Audi TT Platform 2009 Quick Reference
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Audi TT Platform 2009 Quick Reference

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2009
TT Platform
Quick Reference
Specification Book

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Summary of Contents for Audi TT Platform 2009

  • Page 1 2009 TT Platform Quick Reference Specification Book...

  • Page 2: Table Of Contents

    Sealing Flange – Tightening Sequence .........23 Flywheel/Drive Plate – Tightening Torques ......23 Crankshaft Assembly – Tightening Sequence .......24 Crankshaft Dimensions ............25 Identification on Crankshaft Bearing, Top ......25 Piston and Connecting Rod – Tightening Torques ....25 Audi TT Quick Reference Specification Book • May 2009...
  • Page 3 Valve Dimensions ..............39 Camshaft – Tightening Torques ..........39 Valvetrain – 3.2L Engine – CBRA ........40 Valvetrain – Tightening Torques ..........40 Valve Dimensions ..............40 Camshaft – Tightening Sequence .........41 Camshaft – Tightening Torques ..........41 Audi TT Quick Reference Specification Book • May 2009...
  • Page 4 Fuel Injection – 3.2L – CBRA..........53 Fuel Injection System Data ............53 Intake Manifold – Tightening Torques ........53 Air Filter Assembly – Tightening Torques.......53 Exhaust System – 2.0L – CCTA .........54 Exhaust System – Tightening Torques ........54 Audi TT Quick Reference Specification Book • May 2009...
  • Page 5 02E Direct Shift Automatic Transmission Capacities .....68 02E Bevel Box Capacities .............68 Automatic Transmission Controls – 02E ......68 02E Selector Mechanism – Tightening Torques ....68 02E Selector Shaft – Tightening Torques ......68 Audi TT Quick Reference Specification Book • May 2009...
  • Page 6 Left Rear Level Control System Sensor G76 – Tightening Torques ................82 Wheel Bearing Housing – Tightening Torques ......83 Trailing Link – Tightening Torques .........83 Shock Absorbers – Tightening Torques .........83 Stabilizer Bar – Tightening Torques ........83 Audi TT Quick Reference Specification Book • May 2009...
  • Page 7 Tightening Torques ............92 Hydraulic Unit, Brake Booster/Brake Master Cylinder – Tightening Torques ............92 Steering ................92 Steering – Technical Data ............92 Steering Column – Tightening Torques .........93 Steering Gear – Tightening Torques ........93 Audi TT Quick Reference Specification Book • May 2009...
  • Page 8 A/C Refrigerant System – Tightening Torques ....106 Electrical Equipment ..........107 Battery – Tightening Torques ..........107 Generator – Tightening Torques ..........107 Generator 2.0LTFSI – Tightening Torques ......107 2.0L TFSI Generator Mounting Bracket Bolts – Tightening Sequence ..............107 Audi TT Quick Reference Specification Book • May 2009...
  • Page 9 Headlamp Washer Spray Jets – Tightening Torques ...108 Front and Rear Lamp – Tightening Torques ......109 Horn – Tightening Torques ..........109 Instruments – Tightening Torques ........109 Vehicle Level Sensors – Tightening Torques .......109 viii Audi TT Quick Reference Specification Book • May 2009...

  • Page 10: General Information

    0.39370 50.00 1.9685 20.000 0.78740 60.00 2.3622 30.000 1.18110 70.00 2.7559 40.000 1.57480 80.00 3.1496 50.000 1.96850 90.00 3.5433 60.000 2.36220 100.00 3.9370 70.000 2.75591 80.000 3.14961 90.000 3.54331 100.000 3.93701 Audi TT Quick Reference Specification Book • May 2009...

  • Page 11: Tightening Torque

    Tightening Torque n·m -to- lb·ft (ft·lb) To calculate: N·m x 0.738 = lb·ft lb·ft lb·ft lb·ft n·m n·m n·m (ft·lb) (ft·lb) (ft·lb) Audi TT Quick Reference Specification Book • May 2009...
  • Page 12 (in·lb) (in·lb) n·cm -to- lb·in (in·lb), kg·cm To calculate: N·cm x 0.089 = lb·in • N·cm x 0.102 = kg·cm lb·in lb·in n·cm kg·cm n·cm kg·cm (in·lb) (in·lb) 1000 Audi TT Quick Reference Specification Book • May 2009...

