Body Repairs

Service
Body Repairs
Audi TT 2007 ➤
Edition 09.2009
Service Department. Technical Information

Service
Repair Group overview for Body Repairs
Repair Group
00 - Technical data
50 - Body - front
51 - Body - centre
53 - Body - rear
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 A008JKI0120

Audi TT 2007 ➤
Body Repairs - Edition 09.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Type plate and vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Expanded foam inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 General notes on repairs to aluminium parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 General notes on repairs to steel parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6 Body construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Aluminium panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8 Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.1 Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.2 Spot-welded/bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.3 Inspecting and repairing bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8.4 Repair methods for replacing body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9.1 Body - front and centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
10 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.1 Floor group, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10.2 Floor group, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
10.3 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10.4 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10.5 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11 Straightening jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11.2 Portal gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1 Longitudinal member, upper part with console (Coupé and Roadster identical) . . . . . . . . 36
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2 Support, left-side - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . . . . . . . 43
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3 Support, right-side - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . . . . . . . 46
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Upper longitudinal member for wheel housing - Renewal (Coupé and Roadster identical)
........................................................................ 50
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5 Suspension strut mounting - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . 55
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6 Longitudinal member for wheel housing, upper, inner - Renewal (Coupé and Roadster
identical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7 Front longitudinal member - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . 65
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Audi TT 2007 ➤
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8 Front longitudinal member - Partial renewal (Coupé and Roadster identical) . . . . . . . . . . 70
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9 Longitudinal member (front section) - Renewal (Coupé and Roadster identical) . . . . . . . . 73
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1 Roof - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2 Roof side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.3 Foam-filling roof side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3 Outer roof frame - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4 Front roof cross member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5 Rear roof frame - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6 Outer A-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7 Reinforcement tube and inner A-pillar - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . 122
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
8 Inner A-pillar - Renewal (Coupé and Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
9 Inner B-pillar - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
9.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
10 Outer side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
11 Inner side member - Partial renewal (old part section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
11.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
12 Inner side member - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
12.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
13 Floor panel - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
13.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1 Rear cross panel (top section) - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . 168
1.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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Audi TT 2007 ➤
1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

2 Cross panel (inner section) - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . 173
2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3 Rain channel - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4 Rear suspension strut mounting - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . 183
4.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
5 Rear longitudinal member - Partial renewal (Coupé and Roadster identical) . . . . . . . . . . 186
5.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6 Side panel - Renewal (Coupé) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7 Side panel - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
8 Inner side panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
9 Rear wheel housing - Partial renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . 217
9.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
9.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
10 Rear wheel housing - Renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . . . . . 222
10.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
10.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
11 Spare wheel well - Partial renewal (Coupé and Roadster identical) . . . . . . . . . . . . . . . . . . 226
11.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
11.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
12 Spare wheel well - Renewal (Coupé and Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
12.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
12.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Contents iii
Audi TT 2007 ➤
iv Contents
Audi TT 2007 ➤
00 – Technical data
1 General notes
This Manual describes only selected repair operations. A de‐
scription is given where the repair method differs from the original
manufacturing process.
Where the repair operation is not described: Separate the original
joint and repair using a replacement part.
If no description is given for any sub-parts supplied, these should
be matched up and butt welded with an SG continuous seam.
Please refer to the information in the Workshop Manual ⇒ General
Information; Body Repairs, General Body Repairs .
1. General notes 1
Audi TT 2007 ➤
2 Vehicle identification data
2.1 Type plate and vehicle identification number

The vehicle identification number -B- (chassis number) is stam‐
ped on the flange in the plenum chamber.
The type plate -A- is attached to the wing mounting flange (right-
side).
2 Rep. Gr.00 - Technical data

Audi TT 2007 ➤
2.2 Vehicle data sticker

The vehicle data sticker is located in the spare wheel well at the
rear of the vehicle.
2. Vehicle identification data 3

