-.

The tester is ready as soon as a picture of a car appears in the display.

– Switch on ignition.

– Press the Guided Fault Finding button on the display screen.

– Select the following:

♦ Make

♦ Model

♦ Model year

♦ Version

♦ Engine code letters

– Confirm the entered information.

Wait until the tester has interrogated all the control units in the vehicle.

– Press the Go to button and select the option “Function/com‐

ponent selection”.

Follow the instructions in the display to begin with the desired functions.

Audi TT 2007 ➤

Brake system - Edition 04.2009

2. Connecting VAS 505x and selecting functions 9

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Audi TT 2007 ➤ Brake system - Edition 04.2009

3 Components and fitting locations on brake system ABS/ESP Mark 60

1 - ESP and TCS warning lamp

-K155❑ Fitting location: in rev.

counter.

❑ Flashes when the vehi‐

cle is in motion and the ESP/TCS control is in operation

❑ Lights up when the igni‐

tion is switched on and goes out after a short self-test has been com‐ pleted

❑ Lights up if there is a

malfunction in the ESP

❑ Lights up if there is a

malfunction in the ABS, since the ESP works in conjunction with the ABS

❑ Lights up when the ESP

is switched off

❑ Lights up during auto‐

matic self-adaption of the sensor systems when:

♦ the battery has been dis‐

connected and then re-con‐ nected

♦ the vehicle has been jump-

started

♦ the battery charge level is

very low

❑ The warning lamp goes

out after the vehicle has been in motion for a short time as soon as the learning procedure of the sensor systems is finalised.

2 - Brake pad warning lamp -K32-

❑ Fitting location: in centre display zone ❑ Lights up when wear limit of the brake pads is reached ⇒ page 1

3 - Brake system warning lamp -K118-

❑ Fitting location: in speedometer ❑ Lights up when the handbrake is applied. ❑ Lights up if there is a malfunction in the ABS system. ❑ Flashes if brake fluid level is too low

4 - ABS warning lamp -K47-

❑ Fitting location: in speedometer ❑ Lights up for a few seconds when the ignition is switched on and goes out after the automatic ABS self-

test has been completed, providing no faults have been detected in the ABS.

❑ There is a malfunction of the ABS if the warning lamp:

♦ does not light up when the ignition is switched on,

♦ does not go out again after a few seconds,

10 Rep. Gr.45 - Anti-lock brake system

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Audi TT 2007 ➤

Brake system - Edition 04.2009

♦ lights up while the vehicle is in motion.

❑ Malfunctions in the ABS system do not influence the brake system itself. However, a change in braking

behaviour must be reckoned with.

❑ The ESP warning lamp will light up as well as the ABS warning lamp if there is a malfunction in the ABS,

since the two systems work in conjunction.

5 - TCS and ESP button -E256-

❑ Fitting location: on the centre console

6 - Rear left speed sensor -G44- , rear right speed sensor -G46- -

❑ 8 Nm

7 - Steering angle sender -G85-

❑ Fitting location: on steering column between steering wheel and steering column switch ❑ Removing and installing ⇒ page 16

8 - Diagnostic connection

❑ Fitting location: cover in driver's footwell

9 - Brake pedal

❑ Removing and installing ⇒ page 91

10 - Front left speed sensor -G45- , front right speed sensor -G47-

❑ Removing and installing ⇒ page 40 ❑ 8 Nm

11 - Brake servo

❑ Removing and installing ⇒ page 113

Note

♦

On vehicles with TTS engine the noise amplifier must be removed and installed ⇒ page 129 .

♦

The noise amplifier is located in the engine compartment in front of the brake servo.

❑ With integrated brake vacuum sender -G 483 ❑ Brake vacuum sender -G 483 is not fitted on all models ❑ Removing and installing brake servo vacuum sender -G 483 ⇒ page 17

Note

The brake vacuum sender -G 483 is only installed on vehicles with OHBV.

12 - Brake master cylinder

❑ With brake light switch attached ❑ Removing and installing ⇒ page 117

Note

♦

On vehicles with TTS engine the noise amplifier must be removed and installed ⇒ page 129 .

♦

The noise amplifier is located in the engine compartment in front of the brake servo.

3. Components and fitting locations on brake system ABS/ESP Mark 60 11

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Audi TT 2007 ➤ Brake system - Edition 04.2009

13 - Brake light switch

❑ Removing and installing ⇒ page 13 ❑ Removing and installing (TT RS) ⇒ page 13 ❑ The brake light switch is not adjustable. ❑ Location: On brake master cylinder ❑ 5 Nm

14 - ABS control unit (with ESP) -J104-

❑ Fitting location: on hydraulic unit -N55 on right-side of engine compartment. ❑ Do not unplug connector before completing self-diagnosis. Switch off ignition before detaching connector. ❑ Removing and installing ⇒ page 20 ❑ Removing and installing (TFSI engine) ⇒ page 25 ❑ Removing and installing (vehicles with diesel particulate filter) ⇒ page 34

Caution

ABS control unit -J104and ABS hydraulic unit N55- must not be sepa‐ rated.

15 - ABS hydraulic unit -N55-

❑ Fitting location: in engine compartment (right-side) on control unit -J104-. ❑ Removing and installing ⇒ page 20 ❑ Removing and installing (TFSI engine) ⇒ page 25 ❑ Removing and installing (vehicles with diesel particulate filter) ⇒ page 34 ❑ The ABS hydraulic pump -V64- , the ABS hydraulic unit -N55- and the ABS control unit (with ESP) -J104-

together make up the hydraulic control unit. ❑ With integrated brake pressure sender -G201❑ The brake pressure sender -G201- cannot be renewed separately. ❑ Allocation ⇒ ETKA

16 - ESP sensor unit -G419-

❑ 9 Nm ❑ Fitting location: on centre console in front of gear lever. ❑ Combined lateral acceleration sender -G200- and yaw rate sender -G202❑ Longitudinal acceleration sender -G251- (only four-wheel drive vehicles) ❑ Removing and installing ESP sensor unit ⇒ page 15

Note

The ABS sensor ring / rotor is incorporated in the corresponding wheel bearing unit and cannot be renewed.

12 Rep. Gr.45 - Anti-lock brake system

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4 Removing and installing parts of

ABS/ESP system

4.1 Removing and installing brake light switch

Removing

Note

♦

The brake light switch is located on the brake master cylinder.

♦

The brake light switch is not adjustable.

– Unplug electrical connector -1-.

– Remove securing bolt for brake light switch -2- from brake

master cylinder.

– Pull brake light switch at bottom out of brake master cylinder

and lift switch out of retaining tab at top.

Installing

– Installation is carried out in the reverse sequence. Ensure

proper seating of switch in retaining tab at top.

Audi TT 2007 ➤

Brake system - Edition 04.2009

Note

The brake light switch is not adjustable.

4.2 Removing and installing brake light switch (TT RS)

Removing

Note

♦

The brake light switch is located on the brake master cylinder.

♦

The brake light switch is not adjustable.

– Lift off engine cover panel -1-.

4. Removing and installing parts of ABS/ESP system 13

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Unscrew bolts -arrows- and detach air duct.

– Unscrew bolts -arrows- and detach air cleaner housing.

– Unplug electrical connector -1-.

– Remove securing bolt for brake light switch -2- from brake

master cylinder.

– Pull brake light switch at bottom out of brake master cylinder

and lift switch out of retaining tab at top.

Installing

– Installation is carried out in the reverse sequence. Ensure

proper seating of switch in retaining tab at top.

Note

The brake light switch is not adjustable.

– Insert air cleaner housing and tighten bolts -arrows-.

14 Rep. Gr.45 - Anti-lock brake system

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– Insert air duct and tighten bolts -arrows-.

– Install engine cover panel.

4.3 Removing and installing ESP sensor unit -G419-

WARNING

The ESP sensor unit is sensitive to impact. The ESP sensor unit can be damaged if subjected to impact. If the ESP sensor unit has been dropped by mistake it may not work properly and must not be installed in the vehicle.

Audi TT 2007 ➤

Brake system - Edition 04.2009

– After renewing ESP sensor unit -G419-, a basic setting (cali‐

bration) for

♦ Lateral acceleration sender -G200-

♦ Yaw rate sender -G202-

♦ Longitudinal acceleration sender -G251- (on four-wheel drive

vehicles)

– must be performed

Removing

Note

ESP sensor unit -G419 is fitted on centre console under trim in front of gear lever / selector lever.

– Remove centre console trim ⇒ Rep. Gr. 68 .

– Unplug connector.

– Remove bolts.

– Lift out ESP sensor unit -G419-.

Installing

Installation is performed in reverse sequence; note the following:

Calibrate lateral acceleration sender -G200 and longitudinal ac‐ celeration sender -G251 on vehicles with four-wheel drive. To do so, use the vehicle diagnosis, testing and information system VAS 505x- .

– Select on the display:

♦ Running gear

♦ Brake system (Repair group 01; 45)

♦ 01 - Self-diagnosis compatible systems

4. Removing and installing parts of ABS/ESP system 15

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Audi TT 2007 ➤ Brake system - Edition 04.2009

♦ 03 - Brake electronics ABS/ESP Mark 60

– Select the function you require on the display.

♦ Calibrate lateral acceleration sender -G200-

♦ Calibrate longitudinal acceleration sender -G251- (only on

four-wheel drive vehicles)

– Carry out ESP road test and system test.

4.4 Removing and installing steering angle sender -G85-

Removing

– Turn wheels to straight ahead position.

– Remove airbag unit and steering wheel ⇒ Rep. Gr. 48 .

Item -1-: Return ring with slip ring

- Clipped to switch for turn signal indicator, main beam, dipped

beam and headlight flasher

Item -2- Steering angle sender -G85-

- Clipped to return ring with slip ring

WARNING

The return ring with slip ring must not be rotated following re‐ moval.

– Remove driver's storage compartment ⇒ Rep. Gr. 68 .

– Remove steering column switch module ⇒ Rep. Gr. 94 .

Installing

Installation is carried out in the reverse sequence.

– Install airbag unit and steering wheel. ⇒ Rep. Gr. 48

Calibrate steering angle sender -G85.

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

– Select on the display:

♦ Running gear

♦ Brake system (Repair group 01; 45)

♦ 01 - Self-diagnosis compatible systems

♦ 03 - Brake electronics ABS/ESP Mark 60

– Select the function you require on the display.

♦ J104 - Control unit for ABS/TCS/ESP, Functions

♦ G-85 - Calibrate steering angle sensor ⇒ Vehicle diagnosis,

testing and information system -VAS 505x- .

– Carry out ESP road test and system test.

16 Rep. Gr.45 - Anti-lock brake system

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4.5 Removing and installing brake servo vacuum sender -G483- . Only on vehi‐ cles with (OHBV) optimised hydraulic brake assistance/vacuum sender

Note

♦

On vehicles with TTS engine the noise amplifier must be re‐ moved and installed ⇒ page 129 .

♦

The noise amplifier is located in the engine compartment in front of the brake servo.

Note

Vehicles on which the brake vacuum is supplied entirely by the intake manifold and vehicles with mechanical vacuum pump are not fitted with brake servo vacuum sender -G483.