  • Page 13: Warnings And Cautions

    Never work under a car that is supported solely by a jack. Never work under the car while the engine is running. Audi TT Quick Reference Specification Book • May 2009...
  • Page 14 Disconnect the battery negative (-) terminal (ground strap) whenever you work on the fuel or electrical system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy. Audi TT Quick Reference Specification Book • May 2009...
  • Page 15 Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the tire from the rim before attempting any repair. Audi TT Quick Reference Specification Book • May 2009...
  • Page 16 Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque specification listed. Audi TT Quick Reference Specification Book • May 2009...
  • Page 17 Do not allow battery charging voltage to exceed 16.5 volts. If the battery begins producing gas or boiling violently, reduce the charging rate. Boosting a sulfated battery at a high charging rate can cause an explosion. Audi TT Quick Reference Specification Book • May 2009...

  • Page 18: Maintenance

    © 2009 Audi of America, Inc. All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

  • Page 19: Vehicle Identification

    It is visible from the outside. VIn on Suspension Strut Mount The VIN - B - (chassis number) is stamped into the upper inner longitudinal member. Audi TT Quick Reference Specification Book • May 2009...

  • Page 20: Vin Decoder

    VIn Decoder Audi TT Quick Reference Specification Book • May 2009...

  • Page 21: Type Plate - Location

    The vehicle data sticker can also be found in the service schedule for the customer. Audi TT Quick Reference Specification Book • May 2009...

  • Page 22: Sales Codes

    SALES CoDES Engine Codes CCTA 2.0L 4-cylinder 4V turbo CBRA 3.2L 6-cylinder 4V Transmission Codes 6-speed manual 6-speed direct shift automatic Audi TT Quick Reference Specification Book • May 2009...

  • Page 23: Vehicle Lifting

    Rear: On aluminum case part in front of rear axle mounting point. Note:The support plate must not touch the trailing arm mounting tab, the wheel guide could be damaged. Audi TT Quick Reference Specification Book • May 2009...

  • Page 24: Engine Mechanical, Fuel Injection & Ignition

    In addition, a sticker with the engine code and serial number is affixed to the timing belt cover. The engine code is also on the vehicle data plate. Audi TT Quick Reference Specification Book • May 2009...

  • Page 25: Engine Number - Location - 3.2L - Cbra

    Turbocharger, G-Charger Oxygen sensor regulation 4 sensors 4 sensors Variable valve timing Variable intake manifold Secondary Air Injection (AIR) Valve per cylinder Super unleaded RON 95 is permissible, although with reduced power. Audi TT Quick Reference Specification Book • May 2009...
  • Page 26 Nm at RPM 280/1800 - 5000 320/2500 Bore 82.5 84.0 Stroke 92.8 95.5 Compression ratio 10.5:1 10.85:1 Fuel injection/ignition min. 98 unleaded 98 unleaded Unleaded RON 95 is also permissible, although with reduced power. Audi TT Quick Reference Specification Book • May 2009...

  • Page 27: Engine - Removing And Installing

    Item Bolt M12 x 55 M12 x 65 4, 5 M10 x 50 M12 x 80 Alignment sleeves for centering Bolt with threaded pin M8. Install in transmission from engine side. Audi TT Quick Reference Specification Book • May 2009...

  • Page 28: Direct Shift Automatic Transmission To Engine Mounting

    Bolt 1, 3, 6 M12 x 55 2, 4 M10 x 45 (Starter Mount) 5, 10 M12 x 65 7, 8 M10 x 50 M10 x 45 Alignment sleeves for centering Audi TT Quick Reference Specification Book • May 2009...

  • Page 29: Assembly Mountings - Tightening Torques

    90° (¼ turn) Pendulum support mounting to body (always replace) 100 plus an additional 90° (¼ turn) Pendulum support mounting/bracket to body (always 40 plus an replace) additional 90° (¼ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 30: Crankshaft/Cylinder Block - 4-Cylinder - Turbo Engine - 2.0L - Ccta

    Step Component Tighten bolts 1 - 5 in sequence Hand tighten Tighten bolts 1 - 5 in sequence Tighten bolts 1 - 5 in sequence Tighten an additional 90° (¼ turn). Audi TT Quick Reference Specification Book • May 2009...

  • Page 31: Assembly Attachments Mounting - Tightening Torques

    Oil filter bracket to engine bolt 15 plus an additional 90° (¼ turn) Engine speed (RPM) sensor G28 to intake manifold support to engine bolt Coolant thermostat housing with coolant thermostat to engine bolt Audi TT Quick Reference Specification Book • May 2009...

  • Page 32: Sealing Flange - Tightening Sequence

    Flywheel/drive plate to cylinder block bolt 60 plus an additional 90° (¼ turn) Dual-mass flywheel to crankshaft 60 plus an additional 90° (¼ turn) Sensor wheel to crankshaft bolts 10 plus an additional 90° (¼ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 33: Crankshaft Assembly - Tightening Sequence

    Hand tighten Tighten bolts 1 – 10 in sequence Tighten bolts 1 – 10 in sequence An additional 90° (¼ turn) ➡ Tighten bolts ➡ Tighten bolts An additional 90° (¼ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 34: Crankshaft Dimensions

    White Piston and Connecting Rod – Tightening Torques Component Connecting rod bearing cap to connecting rod bolts 45 plus an additional 90° (¼ turn) Pressure relief valve to oil spray jet Audi TT Quick Reference Specification Book • May 2009...