Audi TT 2007 ➤
3 Expanded foam inserts

Various body cavities of the Audi TT 2007 are fitted with expanded
foam inserts.
The foam inserts reduce the noise transmitted to the interior when
driving.
These pre-moulded parts are fitted during body manufacture and
subsequently increase their volume in the paint shop drying oven
at approx. 180 °C after priming.
Caution
The replacement foam inserts expand only after reaching

about 180°C. For this reason, an additional filler foam is used
when performing repairs.
Filler foam required for repairs: D 506 KG1 A3.
As the required temperatures cannot be achieved under normal

workshop conditions, proceed as follows:
Remove residue of foam material on vehicle.
Restore paint coating; apply two coats (wet on wet) of glass/paint
primer D 009 200 02 if necessary, flash-off time approx.10 mi‐
nutes.
Requirement
Before continuing with this procedure, ensure that the replace‐
ment panel is ready for installation, i.e. cut to shape, matched up
to the vehicle, corrosion protection applied.
Renewing expanded foam insert
Fix expanded foam insert to vehicle.
Apply filler foam D 506 KG1 A3 to replacement panel.
Secure new part in position. Gently press in new part in vicinity of
expanded foam insert until it makes contact, and then weld into
place.
The foam hardens within 25 minutes.
Do not weld (SG) within 15 mm of the foam insert (on either side).
After painting the vehicle the repaired area must be cavity-sealed.
Location of expanded foam parts

Audi TT 2007 ➤
3. Expanded foam inserts 5

Audi TT 2007 ➤
4 General notes on repairs to alumini‐

um parts
The repair methods required for the purely aluminium body parts
are similar to the established procedures for the other Audi mod‐
els with aluminium body.
New joining technique
Flow-drill screws
Flow-drill screws can be easily released in the workshop and re‐
placed with new screws. Oversize screws are available for dam‐
aged threads. New panels have to be pre-drilled to take these
screws.

Audi TT 2007 ➤
5 General notes on repairs to steel

parts
Note
We recommend that repairs should be performed in a specialist

Audi workshop for aluminium.
These repairs are essentially the same as for vehicles with an all-
steel body. However, special precautions are required due to the
risk of contact corrosion occurring on the aluminium parts of the
body. The dust produced when sanding or grinding steel parts,
and in particular sparks from cutting and welding operations, must
not be allowed to drop onto aluminium parts. This also applies to
painted aluminium panels. The glowing steel particles can dam‐
age the paint and come into contact with the aluminium, which
can cause contact corrosion on the undamaged aluminium body.
For these reasons, the entire body must be carefully protected
with suitable covers and masking while steel repairs are being
performed. Similarly, cutting operations may only be carried out
with mechanical tools (body saw or nibbler). Where sanding or
grinding is unavoidable, use non-sparking sanding/grinding discs
(or such that produce only a minimum amount of sparking).
5. General notes on repairs to steel parts 7

Audi TT 2007 ➤
6 Body construction
The Audi TT 2007 employs the ASF (Audi Space Frame) con‐
struction in an aluminium/steel body.
The repair methods are basically the same as the familiar alumi‐
nium repair methods, except that the combination of aluminium
and steel requires a number of new procedures.
This Workshop Manual describes standard repairs and repairs
carried out using repair methods which deviate from the original
manufacturing process.
Note the following for any repairs which are not described:
Separate at original joint; repair original joint using only genuine
replacement parts: see ⇒ General information; Body repairs,
General body repairs; Safety notes .
6.1 Aluminium panels

The areas of the body marked in grey - bonnet, plenum chamber,
front end and middle section - are made of aluminium.
⇒ Workshop Manual, General information; chapter on Work pro‐
cedures
Extra-high-strength body panels
Extra-high-strength body panels are used in the following areas:

The steel panels marked in yellow have a tensile strength of 340
– 500 N/mm2.
⇒ Workshop Manual, General information; chapter on Work pro‐
cedures

Audi TT 2007 ➤
6. Body construction 9
Audi TT 2007 ➤
7 Corrosion protection
The rear section of the body is manufactured from panels galvan‐
ised on both sides. Certain areas are cavity-sealed and have to
be re-sealed after completing repair work.