Audi TT 2007 ➤

Brake system - Edition 04.2009

Special tools and workshop equipment required

♦ Vehicle diagnostic, testing and information system -VAS 505x-

Note

♦

Brake servo vacuum sender -G483- does not have to be cali‐ brated after renewal.

♦

The "Guided Fault Finding" contains a description of the elec‐ trical check.

Removing

Note

♦

On vehicles with TTS engine the noise amplifier must be re‐ moved and installed ⇒ page 129 .

♦

The noise amplifier is located in the engine compartment in front of the brake servo.

– Unplug electrical connector -1- for vacuum sender -2-.

4. Removing and installing parts of ABS/ESP system 17

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Pull back retaining ring -1- on OHBV and remove sender -

G483 -2- from brake servo.

Installing

Note

♦

On vehicles with TTS engine the noise amplifier must be re‐ moved and installed ⇒ page 129 .

♦

The noise amplifier is located in the engine compartment in front of the brake servo.

Installation is carried out in reverse sequence.

18 Rep. Gr.45 - Anti-lock brake system

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Brake system - Edition 04.2009

5 ABS/ESP Mark 60 control unit -J104-

and hydraulic unit -N55-

5.1 Exploded view

1 - Brake lines

♦ Marking - DK - Brake mas‐

ter cylinder/primary piston circuit to hydraulic unit.

♦ Marking - HL - To rear left

brake caliper.

♦ Marking - VR - To front right

brake caliper.

♦ Marking - VL - To front left

brake caliper.

♦ Marking - HR - To rear right

brake caliper.

♦ Marking - SK - Brake mas‐

ter cylinder/secondary pis‐

ton circuit to hydraulic unit. ❑ 14 Nm ❑ Perform final control di‐

agnosis after securing brake lines to hydraulic unit. To do this, use ve‐ hicle diagnosis, testing and information system

-VAS 505x- .

2 - ABS control unit (with ESP)

-J104❑ Fitting location: on hy‐

draulic unit -N55 on right-side of engine

compartment. ❑ Allocation ⇒ ETKA ❑ Removing and installing

⇒ page 20

❑ Removing and installing

(TFSI engine)

⇒ page 25

❑ Removing and installing (TT RS) ⇒ page 29 ❑ Removing and installing (vehicles with diesel particulate filter) ⇒ page 34

Audi TT 2007 ➤

Caution

ABS control unit -J104and ABS hydraulic unit N55- must not be sepa‐ rated. Control unit and hydraulic unit must be re‐ newed as one unit.

3 - ABS hydraulic unit -N55-

❑ Fitting location: in engine compartment (right-side) on control unit -J104❑ Allocation ⇒ ETKA

5. ABS/ESP Mark 60 control unit -J104- and hydraulic unit -N55- 19

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Audi TT 2007 ➤ Brake system - Edition 04.2009

❑ Removing and installing ⇒ page 20 ❑ Removing and installing (TFSI engine) ⇒ page 25 ❑ Removing and installing (TT RS) ⇒ page 29 ❑ Removing and installing (vehicles with diesel particulate filter) ⇒ page 34

4 - Bracket

❑ Removing and installing together with hydraulic unit -N55- and control unit -J104- ⇒ page 20

5 - Bolt

❑ Bracket to hydraulic unit ❑ 8 Nm

6 - Mounting bracket

❑ With rubber buffer

7 - Nut

5.2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55-

Caution

ABS control unit -J104- and ABS hydraulic unit -N55- must not be separated.

Removing hydraulic unit with control unit

– Read out control unit version and note down.

– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 (note

radio code).

– Insert brake pedal actuator -V.A.G 1869/2- between brake

pedal and driver's seat (depress brake pedal at least 60 mm).

– Connect hose of bleeder bottle to bleeder screws of front left

and rear left brake calipers.

– Open bleeder screws of rear left and front left brake calipers

to release pressure in hydraulic unit.

– Close bleeder screws of front left and rear left brake calipers.

– Do not remove brake pedal actuator -V.A.G 1869/2- .

20 Rep. Gr.45 - Anti-lock brake system

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– Release connector at control unit -arrow 1- and unplug

-arrow 2-.

Note

♦

Make sure brake fluid does not get into connector housing of control unit. This can result in corrosion of the contacts and failure of the system.

♦

Use compressed air to carefully clean connector housing if necessary.

– To protect against escaping brake fluid, place a sufficient

number of lint-free cloths in area beneath control unit and hy‐ draulic unit.

– Mark brake lines ⇒ Item 1 (page 19) .

WARNING

Do not bend or kink brake lines.

Audi TT 2007 ➤

Brake system - Edition 04.2009

– Unscrew brake lines from hydraulic unit -2- to brake master

cylinder and tie in place.

– Disconnect remaining brake lines -3- on hydraulic unit.

Note

Hydraulic pump -1- must not be separated from hydraulic unit.

– Seal brake lines and threaded holes using sealing plugs from

repair kit.

5. ABS/ESP Mark 60 control unit -J104- and hydraulic unit -N55- 21

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Carefully pull hydraulic unit -2- together with control unit and

bracket -4- out of rubber buffers on mounting bracket -6-.

– Take hydraulic unit out of vehicle.

– Unscrew bolts -5- from bracket -4- and detach bracket.

WARNING

Severe shocks or jolts can damage the control unit. The control unit must not be re-installed if it has been damaged in any way.

– Place hydraulic unit on a clean flat surface with control unit

facing downwards.

Seal threaded holes and brake lines using sealing plugs 1H0.698.311.A after removing control unit and hydraulic unit.

WARNING

Hydraulic pump must not be separated from hydraulic unit.

Installing

Installation is performed in reverse sequence; note the following:

Note

♦

The hydraulic unit supplied as a replacement is filled with brake fluid.

♦

Do not remove sealing plug of corresponding brake line before fitting, otherwise brake fluid will escape. Proper bleeding is then no longer ensured.

22 Rep. Gr.45 - Anti-lock brake system

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– Secure bracket -4- by tightening bolts -5- to 8 Nm.

– Carefully insert hydraulic unit -2- together with control unit and

bracket -4- in rubber buffers on mounting bracket -6-.

Make sure that rubber buffers are not pressed through mounting bracket when inserting unit.

– Connect brake lines as previously marked.

WARNING

Interchanging brake line connections will result in ESP system malfunction.

– Connect brake lines to hydraulic unit.

– Attach connector to control unit and lock connector.

– Bleed brake system ⇒ page 109 .

– Perform final control diagnosis after securing brake lines to

hydraulic unit.

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

Audi TT 2007 ➤

Brake system - Edition 04.2009

Note

Final control diagnosis can be used to establish whether line con‐ nections have been interchanged.

If a new ABS control unit -J104- has been fitted, it must be enco‐ ded.

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

– Select on the display:

♦ Running gear

♦ Brake system (Repair group 01; 45)

♦ 01 - Self-diagnosis compatible systems

♦ 03 - Brake electronics ABS/ESP Mark 60

– Select required function on the display.

♦ J104 - Control unit for ABS/TCS/ESP Mark 60

♦ J104 - Control unit for ABS/TCS/ESP, Functions

♦ J104 - Encoding control unit

Also calibrate the following senders after renewing control unit J104-.

♦ Steering angle sender -G85-

♦ Lateral acceleration sender -G200-

♦ Brake pressure sender 1 -G201-

♦ Longitudinal acceleration sender -G251- (only on four-wheel

drive vehicles)

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

– Select on the display:

5. ABS/ESP Mark 60 control unit -J104- and hydraulic unit -N55- 23

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Audi TT 2007 ➤ Brake system - Edition 04.2009

♦ Running gear

♦ Brake system

♦ 01 - Self-diagnosis compatible systems

♦ 03 - Brake electronics ABS/ESP Mark 60

– Select required function on the display.

♦ J104 - Control unit for ABS/TCS/ESP Mark 60

♦ J104 - Control unit for ABS/TCS/ESP, Functions

– Then carry out ESP road test and system test.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

24 Rep. Gr.45 - Anti-lock brake system

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6 TFSI engine: ABS control unit -J104-

and ABS hydraulic unit -N55-

6.1 Removing and installing control unit J104- with hydraulic unit -N55- (TFSI)

Caution

ABS control unit -J104- and ABS hydraulic unit -N55- must not be separated.

Removing hydraulic unit with control unit

– Read out control unit version and note down.

– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 (note

radio code).

– Insert brake pedal actuator -V.A.G 1869/2- between brake

pedal and driver's seat (depress brake pedal at least 60 mm).

– Connect hose of bleeder bottle to bleeder screws of front left

and rear left brake calipers.

– Open bleeder screws of rear left and front left brake calipers

to release pressure in hydraulic unit.

– Close bleeder screws of front left and rear left brake calipers.

– Do not remove brake pedal actuator -V.A.G 1869/2- .

– Lower vehicle.

Audi TT 2007 ➤

Brake system - Edition 04.2009

– Detach engine cover panel.

– Using suitable pliers, unfasten clamp at air hose to air duct and

detach hose

– Using suitable pliers, unfasten clamps of air duct and detach.

– Remove air duct to turbocharger from bracket.

– Take air duct out of vehicle.

6. TFSI engine: ABS control unit -J104- and ABS hydraulic unit -N55- 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 2007 ➤ Brake system - Edition 04.2009

– Release connector at control unit -arrow 1- and unplug

-arrow 2-.

Note

♦

Make sure brake fluid does not get into connector housing of control unit. This can result in corrosion of the contacts and failure of the system.

♦

Use compressed air to carefully clean connector housing if necessary.

– To protect against escaping brake fluid, place a sufficient

number of lint-free cloths in area beneath control unit and hy‐ draulic unit.

– Mark brake lines ⇒ Item 1 (page 19) .

WARNING

Do not bend or kink brake lines.

– Unscrew brake lines from hydraulic unit -2- to brake master

cylinder and tie in place.

– Disconnect remaining brake lines -3- on hydraulic unit.

– Seal brake lines and threaded holes using sealing plugs from

repair kit.

Note

The hydraulic pump must not be separated from the hydraulic unit.

26 Rep. Gr.45 - Anti-lock brake system

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.

– Carefully pull hydraulic unit -2- together with control unit and

bracket -4- out of rubber buffers on mounting bracket -6-.

– Take hydraulic unit out of vehicle.

– Unscrew bolts -5- from bracket -4- and detach bracket.

– Place hydraulic unit on a clean flat surface with control unit

facing downwards.

WARNING

Severe shocks or jolts can damage the control unit. The control unit must not be re-installed if it has been damaged in any way.

Seal threaded holes and brake lines using sealing plugs 1H0.698.311.A after removing control unit and hydraulic unit.

WARNING

Hydraulic pump must not be separated from hydraulic unit.

Audi TT 2007 ➤

Brake system - Edition 04.2009

Installing

Installation is performed in reverse sequence; note the following:

Note

♦

The hydraulic unit supplied as a replacement is filled with brake fluid.

♦

If sealing plugs are removed before fitting corresponding brake line, brake fluid will escape. Proper bleeding is then no longer ensured.