  • Page 35: Crankshaft/Cylinder Block - 4-Cylinder - Turbo Engine - 2.0L - Ccta (Continued)

    0.02 to 0.06 0.15 Piston and Cylinder Dimensions Honing dimension Piston diameter Cylinder bore diameter Basic dimension 82.465 * 82.51 * Dimension without graphite coating (thickness 0.02 mm). The graphite coating wears away. Audi TT Quick Reference Specification Book • May 2009...

  • Page 36: Crankshaft/Cylinder Block - 6-Cylinder - 3.2L - Cbra

    3.2L – CBRA Accessory Assembly Bracket Tightening Sequence Tighten bolts in two stages as follows: Step Component Tighten bolts 1 - 5 in sequence Hand tighten Tighten bolts 1 - 5 in sequence Audi TT Quick Reference Specification Book • May 2009...

  • Page 37: Sealing Flange Tightening Sequence

    100 plus an additional 180° (½ turn) Generator to assembly bracket bolt Tensioning device for ribbed belt bolt Engine mount to assembly bracket bolts 40 plus an additional 90° (¼ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 38: Drive Chain - Tightening Torques

    90° (¼ turn) Pin for tensioning track Pin for guide rail Mounting pin Brake Booster Vacuum Pump – Tightening Torques Component Vacuum pump to control housing cover Coolant pipe to bracket Audi TT Quick Reference Specification Book • May 2009...

  • Page 39: Sealing Flanges And Vibration Damper - Tightening Torques

    Pressure relief valve to oil spray jet Piston Ring End Gaps Piston ring (dimensions in mm) Wear limit Compression ring 0.20 to 0.40 1.00 Tapered ring 0.20 to 0.40 1.00 Oil scraping ring 0.25 to 0.50 1.00 Audi TT Quick Reference Specification Book • May 2009...

  • Page 40: Piston Ring Clearance

    Basic dimension 83.965 84.010 Cylinder Head – 2.0L Engine – CCTA Crankcase Ventilation – Tightening Sequence Step Component Tighten bolts 1 – 10 in sequence Audi TT Quick Reference Specification Book • May 2009...

  • Page 41: Cylinder Head - Tightening Torques

    Camshaft Position (CMP) sensor G40 to cylinder block bolt Stud bolt for tensioning roller Stud bolt for exhaust manifold Cylinder Head – Loosening Sequence Step Component ➡ Remove bolts Loosen bolts 1 – 5 in sequence Audi TT Quick Reference Specification Book • May 2009...

  • Page 42: Cylinder Head - Tightening Sequence

    Tighten bolts 1 – 5 in sequence An additional 90° (¼ turn) Tighten bolts 1 – 5 in sequence An additional 90° (¼ turn) ➡ Tighten bolts ➡ Tighten bolts An additional 90° (¼ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 43: Cylinder Head (Valve) Cover - Loosening Sequence

    Cylinder Head (Valve) Cover – Loosening Sequence Loosen cylinder head cover bolts 1 to 6 in sequence. Audi TT Quick Reference Specification Book • May 2009...

  • Page 44: Cylinder Head (Valve) Cover - Tightening Sequence

    Tighten bolts 1 – 6 in sequence An additional 90° (¼ turn) Compression Pressures new bar positive Wear limit bar positive Difference between pressure pressure cylinders bar positive pressure 11.0 to 14.0 Max. 3.0 Audi TT Quick Reference Specification Book • May 2009...

  • Page 45: Cylinder Head - 3.2L Engine - Cbra

    Camshaft adjustment valve 1 N205 to cylinder block bolt Camshaft Position (CMP) sensor G40 to cylinder block bolt Lifting eye Cylinder Head – Removal Sequence Loosen cylinder head bolts 1-to-20 in sequence. Audi TT Quick Reference Specification Book • May 2009...

  • Page 46: Cylinder Head - Tightening Sequence

    Tighten bolts 1 - 20 in sequence Hand tighten Tighten bolts 1 - 20 in sequence Tighten bolts 1 - 20 in sequence Tighten bolts 1 - 20 in sequence Tighten an additional 180° (½ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 47: Cylinder Head Cover - Tightening Sequence

    8 plus an additional 90° (¼ turn) Guide pins Control valve (left thread) Camshaft chain tensioner bolts Camshaft Position (CMP) sensor G40 to cylinder head bolt Balance shaft chain tensioner bolt Audi TT Quick Reference Specification Book • May 2009...