Audi TT 2007 ➤
8 Bonded joints
Bonded and spot-welded bonded joints are employed on the Audi
TT for increased body strength.
8.1 Bonded joints

In the case of adhesive-bonded joints, the joint between the sheet
metal parts is formed only by the adhesive.
8.2 Spot-welded/bonded joints

In spot welded bonded joints an electrically conductive adhesive
is used between the panels, which allows good root penetration
for spot welding.
The welding current must not be increased for spot-weld bonding
operations. The pre-press period must be extended to about 30
– 50 cycles because of the displacement of the adhesive. Always
use a fume extractor.
Spot-weld bonding is not carried out in the service sector.
8.3 Inspecting and repairing bonded joints

Particular attention should be given to these joints when diag‐
nosing accident damage and performing body repairs.
Note the following points: Do not use a chisel to test the strength
of a joint or relieve stresses by hammering as this will damage or
destroy the bonded joint.
These joints should be inspected particularly closely when diag‐
nosing accident damage and after performing straightening work
on the body.
If the joint is not accessible with pop rivets, it must be repaired
with an arc-welded seam (SG). In this case the entire area of the
joint must be re-welded, as the heat produced by welding de‐
stroys the adhesive in the bonded joint. The SG seams should be
welded working from the thin to the thick panel. Always use a fume
extractor.
8.4 Repair methods for replacing body parts

When making repairs, welded joints can be used in place of all
spot-welded bonded joints and certain bonded joints if no suitable
body adhesive is available.
Do not make the repair with only the same spot welds or seams
as originally used in production. These alone are not adequate
for a proper joint.
The repair methods are shown in detail on the following pages.
Note
♦ If the instructions call for additional spot welds, these should

be applied in a single operation.
♦ Do not place new spot welds in-between the original spot
welds.
♦ SG plug welding should only be performed after spot welding.
♦ This avoids any increased shunt current when spot welding.
Ensure good root penetration at all joints.

Seal off repaired joint flanges and apply cavity sealing.
8. Bonded joints 11
Audi TT 2007 ➤
9 Body panel gaps/shut lines

Special tools and workshop equipment required
♦ Setting gauge -3371-
9.1 Body - front and centre

♦ Dimension A = 4.5 mm ± 0.5 mm
♦ Dimension B = 4.5 mm ± 0.5 mm
♦ Dimension C = 3.5 mm ± 0.5 mm
♦ Dimension D = 3.5 mm ± 0.5 mm
♦ Dimension E = 3.5 mm ± 0.5 mm
♦ Dimension F = 3.5 mm ± 0.5 mm

Audi TT 2007 ➤
♦ Check that panel gaps are parallel with body lines
9.1.1 Body - rear

♦ Dimension A = 4.0 mm ± 0.5 mm
♦ Dimension B = 4.5 mm ± 0.5 mm
♦ Dimension C = 3.5 mm ± 0.5 mm
♦ Dimension D = 2.0 mm ± 0.5 mm
9. Body panel gaps/shut lines 13

Audi TT 2007 ➤
♦ Check that panel gaps are parallel with body lines

Audi TT 2007 ➤
10 Body dimensions
10.1 Floor group, front

Distance between rear attachment points of front suspension
-a- 836 ± 2 mm
Distance between front longitudinal members (front)
-b- 899 ± 2 mm
Distance between front attachment points of front suspension
-c- 873 ± 2 mm
Diagonal distance between front longitudinal member and attach‐
ment points of front suspension
-d- 1084 ± 2 mm
10. Body dimensions 15

Audi TT 2007 ➤
10.2 Floor group, rear

Distance between rear longitudinal members (rear)
-a- 978 ± 2 mm
Distance between rear longitudinal members (front)
-b- 980 ± 2 mm
Diagonal distance between longitudinal member (front) and lon‐
gitudinal member (rear)
-c- 1049 ± 2 mm

Audi TT 2007 ➤
10.3 Body - front

Distance between front longitudinal members
-a- 1018 ± 2 mm
Distance between suspension strut mountings

-b- 1129 ± 2 mm
Distance between wing panel mountings
-c- 1271 ± 2 mm
Diagonal distance between suspension strut mounting and wing
panel mounting
-d- 1317 ± 2 mm