6. TFSI engine: ABS control unit -J104- and ABS hydraulic unit -N55- 27

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 ➤ Brake system - Edition 04.2009

– Secure bracket -4- by tightening bolts -5- to 8 Nm.

– Carefully insert hydraulic unit -2- together with control unit and

bracket -4- in rubber buffers on mounting bracket -6-.

Make sure that rubber buffers are not pressed through mounting bracket when inserting unit.

– Connect brake lines as previously marked

⇒ Item 1 (page 19) .

WARNING

Interchanging brake line connections will result in ESP system malfunction.

– Connect brake lines to hydraulic unit.

– Attach connector to control unit and lock connector.

– Insert air duct for turbocharger and use suitable pliers to fasten

clamps.

– Secure air duct for turbocharger at bracket.

– Connect air hose and use suitable pliers to fasten clamp.

– Install engine cover panel.

– Bleed brake system ⇒ page 109 .

– Perform final control diagnosis after securing brake lines to

hydraulic unit.

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

Note

Final control diagnosis can be used to establish whether line con‐ nections have been interchanged.

If a new ABS control unit -J104- has been fitted, it must be enco‐ ded.

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

– Select on the display:

♦ Running gear

♦ Brake system (Repair group 01; 45)

♦ 01 - Self-diagnosis compatible systems

♦ 03 - Brake electronics ABS/ESP Mark 60

– Select required function on the display.

♦ J104 - Control unit for ABS/TCS/ESP Mark 60

♦ J104 - Control unit for ABS/TCS/ESP, Functions

♦ J104 - Encoding control unit

Also calibrate the following senders after renewing control unit J104-.

♦ Steering angle sender -G85-

♦ Lateral acceleration sender -G200-

28 Rep. Gr.45 - Anti-lock brake system

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♦ Brake pressure sender 1 -G201-

♦ Longitudinal acceleration sender -G251- (only on four-wheel

drive vehicles)

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

– Select on the display:

♦ Running gear

♦ Brake system

♦ 01 - Self-diagnosis compatible systems

♦ 03 - Brake electronics ABS/ESP Mark 60

– Select required function on the display.

♦ J104 - Control unit for ABS/TCS/ESP Mark 60

♦ J104 - Control unit for ABS/TCS/ESP, Functions

– Then carry out ESP road test and system test.

WARNING

Audi TT 2007 ➤

Brake system - Edition 04.2009

Before driving vehicle for the first time, make sure function of brakes is OK.

6.2 Removing and installing control unit J104- with hydraulic unit -N55- (TT RS)

Caution

ABS control unit -J104- and ABS hydraulic unit -N55- must not be separated.

Removing hydraulic unit with control unit

– Read out control unit version and note down.

– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 (note

radio code).

6. TFSI engine: ABS control unit -J104- and ABS hydraulic unit -N55- 29

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Insert brake pedal actuator -V.A.G 1869/2- between brake

pedal and driver's seat (depress brake pedal at least 60 mm).

– Connect hose of bleeder bottle to bleeder screws of front left

and rear left brake calipers.

– Open bleeder screws of rear left and front left brake calipers

to release pressure in hydraulic unit.

– Close bleeder screws of front left and rear left brake calipers.

– Do not remove brake pedal actuator -V.A.G 1869/2- .

– Lower vehicle.

– Using suitable pliers, unfasten clamp at air hose to air duct and

detach hose.

– Using suitable pliers, unfasten clamps of air duct and detach.

– Remove air duct to turbocharger from bracket.

– Take air duct out of vehicle.

– Unclip coolant line to coolant expansion tank from bulkhead.

– Carefully press coolant line to one side.

– Release connector at control unit -arrow 1- and unplug

-arrow 2-.

Note

♦

Make sure brake fluid does not get into connector housing of control unit. This can result in corrosion of the contacts and failure of the system.

♦

Use compressed air to carefully clean connector housing if necessary.

– Unfasten cable tie for electrical wiring to connector and move

wiring clear to one side.

– To protect against escaping brake fluid, place a sufficient

number of lint-free cloths in area beneath control unit and hy‐ draulic unit.

– Mark brake lines ⇒ Item 1 (page 19) .

WARNING

Do not bend or kink brake lines.

30 Rep. Gr.45 - Anti-lock brake system

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– Unscrew brake lines from hydraulic unit -2- to brake master

cylinder and tie in place.

– Disconnect remaining brake lines -3- on hydraulic unit.

– Seal brake lines and threaded holes using sealing plugs from

repair kit.

Note

The hydraulic pump must not be separated from the hydraulic unit.

– Carefully pull hydraulic unit -2- together with control unit and

bracket -4- out of rubber buffers on mounting bracket -6-.

– Take hydraulic unit out of vehicle.

– Unscrew bolts -5- from bracket -4- and detach bracket.

– Place hydraulic unit on a clean flat surface with control unit

facing downwards.

Audi TT 2007 ➤

Brake system - Edition 04.2009

WARNING

Severe shocks or jolts can damage the control unit. The control unit must not be re-installed if it has been damaged in any way.

Seal threaded holes and brake lines using sealing plugs 1H0.698.311.A after removing control unit and hydraulic unit.

WARNING

Hydraulic pump must not be separated from hydraulic unit.

Installing

Installation is performed in reverse sequence; note the following:

Note

♦

The hydraulic unit supplied as a replacement is filled with brake fluid.

♦

If sealing plugs are removed before fitting corresponding brake line, brake fluid will escape. Proper bleeding is then no longer ensured.

6. TFSI engine: ABS control unit -J104- and ABS hydraulic unit -N55- 31

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 ➤ Brake system - Edition 04.2009

– Secure bracket -4- by tightening bolts -5- to 8 Nm.

– Carefully insert hydraulic unit -2- together with control unit and

bracket -4- in rubber buffers on mounting bracket -6-.

Make sure that rubber buffers are not pressed through mounting bracket when inserting unit.

– Connect brake lines as previously marked

⇒ Item 1 (page 19) .

WARNING

Interchanging brake line connections will result in ESP system malfunction.

– Connect brake lines to hydraulic unit.

– Attach connector to control unit and lock connector.

– Secure electrical wiring for connector to body using a cable

tie.

– Clip coolant line to coolant expansion tank into retainers in

bulkhead.

Note

Fasten retainers at bulkhead.

– Insert air duct for turbocharger and use suitable pliers to fasten

clamps.

– Secure air duct for turbocharger at bracket.

– Connect air hose and use suitable pliers to fasten clamp.

– Bleed brake system ⇒ page 109 .

– Perform final control diagnosis after securing brake lines to

hydraulic unit.

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

Note

Final control diagnosis can be used to establish whether line con‐ nections have been interchanged.

If a new ABS control unit -J104- has been fitted, it must be enco‐ ded.

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

– Select on the display:

♦ Running gear

♦ Brake system (Repair group 01; 45)

♦ 01 - Self-diagnosis compatible systems

♦ 03 - Brake electronics ABS/ESP Mark 60

– Select required function on the display.

♦ J104 - Control unit for ABS/TCS/ESP Mark 60

32 Rep. Gr.45 - Anti-lock brake system

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.

♦ J104 - Control unit for ABS/TCS/ESP, Functions

♦ J104 - Encoding control unit

Also calibrate the following senders after renewing control unit J104-.

♦ Steering angle sender -G85-

♦ Lateral acceleration sender -G200-

♦ Brake pressure sender 1 -G201-

♦ Longitudinal acceleration sender -G251- (only on four-wheel

drive vehicles)

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

– Select on the display:

♦ Running gear

♦ Brake system

♦ 01 - Self-diagnosis compatible systems

♦ 03 - Brake electronics ABS/ESP Mark 60

– Select required function on the display.

♦ J104 - Control unit for ABS/TCS/ESP Mark 60

♦ J104 - Control unit for ABS/TCS/ESP, Functions

– Then carry out ESP road test and system test.

Audi TT 2007 ➤

Brake system - Edition 04.2009

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

6. TFSI engine: ABS control unit -J104- and ABS hydraulic unit -N55- 33

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 ➤ Brake system - Edition 04.2009

7 Vehicles with diesel particulate filter:

Control unit -J104- with hydraulic unit

-N55-

7.1 Removing and installing control unit J104- with hydraulic unit -N55- (TDI)

Note

The diesel particulate filter must be removed ⇒ Rep. Gr. 26 .

Special tools and workshop equipment required

♦ Torque wrench -V.A.G

1331-

♦ Torque wrench -V.A.G

1410-

♦ Brake pedal actuator -

V.A.G 1869/2-

34 Rep. Gr.45 - Anti-lock brake system

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Sealing plug repair kit, Part no. 1H0 698 311 A

No warranty can be assumed for hydraulic units without transport protection.

1 - Transport protection for valve domes (foam)

2 - Sealing plugs M10 for brake lines and tapped holes

3 - Sealing plugs M12 for brake lines and tapped holes

Caution

ABS control unit -J104- and ABS hydraulic unit -N55- must not be separated.

Removing hydraulic unit with control unit

– Read out control unit version and note down.

– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 (note

radio code).

– Insert brake pedal actuator -V.A.G 1869/2- between brake

pedal and driver's seat. Depress the brake pedal at least 60 mm.

– Connect hose of bleeder bottle to bleeder screws of front left

and rear left brake calipers and open bleeder screws.

Audi TT 2007 ➤

Brake system - Edition 04.2009

Note

This will release the pressure in the hydraulic unit.

– Close front left and rear left bleeder screws.

– Do not remove brake pedal actuator -V.A.G 1869/2- .

– Lower vehicle.

– Remove engine cover panel.

– Remove diesel particulate filter ⇒ Rep. Gr. 26 .

7. Vehicles with diesel particulate filter: Control unit -J104- with hydraulic unit -N55- 35

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Release connector at control unit -arrow 1- and unplug

-arrow 2-.

Note

♦

Make sure brake fluid does not get into connector housing of control unit. This can result in corrosion of the contacts and failure of the system.

♦

Use compressed air to carefully clean connector housing if necessary.

– As protection against escaping brake fluid, place a sufficient

number of lint-free cloths in area beneath control unit and hy‐ draulic unit.

– Mark brake lines.

– Unscrew brake lines from hydraulic unit -1- to brake master

cylinder and tie in place.

– Disconnect remaining brake lines -2- on hydraulic unit.

WARNING

Do not bend or kink the brake lines in the vicinity of the hy‐ draulic unit.

– Seal brake lines and tapped holes with sealing plugs from re‐

pair kit.

36 Rep. Gr.45 - Anti-lock brake system

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– Carefully pull hydraulic unit -2- together with control unit and

bracket -4- out of rubber buffers -6-.

– Take hydraulic unit out of vehicle.

– Unscrew bolts -5- from bracket -4- and detach bracket.

– Place hydraulic unit on a clean flat surface with control unit

facing downwards.

WARNING

Severe shocks or jolts can damage the control unit. The control unit must not be re-installed if it has been damaged in any way.

Seal threaded holes and brake lines using sealing plugs 1H0.698.311.A after removing control unit and hydraulic unit.

WARNING

Hydraulic pump must not be separated from hydraulic unit.