  • Page 48: Valve Dimensions

    5.98 ± 0.01 5.96 ± 0.01 104.0 ± 0.2 101.9 ± 0.2 α degrees Camshaft – Tightening Torques Component Tighten bolts 1 - 6 in sequence 8 plus an additional 90° (¼ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 49: Valvetrain - 3.2L Engine - Cbra

    Dimension Short Long Short Long intake intake exhaust exhaust valve valve valve valve Dia. a 31.00 31.00 27.00 27.00 Dia. b 5.96 5.96 5.94 5.94 102.20 136.10 102.50 136.40 α degrees Audi TT Quick Reference Specification Book • May 2009...

  • Page 50: Camshaft - Tightening Sequence

    Camshaft – Tightening Sequence Camshaft – Tightening Torques Component Bearing cap to cylinder head 5 plus an additional 45° Control housing to cylinder head Audi TT Quick Reference Specification Book • May 2009...

  • Page 51: Engine Lubrication - 2.0L - Ccta

    Step Component Tighten bolts 1 - 14 in sequence Hand tighten Tighten bolts 1 - 14 in sequence Tighten bolts 1 - 20 in sequence Tighten an additional 90° (¼ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 52: Oil Pan Lower Section - Tightening Sequence

    Step Component Tighten bolts 1 - 20 in sequence Hand tighten Tighten bolts 1 - 20 in sequence Tighten bolts 1 - 20 in sequence Tighten an additional 45° ⁄ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 53: Oil Separator - Tightening Torques

    Chain sprocket to oil pump cover to inner rotor to outer 20 plus an rotor to oil pump with balance shaft drive bolt additional 90° (¼ turn) Chain tensioner with tensioning rail to oil pump with balance shaft drive bolt Audi TT Quick Reference Specification Book • May 2009...

  • Page 54: Oil Filter Bracket - Tightening Torques

    Intake line to oil pump Engine Cooling – 2.0L – CCTA Cooling System Components – Tightening Torques Component Expansion tank bolt Coolant fan to air shroud bolts Air shroud to radiator bolts Audi TT Quick Reference Specification Book • May 2009...

  • Page 55: After Run Coolant Pump V51 - Tightening Torques

    10 plus an additional 90° (¼ turn) Toothed belt cover bolts Connecting piece bolts (thermostat) Recommended Coolant Mixture Ratios Frost protection to Anti-freeze quantity G 12 Water -25°C 3.2L 4.8L -35°C 4.0L 4.0L Audi TT Quick Reference Specification Book • May 2009...

  • Page 56: Engine Cooling - 3.2L - Cbra

    -25°C 3.6L 5.4L -35°C 4.5L 4.5L Fuel Storage and Supply – 2.0L – CCTA, 3.2L – CBRA Fuel Pump – Tightening Torques Component Fuel tank bolt Fuel delivery unit locking ring Audi TT Quick Reference Specification Book • May 2009...

  • Page 57: Fuel Tank - Tightening Torques

    Air filter housing bolt Leak Detection Pump (LDP) V144 bracket to LDP V144 bolt Leak Detection Pump (LDP) V144 bracket to LDP V144 Bracket for Leak Detection Pump (LDP) to wheel housing (CBRA) Audi TT Quick Reference Specification Book • May 2009...

  • Page 58: Turbocharger - 2.0L - Ccta

    Tighten bolts in four stages as follows: Step Component Tighten bolts 1 - 5 in sequence Tighten bolts 1 - 5 in sequence Tighten bolts 1 - 5 in sequence Tighten bolts 1 - 5 in sequence Audi TT Quick Reference Specification Book • May 2009...

  • Page 59: Turbocharger - Tightening Torques

    Bracket for turbocharger to cylinder block (use hot bolt paste Electronic Parts Catalog [ETKA]) Turbocharger bracket to turbocharger (use hot bolt paste Electronic Parts Catalog [ETKA]) Right charge air pipe to oil pan Air guide pipe to bracket Audi TT Quick Reference Specification Book • May 2009...

  • Page 60: Charge Air Cooler - Tightening Torques

    Fuel high pressure (produced Approximately 40 bar by a mechanical single-piston positive pressure at idle pump) at approximately 85 Approximately 150 bar degree coolant temperature positive pressure at certain operating points. Audi TT Quick Reference Specification Book • May 2009...

  • Page 61: Engine Cover/Air Filter - Tightening Torques

    N276 bolts Fuel pressure regulator valve N276 supply line Fuel pressure regulator valve N276 return line Low fuel pressure sensor G410 to high pressure pump with fuel pressure regulator valve N276 Audi TT Quick Reference Specification Book • May 2009...