Audi TT 2007 ➤

Audi TT 2007 ➤
10.4 Body - centre

Distance between A-pillars
-a- 1534 ± 2 mm
Height of door opening
-b- 935 ± 2 mm

Audi TT 2007 ➤
10.5 Body - rear

Distance between rear longitudinal members
-a- 1044 ± 2 mm
Distance between side panels
-b- 913 ± 2 mm
Distance between rear cross panel flange and roof flange
-c- 1269 ± 2 mm

Audi TT 2007 ➤
11 Straightening jig
11.1 Overview
Note
♦ The item numbers in the illustrations are identical with the end
numbers on the alignment bracket mountings.
♦ The item numbers of the alignment bracket mountings marked
with a circle are for checking the body with mechanical units
installed.
♦ Check the clearance of the alignment brackets before placing
them on the straightening jig. Any obstructing components
should be detached or removed.
♦ The required basic set size is given for the alignment bracket
mountings.
Alignment bracket set Audi TT -VAS 6384-
11. Straightening jig 21

Audi TT 2007 ➤
2 - MZ 142 and TV 400

3 - Spacer
4 - MZ 142 and alignment bracket mounting
6 - MZ 260
8 - MZ 602
10 - Spacer
12 - MZ 260
14 - MZ 140
16 - Left and right centring piece identical
18 - Bracket without MZ and alignment bracket
20 - MZ 140
22 - MZ 080
24 - MZ 080 and 22
25 - Spacer
26 - MZ 200
28 - MZ 602
30 - MZ 260
32 - MZ 200
Overview of alignment bracket positions with MZ elements for
vehicles with mechanical units installed
Overview of front alignment brackets

Audi TT 2007 ➤
2 - Front longitudinal member

When checking, bolt on MZ last, as the longitudinal position of the
impact absorber mounting can vary by several mm due to pro‐
duction tolerances - if necessary do not bolt down.
3 - Front longitudinal member / top of wheel housing
6 - Engine carrier mounting
7 - Engine carrier mounting

Audi TT 2007 ➤

Audi TT 2007 ➤
6 - Gearbox console

Audi TT 2007 ➤
7 - Engine console

Audi TT 2007 ➤

Audi TT 2007 ➤
8 - Suspension strut mounting

12 - Mounting for subframe
18 - Mounting for side member
Overview of centre alignment brackets

Audi TT 2007 ➤

Audi TT 2007 ➤
18 - Mounting for side member

19 - Spacer, identical on left and right sides

Audi TT 2007 ➤
20 - Mounting for propshaft

Audi TT 2007 ➤
22 -24 - Rear suspension strut mounting

Overview of rear alignment brackets

Audi TT 2007 ➤

Audi TT 2007 ➤
22 - Mounting for rear axle

24 - Spacer, identical on left and right sides
– Line up with holes as shown.
26 - Drilling in longitudinal member
28 - Suspension strut mounting
30 - Drilling in longitudinal member
32 - Mounting for rear longitudinal member
11.2 Portal gauge

Portal gauge supplement Audi TT/TT Roadster -VAS 5007/30-

Audi TT 2007 ➤
A - Extension
B - Telescopic column
C - Cross bar 1200 mm
1 - Mounting for A-pillar
5 - Mounting for B-pillar

Audi TT 2007 ➤
50 – Body - front
RO: 50 40 55 00
1 Longitudinal member, upper part with

console (Coupé and Roadster identi‐
cal)
WARNING
Always observe safety precautions.
Safety notes ⇒ General Information; Body Repairs, General Body

Repairs ; Safety notes .
1.1 Tools
♦ Compact angle grinder -VAS 5167-
♦ Pneumatic glue gun -V.A.G 2005 B-
♦ Shielded arc welding equipment 250A -VAS 6388-
36 Rep. Gr.50 - Body - front