Audi TT 2007 ➤

Brake system - Edition 04.2009

Installing

Installation is performed in reverse sequence; note the following:

Note

♦

The hydraulic unit supplied as a replacement is filled with brake fluid.

♦

If sealing plugs are removed before fitting corresponding brake line, brake fluid will escape. Proper bleeding is then no longer ensured.

7. Vehicles with diesel particulate filter: Control unit -J104- with hydraulic unit -N55- 37

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 ➤ Brake system - Edition 04.2009

– Secure mounting bracket -4- with bolts -5-. Tightening torque:

8 Nm.

– Carefully insert hydraulic unit -2- together with control unit and

bracket -4- in rubber buffers on mounting bracket -6-.

Make sure that rubber buffers are not pressed through mounting bracket when inserting unit.

– Connect brake lines as previously marked.

WARNING

Interchanging brake lines will result in ESP system malfunc‐ tion.

– Connect brake lines to hydraulic unit.

– Attach connector to control unit and lock connector.

– Install diesel particulate filter ⇒ Rep. Gr. 26 .

– Install engine cover panel.

– Bleed brake system ⇒ page 109 .

– Perform final control diagnosis after securing brake lines to

hydraulic unit.

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

Note

Final control diagnosis can be used to establish whether line con‐ nections have been interchanged.

If a new ABS control unit -J104- has been fitted, it must be enco‐ ded.

To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

– Select on the display:

♦ Running gear

♦ Brake system (Repair group 01; 45)

♦ 01 - Self-diagnosis compatible systems

♦ 03 - Brake electronics ABS/ESP Mark 60

– Select required function on the display.

♦ J104 - Control unit for ABS/TCS/ESP Mark 60

♦ J104 - Control unit for ABS/TCS/ESP, Functions

♦ J104 - Encoding control unit

Also calibrate the following senders after renewing control unit J104-.

♦ Steering angle sender -G85-

♦ Lateral acceleration sender -G200-

♦ Brake pressure sender 1 -G201-

♦ Longitudinal acceleration sender -G251- (only on four-wheel

drive vehicles)

38 Rep. Gr.45 - Anti-lock brake system

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To do this, use vehicle diagnosis, testing and information system

-VAS 505x- .

– Select on the display:

♦ Running gear

♦ Brake system

♦ 01 - Self-diagnosis compatible systems

♦ 03 - Brake electronics ABS/ESP Mark 60

– Select required function on the display.

♦ J104 - Control unit for ABS/TCS/ESP Mark 60

♦ J104 - Control unit for ABS/TCS/ESP, Functions

– Then carry out ESP road test and system test.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

Audi TT 2007 ➤

Brake system - Edition 04.2009

7.2 Basic setting of inlet valves and sepa‐ rating valves (Mark 60EC)

The basic setting of the inlet valves should only be performed if the ABS control unit -J104- has been renewed.

To do so, use the vehicle diagnosis, testing and information sys‐ tem -VAS 505x- or -VAS 5052- .

Note

If the basic setting of the inlet valves has to be performed, you must then perform the basic setting of the separating valves.

♦ Running gear

♦ Brake system

♦ 01 - Self-diagnosis compatible systems

♦ 03 ABS control unit J104 MK60EC

♦ 03 Functions ABS MK60EC J104

♦ Basic setting of inlet valves

♦ Basic setting of separating valves

Please follow the instructions on the display exactly.

7. Vehicles with diesel particulate filter: Control unit -J104- with hydraulic unit -N55- 39

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Audi TT 2007 ➤ Brake system - Edition 04.2009

8 ABS/ESP system components on

front axle

8.1 Exploded view

Note

The ABS sensor ring / rotor is incorporated in the corresponding wheel bearing unit ⇒ Rep. Gr. 42 and cannot be renewed.

1 - Speed sensor

❑ Removing and installing

⇒ page 40

2 - Hexagon socket head bolt

❑ 8 Nm

8.2 Removing and installing speed sensor

Removing

– Release connector -1- at speed sensor and unplug.

– Remove bolt -2-.

– Pull speed sensor -1- out of wheel bearing housing.

40 Rep. Gr.45 - Anti-lock brake system

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Installing

Installation is performed in reverse sequence; note the following:

– Before inserting speed sensor, clean inner surface of hole and

coat speed sensor thoroughly with lubricating paste G 000 650.

– Turn steering completely to left and right and check clearance

of speed sensor wire.

Audi TT 2007 ➤

Brake system - Edition 04.2009

8. ABS/ESP system components on front axle 41

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Audi TT 2007 ➤ Brake system - Edition 04.2009

9 ABS/ESP system components on

rear axle (front-wheel drive vehicles)

9.1 Exploded view

Note

The ABS sensor ring / rotor is incorporated in the corresponding wheel bearing unit ⇒ Rep. Gr. 42 and cannot be renewed.

1 - Hexagon socket head bolt

❑ 8 Nm

2 - Speed sensor

❑ Removing and installing

⇒ page 42

9.2 Removing and installing rear speed sen‐ sor

Removing

– Release connector -2- at speed sensor and unplug.

– Remove bolt -1-.

– Pull speed sensor -2- out of wheel bearing housing.

42 Rep. Gr.45 - Anti-lock brake system

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Installing

Installation is performed in reverse sequence; note the following:

– Before inserting speed sensor, clean inner surface of fitting

hole and coat speed sensor thoroughly with grease -G 000 650- .

Audi TT 2007 ➤

Brake system - Edition 04.2009

9. ABS/ESP system components on rear axle (front-wheel drive vehicles) 43

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Audi TT 2007 ➤ Brake system - Edition 04.2009

10 ABS/ESP system components on

rear axle (four-wheel drive vehicles)

10.1 Exploded view

Note

The ABS sensor ring / rotor is incorporated in the corresponding wheel bearing unit ⇒ Rep. Gr. 42 and cannot be renewed.

1 - Speed sensor

❑ Removing and installing

⇒ page 44

2 - Hexagon socket head bolt

❑ 8 Nm

10.2 Removing and installing rear speed sen‐ sor

Removing

– Release connector -1- at speed sensor and unplug.

– Remove bolt -2-.

– Pull speed sensor -1- out of wheel bearing housing.

44 Rep. Gr.45 - Anti-lock brake system

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Installing

Installation is performed in reverse sequence; note the following:

– Before inserting speed sensor, clean inner surface of hole and

coat speed sensor thoroughly with lubricating paste G 000 650.

Audi TT 2007 ➤

Brake system - Edition 04.2009

10. ABS/ESP system components on rear axle (four-wheel drive vehicles) 45

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Audi TT 2007 ➤ Brake system - Edition 04.2009

46 – Brakes - mechanism

1 Servicing front brakes

Observe general notes before servicing.

Note

♦

Use the brake filling and bleeding equipment -VAS 5234- to extract brake fluid from brake fluid reservoir.

♦

Before removing brake caliper or disconnecting brake hose from brake caliper, insert brake pedal actuator -V.A.G 1869/2to prevent brake fluid reservoir from emptying completely.

♦

To draw off brake fluid from brake fluid reservoir use a bleeder bottle which is used only for brake fluid.

♦

Make sure that no brake fluid escapes, otherwise components and paintwork will be damaged.

♦

Always install all parts supplied in repair kit.

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth.

1.1 Servicing front brakes 16" FN3

♦ Install all parts supplied in repair kit.

♦ After replacing brake pads, depress brake pedal firmly several

times with vehicle stationary so that the pads are properly seated in their normal operating position.

Observe general notes ⇒ page 46 .

46 Rep. Gr.46 - Brakes - mechanism

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Audi TT 2007 ➤

Brake system - Edition 04.2009

1 - Wheel bearing unit with in‐ tegrated ABS sensor wheel

❑ Removing and installing

⇒ Rep. Gr. 40

2 - Speed sensor

❑ Removing and installing

⇒ page 40

3 - Hexagon socket head bolt

❑ 8 Nm

4 - Splash plate

5 - Bolt

❑ 10 Nm

6 - Brake disc

❑ Allocation, dimensions

and wear limit ⇒ page 1

❑ To remove, unbolt brake

caliper housing

❑ Do not force brake discs

off wheel hub; if neces‐ sary, use rust remover, otherwise brake discs could be damaged.

❑ Always renew on both

sides of axle

7 - Bolt

❑ Do not loosen unless re‐

moving brake disc

❑ 4 Nm

8 - Brake carrier

❑ Bolt to wheel bearing

housing

❑ 200 Nm ❑ Renew protective caps if they have been damaged (repair kit); use grease sachet supplied to lubricate

the guide pins

9 - Brake pads

❑ With wear indicator (on inner brake pad on left-side only) ❑ Pad thickness, wear limit ⇒ page 1 ❑ Always renew on both sides of axle

Before fitting pads, clean guide surfaces and apply a thin coating of grease ⇒ ETKA .

❑ Removing and installing ⇒ page 49 ❑ Checking pad thickness: ⇒ Maintenance ; Booklet 808

Note

Clean the brake caliper thoroughly (grease-free) before inserting new brake pads. It is particularly impor‐ tant to ensure that contact surfaces for brake pads are clean.

10 - Retaining spring

❑ Insert in both holes in brake caliper housing

1. Servicing front brakes 47

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Audi TT 2007 ➤ Brake system - Edition 04.2009

11 - Brake caliper housing

❑ Piston diameter ⇒ page 1 ; versions available ⇒ ETKA ❑ Unscrew from brake carrier to replace brake pads ❑ Removing and installing ⇒ page 52 ❑ Servicing ⇒ page 96

Brake line connection to brake caliper, 19 Nm

Brake line connection to brake hose, 12 Nm

Counterhold at hexagon flats on brake hose when connecting brake line to brake hose.

❑ Brake caliper with vibration damper ⇒ page 74

12 - Bracket

13 - Bolt

❑ Bracket to brake caliper

14 - Protective cap

15 - Guide pin

❑ Brake caliper to brake carrier ❑ 30 Nm

16 - Bearing bush

17 - Protective cap

18 - Bolt

❑ Brake carrier to wheel bearing housing ❑ Always renew if removed ❑ 200 Nm

Brake hose connection with locating pin

Tightening torque for brake hose to brake caliper for 16" FN-3 brakes: 35 Nm

– Make sure groove in banjo union of brake hose is inserted on

locating pin -arrow-.

48 Rep. Gr.46 - Brakes - mechanism

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Audi TT 2007 ➤

Brake system - Edition 04.2009

1.2 Removing and installing brake pads - front brakes 16" FN3

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1410-

♦ Torque wrench -V.A.G 1332-

♦ Brake pedal actuator -V.A.G 1869/2-

♦ Piston resetting appliance -T10145-

Removing

– Raise vehicle.

– Remove wheels.

Note

Mark brake pads when removing them if they are to be reinstalled. Reinstall in their original position to prevent uneven braking.

1. Servicing front brakes 49

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Unplug connector -1- of brake pad wear indicator at left brake.

– Do not loosen bolt -2-.

– Lever off brake pad retaining spring from brake caliper housing

with a screwdriver -arrow- and remove.