  • Page 62: Fuel Injection - 3.2L - Cbra

    Air Filter Assembly – Tightening Torques Component Mass Air Flow (MAF) sensor G70 with Intake Air Temperature (IAT) sensor G42 bolt Upper air filter housing Lower section of air filter bolts and retaining pins Audi TT Quick Reference Specification Book • May 2009...

  • Page 63: Exhaust System - 2.0L - Ccta

    Front exhaust pipe to exhaust manifold Exhaust manifold heat shield to cylinder head Oxygen sensor before catalytic converter in front exhaust pipe Dome brace to body or bracket Oxygen sensor behind catalytic converter in catalytic converter Audi TT Quick Reference Specification Book • May 2009...

  • Page 64: Secondary Air Injection (Air) System - Tightening Torques

    Camshaft Position (CMP) sensor G40 bolt Spark Plug Data Engine code Electrode gap 0.7 to 0.8 mm Tightening torque 30 Nm Engine code CBRA Electrode gap 1.0 to 1.1 mm Tightening torque 30 Nm Audi TT Quick Reference Specification Book • May 2009...

  • Page 65: Manual Transmission

    MAnUAL TRAnSMISSIon General, Technical Data 02Q Transmission Identification ➡ Identification and date of construction 1 ➡ Manual transmission 02Q All Wheel Drive 2 Audi TT Quick Reference Specification Book • May 2009...
  • Page 66 ➡ Manual transmission 02Q All Wheel Drive 2 ➡ Transmission code letters and date of manufacture Example: Code letters Month Year 2003 of production Audi TT Quick Reference Specification Book • May 2009...

  • Page 67: 02Q Manual Transmission Specifications

    The following information can be found in the Electronic Parts Catalog (ETKA): • Gear oil specification • Bevel box axle oil specification • Drive shaft flanges allocation • Clutch allocation • Rear final drive allocation Audi TT Quick Reference Specification Book • May 2009...

  • Page 68: Clutch - 02Q

    Component Metal slave cylinder to transmission (replace bolts) Plastic slave cylinder to transmission (replace bolts) Clutch (Sachs) – Tightening Torques Component Bolt M7 Clutch (LuK) – Tightening Torques Component Bolt M6 Audi TT Quick Reference Specification Book • May 2009...

  • Page 69: Cable Retainer Dimensions

    Dimension “a” (mm) Shift cable to transmission shift lever Selector cable to relay lever Shift Cable Retainer – Tightening Torques Component Shift mechanism housing to body Cable mounting bracket to transmission Audi TT Quick Reference Specification Book • May 2009...

  • Page 70: Manual Transmission - Installing - 02Q

    Install in transmission from engine side. 02Q Transmission – Tightening Torques Location/Fastener Transmission plate to transmission 60 plus an additional 90° (¼ turn) Transmission to left assembly mounting 60 plus an additional 90° (¼ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 71: O2Q Transmission Pendulum Support

    Mechanism – Tightening Torques Component Back up light switch F4 Selector shaft locking bolt Clutch housing bolts (always replace) 15 plus an additional 90° (¼ turn) Selector mechanism bolts (always replace) Audi TT Quick Reference Specification Book • May 2009...

  • Page 72: Installation Position Of Shafts And Selector Rods In Transmission

    Drive flange shaft with spring countersunk bolt Shield for right drive axle 02Q Transmission Housing and Clutch Housing – Tightening Torques Component Self-locking socket head cap bolt (always replace) Oil drain plug Audi TT Quick Reference Specification Book • May 2009...

  • Page 73: Automatic Transmission

    AUToMATIC TRAnSMISSIon General, Technical Data 02E Transmission Identification Example: • GKF = Transmission code • 10.05.2 = Production date May 10th, 2002. • The rest of the numbers depend on manufacturing. Audi TT Quick Reference Specification Book • May 2009...

  • Page 74: 02E Transmission Specifications

    22:14 x 22:14 x 32:15 = 33:13 = 32:15 = 3.352 3.352 3.352 itotal in top gear 2.970 2.888 2.970 Allocation of Designation Rear final drive 02D and 0AV rear final drive Audi TT Quick Reference Specification Book • May 2009...
  • Page 75 22:14 x 22:14 x 32:15 = 32:15 = 32:15 = 3.352 3.352 3.352 itotal in top gear 2.970 2.970 2.970 Allocation of Designation Rear final drive 02D and 0AV rear final drive Audi TT Quick Reference Specification Book • May 2009...
  • Page 76 32:15 = 27:13 = 32:15 = 27:13 = 3.352 3.264 3.352 3.264 itotal in top gear 2.970 3.000 2.970 3.000 Allocation of Designation Rear final drive 02D and 0AV rear final drive Audi TT Quick Reference Specification Book • May 2009...

