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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT00320
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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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
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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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
7.5 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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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
iv Contents
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Audi TT 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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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
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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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
2 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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with respect to the correctness of information in this document. Copyright by AUDI AG.
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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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
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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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
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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with respect to the correctness of information in this document. Copyright by AUDI AG.
– 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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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
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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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
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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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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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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