– Remove brake caliper. ⇒ page 52

– Remove brake caliper and secure such that the weight of the

caliper does not damage the brake line.

Note

Brake hose/line must not be twisted or kinked.

– Take brake pads out of brake caliper housing or from brake

carrier.

– Clean brake caliper housing; in particular the bonding surface

for the brake pad must be free of any traces of adhesive and grease.

Only use methylated spirits to clean the brake caliper housing.

Installing

Before fitting pads, clean guides and apply a thin coating of grease ⇒ ETKA .

Press back brake pistons using piston resetting appliance T10145- when fitting new brake pads ⇒ page 73 .

Make sure that no brake fluid escapes from brake fluid reservoir; otherwise components and paintwork will be damaged.

To draw off brake fluid from brake fluid reservoir use a bleeder bottle which is used only for brake fluid.

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth. On account of its corrosive effect it must also not be allowed to come into contact with paintwork.

Perform further installation in reverse order; note the following:

– Insert brake pads in brake carrier, paying attention to fitting

location:

50 Rep. Gr.46 - Brakes - mechanism

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When properly installed, arrow on backplate of brake pad must face downwards.

1 - Right-side brake pad (facing piston)

2 - Left-side brake pad (facing piston)

Note

The wear indicator is located on inner brake pad on front left brake caliper.

– Pull protective foil off outer brake pad backplate.

– Fit brake caliper onto brake carrier and brake disc.

– Secure brake caliper with both guide pins to brake carrier

⇒ page 52 . Note tightening torque ⇒ Item 15 (page 48) .

Audi TT 2007 ➤

Brake system - Edition 04.2009

1. Servicing front brakes 51

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Insert retaining spring -arrow- in brake caliper housing.

Note

Make sure not to twist or stretch brake hose when installing.

– Fit both protective caps onto guide pins.

– Insert retaining spring into brake caliper housing.

– Press in spring clip.

– Plug in connector for wear indicator.

– Press connector for wear indicator into bracket and insert wire.

– Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

WARNING

♦ The retaining spring must be pressed under the brake

carrier after inserting into both holes. If incorrectly instal‐ led, the wear of the outer pad cannot be adjusted, and the pedal travel will be increased as a result.

♦ After installing the brake pads and bleeding brake system,

depress pedal firmly several times with the vehicle sta‐ tionary, so that the brake pads are properly seated in their normal operating position.

– Check brake fluid level and top up if necessary.

–

WARNING

After installing the brake pads, depress pedal firmly several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

1.3 Removing and installing brake caliper front brakes 16" FN3

Special tools and workshop equipment required

52 Rep. Gr.46 - Brakes - mechanism

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♦ Brake pedal actuator -V.A.G 1869/2-

Removing

– Insert brake pedal actuator -V.A.G 1869/2- between brake

pedal and driver's seat (depress brake pedal at least 60 mm).

Note

This closes the valves in the brake master cylinder and stops the brake fluid reservoir from running empty.

Audi TT 2007 ➤

Brake system - Edition 04.2009

– Connect hose of bleeder bottle to bleeder screw of removed

brake caliper.

– Open bleeder screw.

– Do not remove brake pedal actuator -V.A.G 1869/2- .

– Close bleeder screws.

– Disconnect brake hose from brake caliper.

– Remove protective caps from guide pins -arrows-.

1. Servicing front brakes 53

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Remove guide pins -arrows-.

– Pull both guide pins out of brake caliper and bearing bushes.

– Remove brake pads ⇒ page 49 .

Installing

Installation is performed in reverse sequence; note the following:

– Remove brake pedal actuator -V.A.G 1869/2- .

Press back brake pistons using piston resetting appliance T10145- when fitting new brake pads ⇒ page 73 .

Make sure that no brake fluid escapes from brake fluid reservoir; otherwise components and paintwork will be damaged.

To draw off brake fluid from brake fluid reservoir use a bleeder bottle which is used only for brake fluid.

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth. On account of its corrosive effect it must also not be allowed to come into contact with paintwork.

– Install brake pads ⇒ page 49 .

– Secure brake caliper with both guide pins to brake carrier

⇒ page 52 . Note tightening torque ⇒ Item 15 (page 48) .

– Secure brake hose to brake caliper.

Brake hose connection with locating pin

Tightening torque for brake hose to brake caliper for 16" FN-3 brakes: 35 Nm

– Make sure groove in banjo union of brake hose is inserted on

locating pin -arrow-.

– Bleed brake system ABS/ESP Mark 60 ⇒ page 109 .

– Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

WARNING

After installing the brake pads, depress pedal firmly several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

54 Rep. Gr.46 - Brakes - mechanism

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2 Servicing front brakes 17" FNR G57

♦ Install all parts supplied in repair kit.

♦ After replacing brake pads, depress brake pedal firmly several

times with vehicle stationary so that the pads are properly seated in their normal operating position.

Observe general notes ⇒ page 46 .

1 - Brake disc

❑ Always renew on both

sides of axle

❑ Detach brake caliper

prior to removing

❑ Lubricate contact surfa‐

ces between brake disc and wheel hub with pol‐ ycarbamide grease -G 052 142 A2- . ⇒ Rep. Gr. 44

❑ Allocation, dimensions

and wear limit ⇒ page 1

❑ Checking thickness

⇒ Maintenance ; Book‐ let 808

2 - Retaining spring

❑ Ensure correct installa‐

tion position

3 - Brake caliper housing

❑ Piston diameter

⇒ page 1 ⇒ ETKA

❑ Unscrew from brake

carrier to replace brake pads

❑ Removing and installing

⇒ page 60

❑ Servicing brake caliper

⇒ page 100

❑ Brake caliper with vibra‐

tion damper

⇒ page 74

4 - Bearing bush

❑ Insert into brake caliper

housing

5 - Guide pin

❑ 30 Nm

6 - Protective cap

Audi TT 2007 ➤

Brake system - Edition 04.2009

7 - Cable retainer for wear indicator

8 - Bolt

❑ Cable retainer to brake caliper ❑ 25 Nm

9 - Protective cap

10 - Bolt

❑ Bracket for brake line to brake caliper

2. Servicing front brakes 17" FNR G57 55

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Audi TT 2007 ➤ Brake system - Edition 04.2009

❑ 15 Nm

11 - Bracket for brake line

❑ Bolt to brake caliper housing ❑ Attach brake line

12 - Brake line

❑ Screw into brake caliper housing with ⇒ Item 11 (page 56) ❑ Do not twist hose when fitting

♦ Brake line connection to brake caliper, 14 Nm

♦ Brake line connection to brake hose, 14 Nm

♦ Counterhold at hexagon flats on brake hose when connecting brake line to brake hose.

13 - Spring clip

❑ Secures brake line in bracket ⇒ Item 11 (page 56)

14 - Brake pads

❑ With wear indicator (on inner brake pad on left-side only) ❑ Pad thickness, wear limit ⇒ page 1 ❑ Removing and installing ⇒ page 57

Before fitting pads, clean guide surfaces and apply a thin coating of grease ⇒ ETKA .

❑ Always renew on both sides of axle ❑ Checking pad thickness: ⇒ Maintenance ; Booklet 808

Note

Clean the brake caliper thoroughly (grease-free) before inserting new brake pads. It is particularly impor‐ tant to ensure that contact surfaces for brake pads are clean.

15 - Brake carrier

❑ Bolt to wheel bearing housing ❑ 200 Nm

16 - Bolt

❑ Brake carrier to wheel bearing housing ❑ Always renew if removed ❑ 200 Nm

56 Rep. Gr.46 - Brakes - mechanism

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Audi TT 2007 ➤

Brake system - Edition 04.2009

2.1 Removing and installing brake pads - front brakes 17" FNR G57

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1410-

♦ Torque wrench -V.A.G 1332-

♦ Brake pedal actuator -V.A.G 1869/2-

♦ Piston resetting appliance -T10145-

Removing

Note

♦

Mark brake pads when removing them if they are to be rein‐ stalled. Reinstall in their original position to prevent uneven braking.

♦

When installing brake discs, note direction of travel -indicated by arrow on brake disc- and fitting location -left or right-.

– Raise vehicle.

2. Servicing front brakes 17" FNR G57 57

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Remove wheels.

– Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

– Lever brake pad retaining spring out of brake caliper housing

with a screwdriver and remove.

Loosen bolt -1- only when removing brake disc (4 Nm).

– Unplug connector for brake pad wear indicator -1-.

– Do not loosen bolt -2-.

– Unplug connector for brake pad wear indicator from bracket

and detach wire.

58 Rep. Gr.46 - Brakes - mechanism

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– Take spring clip -arrow- out of bracket for brake line.

– Detach brake line from bracket.

– Remove bolt and detach bracket for brake line.

– Remove brake caliper ⇒ page 60 .

– Remove brake caliper and secure such that the weight of the

caliper does not damage the brake line.

Note

Brake hose/line must not be twisted or kinked.

– Take brake pads out of brake caliper housing or from brake

carrier.

– Clean brake caliper housing; in particular the bonding surface

for the brake pad must be free of any traces of adhesive and grease.

Only use methylated spirits to clean the brake caliper housing.

Installing

Before fitting pads, clean guide surfaces and apply a thin coating of grease ⇒ ETKA .

Press back brake pistons using piston resetting appliance T10145- when fitting new brake pads ⇒ page 73 .

Make sure that no brake fluid escapes from brake fluid reservoir; otherwise components and paintwork will be damaged.

To draw off brake fluid from brake fluid reservoir use a bleeder bottle which is used only for brake fluid.

Audi TT 2007 ➤

Brake system - Edition 04.2009

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth. On account of its corrosive effect it must also not be allowed to come into contact with paintwork.

Perform further installation in reverse order; note the following:

Note

The wear indicator is located on inner brake pad on front left brake caliper.

– Insert brake pad with retaining spring and wear indicator into

brake caliper housing (piston).

2. Servicing front brakes 17" FNR G57 59

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Fit outer brake pad -2- in brake caliper.

– The wear indicator wire is fitted to the inner pad -1- at front left

wheel.

– Fit brake caliper together with inserted brake pads onto brake

carrier and brake disc.

– Secure brake caliper housing with both guide pins to brake

carrier. ⇒ page 60 Note specified tightening torque.

⇒ Item 5 (page 55)

Note

Make sure not to twist or stretch brake hose when installing.

– Fit both protective caps.

– Secure bracket for brake line.

– Insert retaining spring into brake caliper housing.

– Attach brake line to bracket.

– Press in spring clip.

– Plug in connector for wear indicator.

– Press connector for wear indicator into bracket and insert wire.

– Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

Note

The retaining spring must be pushed under the brake carrier after engaging onto both studs. If incorrectly installed, the wear of the outer pad cannot be adjusted, and the pedal travel will be in‐ creased as a result.

Note

Check that the brake caliper moves freely by moving it from side to side.

– Check brake fluid level and top up if necessary.

WARNING

After installing the brake pads, depress pedal firmly several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

2.2 Removing and installing brake caliper front brakes 17" FNR G57

Special tools and workshop equipment required

60 Rep. Gr.46 - Brakes - mechanism

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♦ Brake pedal actuator -V.A.G 1869/2-

Removing

– Insert brake pedal actuator -V.A.G 1869/2- between brake

pedal and driver's seat (depress brake pedal at least 60 mm).