  • Page 77: Direct Shift Automatic Transmission Capacities

    Selector lever cable adjustment bolt (02E) 02E Selector Shaft – Tightening Torques Component Selector shaft lever to transmission 02E Transmission Input Speed (RPM) Sensor G182 and Clutch oil Temperature Sensor G509 – Tightening Torques Component Sensor Audi TT Quick Reference Specification Book • May 2009...

  • Page 78: Direct Shift Gearbox (Dsg) Mechatronic J743 - Tightening Torques

    02E Direct Shift Gearbox (DSG) Mechatronic J743 – Tightening Sequence Component Tighten bolts 1-10 in sequence 5 plus an additional 90° (¼ turn) Transmission fluid pump cover to transmission (replace bolts) Audi TT Quick Reference Specification Book • May 2009...

  • Page 79: 02E Oil Pan - Tightening Torques

    02E oil Pan – Tightening Torques Component ➡ Tighten the bolts diagonally in steps 02E Drain Plug and Filter housing – Tightening Torques Component Oil drain plug, M24 Oil filter housing Audi TT Quick Reference Specification Book • May 2009...

  • Page 80: Automatic Transmission Installing - 02E

    M12 x 65 6, 7, 8 M10 x 50 M12 x 70 M12 x 55 Alignment sleeves for centering The bolt, item 3, is accessible only through the opening from the removed starter Audi TT Quick Reference Specification Book • May 2009...

  • Page 81: Transmission To 3.2L Mpi Engine - Tightening Torques

    Oil pump bolts (all four) 5 plus an additional 90° (¼ turn) Oil pump countersunk bolt Oil pump (remaining 3 bolts) 8 plus an additional 90° (¼ turn) Oil pump cover (tighten diagonally) Audi TT Quick Reference Specification Book • May 2009...

  • Page 82: 02E Transmission Mount - Tightening Torques

    02E Transmission Mount – Tightening Torques Component Transmission mount to body (replace bolts) 40 plus an additional 90° (¼ turn) Transmission mount to transmission support (replace 60 plus an bolts) additional 90° (¼ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 83: Rear Final Drive

    REAR FInAL DRIVE Identification Part number, transmission code and rear final drive production ➡ date Audi TT Quick Reference Specification Book • May 2009...
  • Page 84 Rear final drive 02D ➡ Rear final drive part number ➡ Rear final drive code letters ➡ Rear final drive production date Example: 02D.525.010.AQ Part number Code letters Month Production year (2004) Audi TT Quick Reference Specification Book • May 2009...
  • Page 85 Rear final drive 0AV ➡ Rear final drive part number ➡ Rear final drive code letters ➡ Rear final drive production date Example: Code letters Month Production year (2005) Audi TT Quick Reference Specification Book • May 2009...

  • Page 86: Identification Code Letters, Allocation, Gear Ratios And Capacities

    Change interval. See Maintenance Service Circular for appropriate model and year. Please retrieve the following information from Electronic Parts Catalog (ETKA): • Rear final drive transmission oil specification • Haldex clutch high performance oil specification • Transmission allocation Audi TT Quick Reference Specification Book • May 2009...

  • Page 87: Rear Final Drive - Tightening Torques

    Rear Final Drive – Tightening Torques Components Rear final drive axle oil filler plug All wheel drive control module bolts Haldex drive to driveshaft flange nut Haldex clutch pump V181 bolts Haldex oil filler sealing cap Audi TT Quick Reference Specification Book • May 2009...

  • Page 88: Suspension, Wheels, Brakes, Steering

    Console to body M12 x 1.5 x 90 70 plus an additional 90° (¼ turn) Left front level control system sensor M6 x 16 G78 to console Shielding plate M6 self-tapping Audi TT Quick Reference Specification Book • May 2009...

  • Page 89: Control Arm - Tightening Torques

    15 plus an additional 90° (¼ turn) To wheel bearing housing M12 x 1.5 x 80 70 plus an additional 90° (¼ turn) Strut mounting to piston rod M14 x 1.5 Audi TT Quick Reference Specification Book • May 2009...

  • Page 90: Drive Axle - Tightening Torques

    M6 x 10 housing Front speed sensor to wheel bearing M6 x 16 housing Tie rod end to wheel bearing housing M12 x 1.5 20 plus an additional 90° (¼ turn) Audi TT Quick Reference Specification Book • May 2009...