Note

This closes the valves in the brake master cylinder and stops the brake fluid reservoir from running empty.

Audi TT 2007 ➤

Brake system - Edition 04.2009

– Connect hose of bleeder bottle to bleeder screw of removed

brake caliper.

– Open bleeder screw.

– Do not remove brake pedal actuator -V.A.G 1869/2- .

– Close bleeder screws.

– Disconnect brake hose from brake caliper.

– Remove protective caps from guide pins -arrows-.

2. Servicing front brakes 17" FNR G57 61

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Remove guide pins -arrows-.

– Pull both guide pins out of brake caliper and bearing bushes.

– Remove brake pads ⇒ page 57 .

Installing

Installation is performed in reverse sequence; note the following:

– Remove brake pedal actuator -V.A.G 1869/2- .

Press back brake pistons using piston resetting appliance T10145- when fitting new brake pads ⇒ page 73 .

Make sure that no brake fluid escapes from brake fluid reservoir; otherwise components and paintwork will be damaged.

To draw off brake fluid from brake fluid reservoir use a bleeder bottle which is used only for brake fluid.

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth. On account of its corrosive effect it must also not be allowed to come into contact with paintwork.

– Install brake pads ⇒ page 57 .

– Push both guide pins through bearing bushes into brake cali‐

per.

– Secure brake caliper housing with both guide pins to brake

carrier. Note specified tightening torque ⇒ Item 5 (page 55) .

– Secure brake hose to brake caliper.

Tightening torque for brake hose to brake caliper for 17" FNRG57 brakes: 14 Nm

– Bleed brake system ABS/ESP Mark 60 ⇒ page 109 .

Note

♦

Check that the brake caliper moves freely by moving it from side to side.

♦

Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

– Lower vehicle.

WARNING

After installing the brake pads, depress pedal firmly several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

62 Rep. Gr.46 - Brakes - mechanism

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3 Servicing front brakes (TT RS)

♦ Install all parts supplied in repair kit.

♦ After replacing brake pads, depress brake pedal firmly several

times with vehicle stationary so that the pads are properly seated in their normal operating position.

1 - Bleeder screw

❑ 10 Nm

Note

2 - Bolt

❑ Unscrew for removal of

brake caliper

❑ 200 Nm

Note

Audi TT 2007 ➤

Brake system - Edition 04.2009

3 - Speed sensor

4 - Bolt

❑ For speed sensor ❑ 8 Nm

5 - Brake caliper

Note

❑ Removing and installing

⇒ page 67

❑ Renewing ⇒ page 69

6 - Brake disc

❑ Wear limit ⇒ page 1

Note

❑ Removing and installing

⇒ page 71

7 - Bolt

❑ For securing brake disc ❑ 4 Nm

Note

8 - Brake pads

❑ With brake pad wear cable (only in left brake caliper) ❑ Wear limit ⇒ page 1 ❑ Removing and installing ⇒ page 64

Before fitting pads, clean guides and apply a thin coating of grease ⇒ ETKA .

Before fitting pads, peel off adhesive foil

9 - Brake pad wear cable

❑ Only installed in left brake caliper

3. Servicing front brakes (TT RS) 63

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Audi TT 2007 ➤ Brake system - Edition 04.2009

10 - Retaining clip

❑ Ensure correct installation position

Note

11 - Brake pad retaining pins

Note

12 - Bolt

❑ For bracket ❑ 18 Nm

13 - Brake hose

❑ Screw into brake caliper ❑ Insert in bracket ❑ 35 Nm

Tightening torque for brake hose to brake caliper for TT RS: 35 Nm

Note

14 - Bracket

❑ For brake hose and brake pad wear cable

3.1 Removing and installing brake pads front brakes (TT RS)

Special tools and workshop equipment required

♦ Piston resetting appliance -T10145-

Mark brake pads when removing them if they are to be reinstalled. Reinstall in their original position to prevent uneven braking.

Removing

– Raise vehicle.

– Remove wheels.

Note

The brake pad wear cable is only installed at the left brake caliper.

64 Rep. Gr.46 - Brakes - mechanism

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– Unclip brake pad wear cable -9- from bracket.

Note

Do not loosen bolts -2-.

– Unplug electrical connector from brake pad wear cable.

– Press brake pistons at brake pads slightly back into brake cal‐

iper using a suitable tool.

Note

Take care not to scratch or damage brake caliper.

Audi TT 2007 ➤

Brake system - Edition 04.2009

3. Servicing front brakes (TT RS) 65

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Pull brake pad wear cable -9- out of retaining clip -10-.

– Pull one brake pad retaining pin -11- out of brake caliper. While

doing so, press down retaining clip -10-.

– Pull second brake pad retaining pin -11- out of brake caliper.

– Take brake pads out of brake caliper.

Only use methylated spirits to clean the brake caliper housing.

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth. On account of its corrosive effect it must also not be allowed to come into contact with paintwork.

Installing

If provided, peel adhesive foil off back of brake pads.

Before fitting pads, clean guides and apply a thin coating of grease ⇒ ETKA .

Press back brake pistons using piston resetting appliance T10145- when fitting new brake pads ⇒ page 73 .

Make sure that no brake fluid escapes from brake fluid reservoir; otherwise components and paintwork will be damaged.

To draw off brake fluid from brake fluid reservoir use a bleeder bottle which is used only for brake fluid.

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth. On account of its corrosive effect it must also not be allowed to come into contact with paintwork.

Perform further installation in reverse order; note the following:

– Insert brake pads into brake caliper.

Note

♦

Make sure that brake pads are seated correctly.

♦

The brake pads with the brake pad wear cable are only fitted in the left brake caliper.

♦

The brake pad wear cable is fitted in the left brake caliper in both brake pads.

66 Rep. Gr.46 - Brakes - mechanism

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– Slide one brake pad retaining pin -11- through brake caliper

and brake pads from inside to outside.

– Insert retaining spring -10- underneath retaining pin -11-.

– Slide second retaining pin through brake caliper and brake

pads from inside to outside. While doing so, press down re‐ taining spring -10-.

WARNING

Both brake pad retaining pins must be pressed through the brake caliper and the brake pads as far as the stop so that the spring is seated at the retaining pin in the brake caliper.

– Insert brake pad wear cable -9- in retaining spring -10-.

– Connect brake pad wear cable.

– Insert brake pad wear cable in bracket.

Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

– Lower vehicle.

– Check brake fluid level and top up if necessary.

Audi TT 2007 ➤

Brake system - Edition 04.2009

WARNING

After installing the brake pads, depress pedal firmly several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

3.2 Removing and installing brake caliper front brakes (TT RS)

Removing

– Raise vehicle.

– Remove wheels.

Note

The brake pad wear cable is only installed at the left brake caliper.

3. Servicing front brakes (TT RS) 67

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Unclip brake pad wear cable -9- from bracket.

– Unplug electrical connector from brake pad wear cable.

– Unclip brake hose -13- from bracket.

– Press brake pistons at brake pads slightly back into brake cal‐

iper using a suitable tool.

Note

Take care not to scratch or damage brake caliper.

– Remove bolts -2-.

– Detach brake caliper.

Note

Do not suspend the brake caliper from the brake hose. Secure it to the body with a suitable wire.

Installing

Note

Renew bolts -2-.

– Carefully slide brake caliper (with brake pads fitted) over brake

disc and install.

68 Rep. Gr.46 - Brakes - mechanism

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– Secure brake caliper with new bolts -2-. 200 Nm

– Fit brake hose -13- in bracket.

– Connect brake pad wear cable -9-.

– Insert brake pad wear cable in bracket.

Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

– Lower vehicle.

– Check brake fluid level and top up if necessary.

WARNING

Firmly depress the brake pedal several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

Audi TT 2007 ➤

Brake system - Edition 04.2009

3.3 Renewing brake caliper - front brakes (TT RS)

Note

Mark brake pads when removing them if they are to be reinstalled. Reinstall in their original position to prevent uneven braking.

Removing

– Raise vehicle.

– Remove wheels.

Note

The brake pad wear cable is only installed at the left brake caliper.

3. Servicing front brakes (TT RS) 69

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Insert brake pedal actuator -V.A.G 1869/2- between brake

pedal and driver's seat (depress brake pedal at least 60 mm).

Note

This closes the valves in the brake master cylinder and stops the brake fluid reservoir from running empty.

– Connect hose of bleeder bottle to bleeder screw of removed

brake caliper.

– Open bleeder screw.

– Do not remove brake pedal actuator -V.A.G 1869/2- .

– Close bleeder screws.

– Disconnect brake hose from brake caliper.

– Remove brake pads ⇒ page 64 .

– Disconnect brake hose -13- from brake caliper.

– Remove bolts -2-. Hold brake caliper in position while doing

so.

– Detach brake caliper.

Installing

Note

Renew bolts -2-.

– Remove brake pedal actuator -V.A.G 1869/2- .

– Install brake caliper.

– Secure brake caliper with new bolts -2-. 200 Nm

Press back brake pistons using piston resetting appliance T10145- when fitting new brake pads ⇒ page 73 .

Make sure that no brake fluid escapes from brake fluid reservoir; otherwise components and paintwork will be damaged.

To draw off brake fluid from brake fluid reservoir use a bleeder bottle which is used only for brake fluid.

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth. On account of its corrosive effect it must also not be allowed to come into contact with paintwork.

– Install brake pads ⇒ page 64 .

70 Rep. Gr.46 - Brakes - mechanism

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– Attach brake hose -13- to caliper and tighten connection.

Tightening torque for brake hose to brake caliper for TT RS: 35 Nm

– Bleed brake system at all bleeder screws.

Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

– Lower vehicle.

– Check brake fluid level and top up if necessary.

WARNING

After installing the brake pads, depress pedal firmly several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

Audi TT 2007 ➤

Brake system - Edition 04.2009

3.4 Removing and installing brake disc front brakes (TT RS)

Note

Mark brake pads when removing them if they are to be reinstalled. Reinstall in their original position to prevent uneven braking.

Removing

– Raise vehicle.

– Remove wheels.

Note

The brake pad wear cable is only installed at the left brake caliper.

– Remove brake caliper ⇒ page 67 .

Note

Do not suspend the brake caliper from the brake hose. Secure it to the body with a suitable wire.

3. Servicing front brakes (TT RS) 71

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Remove bolt -7-.

– Pull brake disc off wheel hub.

Note

Keep brake disc straight while detaching it.

Installing

Note

Always renew bolt -7-.

– Clean contact surfaces on wheel hub and brake disc.

– Fit brake disc onto wheel hub.

Note

Keep brake disc straight while installing it.

– Secure brake disc with new bolt -7- (4 Nm).

– Install brake caliper ⇒ page 67 .

Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

– Lower vehicle.

– Check brake fluid level and top up if necessary.

WARNING

Firmly depress the brake pedal several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

72 Rep. Gr.46 - Brakes - mechanism

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4 Pressing back brake piston in front

brake caliper

Special tools and workshop equipment required

♦ Piston resetting appliance -T10145-

Note

Before inserting new brake pads, press brake piston back into cylinder with resetting appliance. Before pressing the piston back, draw off brake fluid from the reservoir with a bleeder bottle, oth‐ erwise components can be damaged by escaping brake fluid.

Press back brake pistons using piston resetting appliance T10145- ⇒ page 73 .

Make sure that no brake fluid escapes from brake fluid reservoir; otherwise components and paintwork will be damaged.

To draw off brake fluid from brake fluid reservoir use a bleeder bottle which is used only for brake fluid.

Audi TT 2007 ➤

Brake system - Edition 04.2009

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth. On account of its corrosive effect it must also not be allowed to come into contact with paintwork.

Pressing piston back

4. Pressing back brake piston in front brake caliper 73

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Audi TT 2007 ➤ Brake system - Edition 04.2009

5 Vibration damper on brake caliper -

front brakes

The vibration damper is not fitted with all models. This has no influence on removal, installation and servicing of the brake cali‐ per.

1 - Dust cap

2 - Bolt

❑ Always renew ❑ 10 Nm

3 - Vibration damper

❑ Removing and installing

⇒ page 74

4 - Washer

5 - Brake caliper

5.1 Removing and installing vibration damp‐ er

Removing

– Raise vehicle.

– Remove front wheels.

– Remove dust cap.

74 Rep. Gr.46 - Brakes - mechanism

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– Remove bolt -2-.

– Detach vibration damper -3- and washer -4- from brake cali‐

per.

Installing

– Clean brake caliper in area of vibration damper.

– Insert washer -4- and vibration damper -3- in brake caliper.

– Insert new bolt -2- and tighten to 10 Nm.

– Insert and press home the dust cap -1-.

– Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

Audi TT 2007 ➤

Brake system - Edition 04.2009

5. Vibration damper on brake caliper - front brakes 75

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Audi TT 2007 ➤ Brake system - Edition 04.2009

6 Servicing rear brakes

Note

♦

Use the brake filling and bleeding equipment -VAS 5234- or the upgrade kit and extraction unit -V.A.G 1869/4- to extract brake fluid from brake fluid reservoir.

♦

Before removing brake caliper or disconnecting brake hose from brake caliper, insert brake pedal actuator -V.A.G 1869/2to prevent brake fluid reservoir from emptying completely.

WARNING

After installing the brake pads, depress pedal firmly several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

6.1 Rear brakes

General notes ⇒ page 76

1 - Brake disc

❑ Allocation, dimensions

and wear limit (frontwheel drive) ⇒ page 2

❑ Allocation, dimensions

and wear limit (fourwheel drive) ⇒ page 2

❑ Allocation, dimensions

and wear limit (TT RS)

⇒ page 2

❑ Do not force brake discs

off wheel hub; if neces‐ sary, use rust remover, otherwise brake discs could be damaged.

❑ Remove brake caliper

prior to removing

❑ Always renew on both

sides of axle

2 - Brake caliper

❑ Do not disconnect brake

hose when changing brake pads

❑ Piston diameter (front-

wheel drive) ⇒ page 2

❑ Piston diameter (four-

wheel drive) ⇒ page 2

❑ Piston diameter (TT RS)

⇒ page 2

❑ Removing and installing

⇒ page 80

❑ Servicing ⇒ page 105 ❑ The handbrake must be

adjusted following re‐

76 Rep. Gr.46 - Brakes - mechanism

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Brake system - Edition 04.2009

pair or replacement

⇒ page 89 .

3 - Brake line

❑ Do not disconnect brake hose and brake line when changing brake pads ❑ Tightening torque for brake line (all models): 14 Nm

4 - Brake hose

❑ Do not disconnect brake hose when changing brake pads ❑ Tightening torque for brake hose (all models): 14 Nm

5 - Protective cap

6 - Bolt

❑ Remove when changing brake pads ❑ Always renew if removed ❑ Brake caliper to brake carrier ❑ Self-locking ❑ When loosening and tightening, counter-hold on guide pin ❑ 35 Nm

Note

Audi TT 2007 ➤

7 - Bleeder screw

❑ 10 Nm

8 - Protective cap

9 - Return spring for handbrake

10 - Nut

❑ Secures handbrake linkage to brake caliper ❑ Do not loosen

11 - Handbrake cable

❑ Removing and installing ⇒ page 87

12 - Handbrake linkage

13 - Pad retaining spring

❑ Always renew when changing pads

14 - Speed sensor wire

15 - Brake pads

❑ Always renew on both sides of axle ❑ Wear limit (front-wheel drive) ⇒ page 2 ❑ Wear limit (four-wheel drive) ⇒ page 2 ❑ Wear limit (TT RS) ⇒ page 2 ❑ Removing and installing ⇒ page 78

Before fitting pads, clean guide surfaces and apply a thin coating of grease ⇒ ETKA .

❑ Removing and installing ❑ Checking pad thickness: ⇒ Maintenance ; Booklet 808 ❑ For correct version refer to ⇒ ETKA

Note

16 - Bolt

❑ Brake carrier to wheel bearing housing ❑ Always renew if removed

6. Servicing rear brakes 77

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Audi TT 2007 ➤ Brake system - Edition 04.2009

❑ 90 Nm + 90°

Note

17 - Brake carrier

❑ Bolt to wheel bearing housing

6.2 Removing and installing rear brake pads

Note

Mark brake pads when removing them if they are to be reinstalled. Reinstall in their original position to prevent uneven braking.

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

Removing

– Raise vehicle.

– Remove wheels.

Do not detach handbrake cable from brake caliper.

– Detach brake caliper housing (counterhold at guide pin).

– Remove brake caliper housing from brake disc.

– Secure brake caliper housing with wire such that the weight of

the caliper does not damage the brake hose.

WARNING

Do not kink or bend brake lines and brake hose.

78 Rep. Gr.46 - Brakes - mechanism

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– Remove brake pads and pad retaining springs from brake car‐

rier -arrows-.

Note

Mark brake pads when removing them if they are to be reinstalled.

Reinstall in their original position to prevent uneven braking.

– Clean brake caliper housing; in particular the bonding surface

for the brake pad must be free of any traces of adhesive and grease.

Only use methylated spirits to clean the brake caliper housing.

Installing

Before fitting pads, clean guide surfaces and apply a thin coating

of grease ⇒ ETKA .

Press back brake pistons using piston resetting appliance -

T10145- when fitting new brake pads ⇒ page 73 .

Make sure that no brake fluid escapes from brake fluid reservoir;

otherwise components and paintwork will be damaged.

To draw off brake fluid from brake fluid reservoir use a bleeder

bottle which is used only for brake fluid.

Audi TT 2007 ➤

Brake system - Edition 04.2009

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth. On account of its corrosive effect it must also not be allowed to come into contact with paintwork.

Perform further installation in reverse order; note the following:

6. Servicing rear brakes 79

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Insert brake pad retaining springs -arrows- and brake pads

into brake carrier.

– Pull protective foil off brake pad backplate.

Note

Fit brake caliper onto brake carrier and brake disc.

– Secure brake caliper housing with new self-locking bolts. Note

tightening torque ⇒ Item 6 (page 77) .

Note

The repair kit includes four self-locking hexagon bolts which must be installed in all cases.

– Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .

– Check brake fluid level and top up if necessary.

WARNING

After installing the brake pads, depress pedal firmly several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

6.3 Removing and installing rear brake cal‐ iper

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

80 Rep. Gr.46 - Brakes - mechanism

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♦ Brake pedal actuator -V.A.G 1869/2-

Removing

– Raise vehicle.

– Remove wheels.

Only detach handbrake cable when brake caliper is being re‐ moved completely ⇒ page 83 .

– Remove brake pads ⇒ page 78 .

Audi TT 2007 ➤

Brake system - Edition 04.2009

Note

Mark brake pads when removing them if they are to be reinstalled. Reinstall in their original position to prevent uneven braking.

– Detach brake caliper housing (counterhold at guide pin).

– Remove brake caliper housing from brake disc.

– Secure brake caliper housing with wire such that the weight of

the caliper does not damage the brake hose.

WARNING

Do not kink or bend brake lines and brake hose.

6. Servicing rear brakes 81

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Insert brake pedal actuator -V.A.G 1869/2- between brake

pedal and driver's seat (depress brake pedal at least 60 mm).

Note

This closes the valves in the brake master cylinder and stops the brake fluid reservoir from running empty.

– Connect hose of bleeder bottle to bleeder screw of rear brake

caliper (removed) and front brake caliper on same side of ve‐ hicle.

– Open both bleeder screws.

– Close front bleeder screw.

– Do not remove brake pedal actuator -V.A.G 1869/2- .

– Disconnect brake hose from brake caliper.

Installing

Press back brake pistons using piston resetting appliance T10145- when fitting new brake pads ⇒ page 73 .

Make sure that no brake fluid escapes from brake fluid reservoir; otherwise components and paintwork will be damaged.

To draw off brake fluid from brake fluid reservoir use a bleeder bottle which is used only for brake fluid.

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth. On account of its corrosive effect it must also not be allowed to come into contact with paintwork.

Perform further installation in reverse order; note the following:

– Install brake pads ⇒ page 78 .

– Secure brake caliper housing with new self-locking bolts. Note

tightening torque ⇒ Item 6 (page 77) .

– Secure brake hose to brake caliper.

Tightening torque for brake hose to brake caliper (all models): 14 Nm

Note

Make sure not to twist or stretch brake hose when installing.

– After fitting a serviced or new brake caliper, the handbrake

must be adjusted ⇒ page 89 . Do not press the brake pedal until after the handbrake has been adjusted.

– Bleed brake system: ABS/ESP Mark 60 ⇒ page 109 .

WARNING

After installing the brake pads, depress pedal firmly several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

82 Rep. Gr.46 - Brakes - mechanism

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WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

6.4 Detaching and attaching handbrake ca‐ ble from/to brake caliper

Removing

– Press brake lever -2- in direction of arrow and disengage

handbrake cable -3-.

– Compress retaining tabs -1- and pull out handbrake cable

through guide.

Installing

– Insert handbrake cable through guide

Audi TT 2007 ➤

Brake system - Edition 04.2009

– Compress retaining tabs -1- and engage. Make sure that both

retaining tabs are engaged.

– Press brake lever -2- in direction of arrow and attach hand‐

brake cable -3-.

6.5 Pressing back piston in rear brake cali‐ per

Special tools and workshop equipment required

♦ Piston compressing tool -T 10165-

6. Servicing rear brakes 83

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Audi TT 2007 ➤ Brake system - Edition 04.2009

Note

Before pressing the piston back, draw off brake fluid from the reservoir. To draw off fluid, use a bleeder bottle or plastic bottle kept specially for this purpose.

WARNING

Brake fluid is poisonous and must NOT be sucked through a hose with the mouth.

– Apply piston compressing tool -T 10165- on piston of brake

caliper housing.

– Screw in piston by turning knurled wheel of piston compress‐

ing tool -T 10165- clockwise, do not damage protective cap when doing so.