  • Page 91: Rear Suspension - Front Wheel Drive

    90 plus an additional 90° (¼ turn) Left Rear Level Control System Sensor G76 – Tightening Torques Threaded connection Thread To subframe M5 x 20 To lower transverse link M5 x 20 Audi TT Quick Reference Specification Book • May 2009...

  • Page 92: Wheel Bearing Housing - Tightening Torques

    ⁄ turn) Stabilizer Bar – Tightening Torques Threaded connection Thread To subframe M8 x 35 20 plus an additional 90° (¼ turn) To coupling rod Coupling rod to wheel bearing housing Audi TT Quick Reference Specification Book • May 2009...

  • Page 93: Rear Suspension - All Wheel Drive

    60 plus an additional 90° (¼ turn) Left Rear Level Control System Sensor G76 – Tightening Torques Threaded connection Thread To subframe M5 x 20 To lower transverse link M5 x 20 Audi TT Quick Reference Specification Book • May 2009...

  • Page 94: Wheel Bearing Housing - Tightening Torques

    Stabilizer Bar – Tightening Torques Threaded connection Thread To subframe M8 x 30 25 plus an additional 90° (¼ turn) To coupling rod M10 x 55 Coupling rod to wheel bearing housing Audi TT Quick Reference Specification Book • May 2009...

  • Page 95: Drive Axle - Tightening Torques

    200 plus an additional 180° (½ turn) Wheels, Tires, Wheel Alignment Wheel Bolts – Tightening Torques Model/type Audi models except RS 2 and RS 4 (type 8D) RS 2 RS 4 (type 8D) RS 4 (type 8E) PAX wheels A 6 (security) A 8 (security) Tire Pressure Sensor –...

  • Page 96: Wheel Alignment Data

    36° 48’ 36° 48’ steering angle at inner wheel * Wheel stop on outer wheel is reduced by this amount. It can also be indicated negatively in alignment computer, depending on manufacturer. Audi TT Quick Reference Specification Book • May 2009...

  • Page 97: Light Alloy Wheels With Metal Valve - Tightening Torques

    FNR- FNR- G-57 G-57 G-57 Pistons dia. Brake disc PR number Front brake disc dia. 312 (16) 312 (16) 340 (17) 340 (17) 340 (17) Brake disc mm 25 thickness, ventilated Audi TT Quick Reference Specification Book • May 2009...

  • Page 98: Rear Brakes Front Wheel Drive - Technical Data

    Brake disc thickness, ventilated mm ------ ------ Brake disc wear limit mm 9 Brake pads Pad thickness, new (not including mm 12 backing plate) Brake pad wear limit (not including mm 2 backing plate) Audi TT Quick Reference Specification Book • May 2009...

  • Page 99: Hydraulic Unit, Brake Booster/Brake Master Cylinder - Abs Mark 70 (Abs/Asr) And 60 (Abs/Edl/Asr/Esp) - Tightening Torques

    Brake lines to hydraulic unit, M10 and M12 ABS System Components on Front and Rear Axles – Tightening Torques Component ABS speed sensor to wheel bearing housing, front ABS speed sensor to stub axle, rear Audi TT Quick Reference Specification Book • May 2009...

  • Page 100: Esp Sensor Unit G419 - Tightening Torques

    Brake line to brake caliper Replace hex head bolt with hex head bolt and Torx® bolt with Torx® bolt. Parking Brake Lever – Tightening Torques Component Parking brake lever hex nuts Audi TT Quick Reference Specification Book • May 2009...

  • Page 101: Hydraulic Components - Front Brake Caliper Fn3/Fnr-G - Tightening Torques

    Steering – Technical Data Front and all wheel drive Steering gear Electromechanically assisted, maintenance- free rack-and-pinion steering Maximum steering lock 36° 48’ angle on inside wheel Turning diameter Approximately 10.9 m Audi TT Quick Reference Specification Book • May 2009...

  • Page 102: Steering Column - Tightening Torques

    Tie rod end to wheel bearing housing M12 x 1.5 20 plus an additional 90° (¼ turn) Tie rod end to tie rod M16 x 1.5 Tie rod to steering rack M16 x 1.5 Audi TT Quick Reference Specification Book • May 2009...

  • Page 103: Body

    Component 4.5 mm ± 0.5 mm 4.5 mm ± 0.5 mm 3.5 mm ± 0.5 mm 3.5 mm ± 0.5 mm 3.5 mm ± 0.5 mm 3.5 mm ± 0.5 mm Audi TT Quick Reference Specification Book • May 2009...

  • Page 104: Center Dimensions

    Center Dimensions Component 3.5 mm ± 0.5 mm 3.5 mm ± 0.5 mm 0 mm to -1 mm 0 mm to +1 mm 3.5 mm ± 0.5 mm Audi TT Quick Reference Specification Book • May 2009...