Note

If piston will not move easily, a 13 mm open-ended spanner can be applied at the appropriate flats -arrow-.

84 Rep. Gr.46 - Brakes - mechanism

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7 Handbrake

7.1 Handbrake - exploded view

1 - Handbrake lever

❑ Available as replace‐

ment part complete with pull rod, pawl, push rod, push-button, compres‐ sion spring and locking segment

❑ Removing and installing

⇒ page 85

❑ Switch for warning lamp

is located under hand‐ brake lever

❑ Removing and installing

handbrake lever trim

2 - Handbrake switch

❑ Removing and installing

⇒ page 86

❑ For handbrake warning

lamp in instrument clus‐ ter

3 - Hexagon nut

❑ 15 Nm

4 - Compensator

❑ With adjustment nut to

adjust handbrake cable

5 - Handbrake cable (left and right)

Audi TT 2007 ➤

Brake system - Edition 04.2009

7.2 Removing and installing handbrake lev‐ er

Removing

– Release handbrake.

– Remove centre console trim ⇒ Rep. Gr. 68 .

– Loosen adjustment nut on compensator -4- until handbrake

cables -5- can be unhooked from compensator on left and right sides.

– Remove handbrake switch -2- ⇒ page 86 .

– Remove nuts -3-.

– Remove handbrake lever from vehicle.

7. Handbrake 85

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Audi TT 2007 ➤ Brake system - Edition 04.2009

Installing

– Installation is carried out in reverse sequence.

– Install handbrake switch ⇒ page 86 .

– Pretension handbrake cable with adjustment nut on compen‐

sator -4-.

Note

The handbrake must be adjusted after installing handbrake cable

⇒ page 89 .

7.3 Removing and installing handbrake switch

1 - Locking knob

2 - Trim, one-piece

❑ Depending on type of

equipment

3 - Trim (left-side)

❑ Depending on type of

equipment

4 - Handbrake switch

❑ For handbrake warning

lamp in instrument clus‐ ter

5 - Trim (right-side)

❑ Depending on type of

equipment

6 - Protective cap

7 - Bolt

❑ 0.7 Nm

Removing

– Remove centre console trim ⇒ Rep. Gr. 68 .

– Detach locking knob -1-.

86 Rep. Gr.46 - Brakes - mechanism

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Note

Note different versions of handbrake trim.

– One-piece trim for handbrake -2-: release and pull off to front.

– Two-piece trim for handbrake: release handle and pull off to

front.

– Remove two-piece trim for handbrake lever.

– Unclip handbrake switch -4-.

– Unplug connector.

Installing

– Installation is carried out in the reverse sequence.

The handbrake does not have to be adjusted after installing the handbrake switch.

7.4 Removing and installing handbrake cable

Audi TT 2007 ➤

Brake system - Edition 04.2009

1 - Guide tube (bottom right) for handbrake cable (right-side)

2 - Clip for guide tube (bottom right)

3 - Nut for clip (bottom right)

❑ Do not loosen when re‐

moving handbrake ca‐ ble and guide tube

❑ 12 Nm

4 - Bolt (left and right)

❑ 4 Nm

5 - Bracket for handbrake ca‐ ble on axle beam (left and right)

❑ On some versions it is

necessary to detach skid plate

6 - Handbrake cable (left and right)

7 - Rubber grommet (left and right)

8 - Handbrake cable (left and right)

9 - Retainer for handbrake ca‐ ble (left and right)

10 - Clip for guide tube (bottom left)

11 - Guide tube (bottom left)

7. Handbrake 87

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Audi TT 2007 ➤ Brake system - Edition 04.2009

Removing

– Release handbrake.

– Use hook to release cover in storage compartment in centre

console (rear) and remove cover.

– Loosen adjustment nut on handbrake cable until the hand‐

brake cables -3- can be unhooked from the compensator -4(left and right sides).

– Raise vehicle.

– Detach handbrake cables from brake calipers ⇒ page 83 (left

and right).

– Unfasten bolt (right-side) on axle beam (right-side) and detach

bracket with handbrake cable.

– Detach handbrake cable (right-side) from compensator.

– Unclip guide tube (right-side) ⇒ Item 1 (page 87) from bracket

⇒ Item 2 (page 87) , do not loosen nut ⇒ Item 3 (page 87) .

– Carefully pull out handbrake cable (right-side) from guide tube

(right-side).

– Unfasten bolt (left-side) on axle beam (left-side) and detach

bracket with handbrake cable.

– Detach handbrake cable left-side) from compensator.

– Unclip guide tube (left-side) ⇒ Item 11 (page 87) from bracket

(left-side) ⇒ Item 10 (page 87) .

– Carefully pull out handbrake cable (left-side) from guide tube

(left-side).

Installing

Note

Install handbrake cable free of tension and stress.

– Installation is carried out in the reverse sequence.

– Carefully push handbrake cables (left and right) through cor‐

responding guide tubes and into vehicle interior.

– Engage handbrake cables on brake calipers ⇒ page 83 (left

and right).

– Lower vehicle.

88 Rep. Gr.46 - Brakes - mechanism

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– Pull handbrake cables (left and right) -3- out of front end of

relevant guide tube -2-.

– Engage handbrake cables (left and right) -3- in compensator

-4-.

– Pretension handbrake cable with adjustment nut on compen‐

sator -4-.

Note

The handbrake must be adjusted after installing handbrake cable

⇒ page 89 .

7.5 Removing and installing guide tubes for handbrake cable

Audi TT 2007 ➤

Brake system - Edition 04.2009

Removing

– Remove handbrake cable ⇒ page 87 .

– Unclip guide tubes from vehicle floor.

– Pull guide tubes -2- out of opening in vehicle floor from below.

– Take care not to damage rubber grommets -1-.

Installing

– Push guide tubes -2- through opening into vehicle interior from

below.

– Take care not to damage rubber grommets -1-.

– Clip guide tubes into retainers on vehicle floor.

7.6 Adjusting handbrake

Note

Adjustment is only necessary if handbrake cables, brake calipers or brake discs have been replaced.

♦ Both rear wheels must turn freely when handbrake lever is not

pulled (released position).

♦ The handbrake lever must return by itself to released position

if not pulled up to the first catch.

♦ The adjustment nut on the compensator must be screwed past

the end of the pull rod.

7. Handbrake 89

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Release handbrake.

– Use hook to release cover in storage compartment in centre

console (rear) and remove cover.

– The handbrake cable -5- must be routed free of stress.

Do not pull up the handbrake lever -1- more than 2 degrees when adjusting the handbrake.

– Tighten adjustment nut on compensator -2- until levers on

brake caliper -4- lift away from stop -3-.

– The sum of distances -a- between lever on brake caliper -4-

and stop -3- on both sides of vehicle must be at least 1 mm (with handbrake lever in released position).

– The distance on one side must not exceed 4 mm.

– The distance -a- to stop -3- on one side must be greater than

0 mm, however not greater than 4 mm.

– Apply handbrake firmly 3 times and then release.

– With handbrake released, check whether both wheels turn

freely. Check whether the distances -a- meet specifications.

– If the handbrake lever is pulled up to the first catch, there must

be a slight brake effect on the rear wheels.

If necessary, adjust via the adjustment nut.

Note

Due to the automatic adjustment of the rear brake, it is no longer necessary to adjust the handbrake after performing initial adjust‐ ment.

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

90 Rep. Gr.46 - Brakes - mechanism

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8 Brake pedal

8.1 Brake pedal - exploded view

WARNING

The brake pedal travel must not be restricted by additional floor coverings.

1 - Brake servo

❑ Removing and installing

⇒ page 122

2 - Brake light switch on brake master cylinder

3 - Mounting bracket

❑ With crash bar

4 - Bearing bush

❑ Before installing, lubri‐

cate pivot points with polycarbamide grease G 052 142 A2- .

5 - Hexagon nut

❑ 25 Nm

6 - Hexagon nut

❑ 25 Nm

7 - Brake pedal

❑ Removing and installing

⇒ page 91

❑ Separating from brake

servo ⇒ page 92

❑ Before installing, lubri‐

cate pivot points with polycarbamide grease G 052 142 A2- .

8 - Cap

9 - Hexagon bolt

Audi TT 2007 ➤

Brake system - Edition 04.2009

8.2 Removing and installing brake pedal

Removing

– Remove driver's storage compartment: ⇒ Rep. Gr. 68

– Separate brake pedal from brake servo ⇒ page 92 .

8. Brake pedal 91

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Audi TT 2007 ➤ Brake system - Edition 04.2009

– Unscrew nut -5-.

– Pull hexagon bolt -9- out of brake pedal and bearing bush.

Installing

Installation is carried out in the reverse sequence.

– Push hexagon bolt -9- through brake pedal and bearing bush.

– Use new nut -5- and tighten. Note tightening torque

⇒ Item 5 (page 91) .

Note

Before installing, lubricate pivot points with polycarbamide grease

-G 052 142 A2- .

Clip brake pedal to ball head of brake servo push rod.

– Hold ball head of push rod in front of mounting and push brake

pedal in direction of brake servo so that the ball head audibly locks into place ⇒ page 92 .

WARNING

Before driving vehicle for the first time, make sure function of brakes is OK.

8.3 Separating brake pedal from brake ser‐ vo

Special tools and workshop equipment required

♦ Release tool -T 40024-

Separating

– Remove driver's storage compartment: ⇒ Rep. Gr. 68

92 Rep. Gr.46 - Brakes - mechanism

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.

– Use release tool -T 40024- to separate brake pedal from brake

servo.

– Position release tool -T 40024- and press handles together

while simultaneously pulling the brake pedal towards driver's seat. (The brake pedal is thereby detached from ball head of push rod).

Installing

Clip brake pedal to ball head of brake servo push rod.

– Hold ball head of push rod in front of mounting and push brake

pedal in direction of brake servo so that the ball head audibly locks into place.

– Install storage compartment on driver's side: ⇒ Rep. Gr. 68

WARNING

Audi TT 2007 ➤

Brake system - Edition 04.2009

Before driving vehicle for the first time, make sure function of brakes is OK.

8. Brake pedal 93

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 ➤ Brake system - Edition 04.2009

47 – Brakes - hydraulics

1 High-pressure and low-pressure

tests

1.1 Tests

Special tools and workshop equipment required

♦ Tester for brake pressure regulator -V.A.G 1310A-

♦ Brake pedal actuator -V.A.G 1869/2-

High-pressure test:

Note

Make sure that the brake system (master cylinder, brake hoses, brake lines and brake calipers) works properly and is free of leaks.

– Screw out bleeder screw at one of the front brake calipers.

Connect tester for brake pressure regulator -V.A.G 1310 Aand bleed.

– Insert brake pedal actuator -V.A.G 1869/2- between brake

pedal and driver's seat. Apply pressure to brake pedal until the gauge indicates a pressure of 50 bar. The pressure must not drop by more than 4 bar during the test period of 45 seconds.

Renew brake master cylinder if drop in pressure exceeds the specification.

Low-pressure test:

– Move the brake pedal actuator back until the pressure gauge

indicates a pressure of 6 bar.

94 Rep. Gr.47 - Brakes - hydraulics