  • Page 105: Rear Coupe Dimensions

    Rear Coupe Dimensions Component 4.5 mm ± 0.5 mm 3.5 mm ± 0.5 mm 4.0 mm ± 0.5 mm 2.0 mm ± 0.5 mm 2.0 mm ± 0.5 mm Audi TT Quick Reference Specification Book • May 2009...
  • Page 106 Component 4.0 mm ± 0.5 mm 4.5 mm ± 0.5 mm 3.5 mm ± 0.5 mm 2 mm all around Audi TT Quick Reference Specification Book • May 2009...

  • Page 107: Rear Roadster Dimensions

    Component Lock carrier bolts, upper Lock carrier bolts, lower Side impact member screws to noise insulation frame Front Fender – Tightening Torques Component Front fender bolts Fender connecting piece hex nut Audi TT Quick Reference Specification Book • May 2009...

  • Page 108: Noise Insulation Panel - Tightening Torques

    Rear lid hinge hex head nut Rear lid latch bracket nuts Rear lid handle unlock switch E234 bolts Rear lid lock nuts Tank Flap Unit – Tightening Torques Component Fuel filler flap Audi TT Quick Reference Specification Book • May 2009...

  • Page 109: Front And Rear Door - Tightening Torques

    Lower part of spoiler bolts Rear Bumper – Tightening Torques Component Rear bumper cover bolts T-24 Rear bumper cover screws Rear bumper cover cap nuts Securing strip hex nuts Guide trim hex nuts Crossmember bolts Audi TT Quick Reference Specification Book • May 2009...

  • Page 110: Front And Rear Door Window - Tightening Torques

    Instrument panel center vent bolts Center instrument panel trim bolts Steering column trim bolts Driver side trim bolts Sun visor bolts Glove compartment bolts Driver side footwell cover bolts Roof grab handle bolts Audi TT Quick Reference Specification Book • May 2009...

  • Page 111: Passenger Protection - Tightening Torques

    Upper A-pillar and B-pillar trim airbag emblem bolt B-pillar trim bolts C-pillar trim nut Side trim bolts Rear lid trim handle recess bolts Luggage compartment cover side storage compartment bolts Luggage compartment side trim bolts Molded headliner bolts Audi TT Quick Reference Specification Book • May 2009...

  • Page 112: Seat Frames - Tightening Torques

    Bucket seat pan bolts Rear seat center backrest bolt Rear seat belt buckle to floor bolt Rear seat side upholstery bolt Rear seat side upholstery nut Rear seat storage unit with center armrest bolts Audi TT Quick Reference Specification Book • May 2009...

  • Page 113: Heating And Air Conditioning

    1K0 820 803 H Zexel from 10.04 120 ± 10 Refrigerant oil Distribution Component Approximate % of total amount of oil in component A/C compressor Condenser Suction hose Evaporator Fluid reservoir Audi TT Quick Reference Specification Book • May 2009...

  • Page 114: Refrigerant R134A Vapor Pressure Table

    (positive pressure) of R134a -0.61 -0.49 -0.34 -0.16 0.06 0.32 0.63 1.00 1.43 1.92 2.49 3.13 3.90 4.70 5.63 6.70 7.83 9.10 10.54 12.11 13.83 15.72 17.79 20.05 22.52 25.21 28.14 31.34 Audi TT Quick Reference Specification Book • May 2009...

  • Page 115: Heating And A/C Components - Tightening Torques

    Drive plate to A/C compressor, version 1 Drive plate to A/C compressor, version 2 Refrigerant lines to condenser bolts Condenser to charge air cooler bolts Fluid reservoir to condenser bolts Refrigerant lines to expansion valve bolts Audi TT Quick Reference Specification Book • May 2009...

  • Page 116: Electrical Equipment

    M10 x 45 A/C compressor to mounting bracket M8 x 100 2.0L TFSI Generator Mounting Bracket Bolts – Tightening Sequence Component A – B – C – D – E – F Audi TT Quick Reference Specification Book • May 2009...
  • Page 117 Filler neck for washer fluid reservoir to wheel housing Rear Wiper/Washer – Tightening Torques Component Wiper motor to rear lid screw Wiper arm nut Headlamp Washer Spray Jets – Tightening Torques Component Washer jet to bumper screw Audi TT Quick Reference Specification Book • May 2009...
  • Page 118 Radio frequency controlled clock receiver to rear bumper screws Vehicle Level Sensors – Tightening Torques Component Left front level control system sensor G78 bolts Left rear level control system sensor G76 bolts Audi TT Quick Reference Specification Book • May 2009...
  • Page 119 Audi TT Quick Spec 09...

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