Audi TT 2007 ➤
♦ Rechargeable riveter -VAS 5279A-
1.2 Procedure
Cutting locations
• Longitudinal member (bottom section) already removed
Engine console
– Separate original joint with rechargeable riveter -VAS 5279B- .
– Remove large punch rivets. Use rechargeable riveter -VAS
5279A- with attachments D13 and D14 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments D13 and
D14 .
– Remove small punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S1 and E2 from -VAS 5279/2 - or
rechargeable riveter -VAS 5279B- with attachments S1 and
E2 .
– Remove remaining material using compact angle grinder -
VAS 5167- .
1. Longitudinal member, upper part with console (Coupé and Roadster identical) 37
Audi TT 2007 ➤
Replacement part
♦ Engine console
♦ Body adhesive DA 001 730 A2
Preparing new part
– Prepare flanges on body and new parts for welding.
Welding in
– Fix new part in position with alignment bracket.
– Weld in engine console using shielded arc welding equipment
250A -VAS 6388- : SG continuous seam.
– Rivet in new part using rechargeable riveter -VAS 5279B- .
Countersink holes, working inwards from outside. Use recharge‐
able riveter -VAS 5279A- with attachments D15 and D16 from -
VAS 5279/2 - or rechargeable riveter -VAS 5279B- with
attachments D15 and D16 .

Audi TT 2007 ➤
– Weld in engine console using shielded arc welding equipment

Audi TT 2007 ➤
Gearbox console
– Separate original joint with rechargeable riveter -VAS 5279B- .

Audi TT 2007 ➤
Replacement part
♦ Gearbox console
Preparing new part
Welding in
– Fix new part in position with alignment bracket.
– Weld in gearbox console using shielded arc welding equip‐
ment 250A -VAS 6388- : SG continuous seam.
Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 50 22 55 50
2 Support, left-side - Renewal (Coupé

and Roadster identical)
WARNING

2.1 Tools
2. Support, left-side - Renewal (Coupé and Roadster identical) 43

Audi TT 2007 ➤
2.2 Procedure
Cutting locations
– Separate original joint with rechargeable riveter -VAS 5279A- .
D14 .
E2 .
VAS 5167- .
Replacement parts
♦ Punch rivet
♦ Support

Audi TT 2007 ➤
Preparing new part

Riveting in
– Rivet in support using rechargeable riveter -VAS 5279A- .
– Weld in support using shielded arc welding equipment 250A -
VAS 6388- : SG continuous seam.
2. Support, left-side - Renewal (Coupé and Roadster identical) 45

Audi TT 2007 ➤
RO: 50 22 55 50
3 Support, right-side - Renewal (Coupé

WARNING

3.1 Tools

Audi TT 2007 ➤
♦ Pneumatic sabre saw -V.A.G 1523A-
3.2 Procedure
Cutting locations
Note
Partial renewal is possible with the separating cut shown. Place

a backing plate of the same material behind the joint and make
SG continuous seam.

D14 .
E2 .
VAS 5167- .
3. Support, right-side - Renewal (Coupé and Roadster identical) 47

Audi TT 2007 ➤
Replacement parts
♦ Punch rivet
♦ Support
Preparing new part
Riveting in
– Rivet in support using rechargeable riveter -VAS 5279A- .
– Weld in support using shielded arc welding equipment 250A -
VAS 6388- : SG continuous seam.

Audi TT 2007 ➤
3. Support, right-side - Renewal (Coupé and Roadster identical) 49

Audi TT 2007 ➤
RO: 50 72 55 00
4 Upper longitudinal member for wheel

housing - Renewal (Coupé and
Roadster identical)
WARNING

4.1 Tools

Audi TT 2007 ➤
4.2 Procedure
Cutting locations
– Roughly cut out part using pneumatic sabre saw -V.A.G
1523A- .
D14 .
E2 .
VAS 5167- .
4. Upper longitudinal member for wheel housing - Renewal (Coupé and Roadster identical) 51
Audi TT 2007 ➤
Replacement parts
Note
Use a 4 mm aluminium solid rivet if pressing out the old rivets

created a hole.
Parts
♦ 3.35 x 5 mm punch rivet
♦ Upper wheel housing longitudinal member
Preparing new part
Riveting in
– Apply 2-component adhesive DA 001 730 A2 to entire riveting
area using pneumatic glue gun -V.A.G 2005 B- .
Riveting in new part
– Position new part and fix in place.

Audi TT 2007 ➤
Note
Holes must be stamped prior to riveting on.
Secure new part on bracket set.

– Rivet in new part using rechargeable riveter -VAS 5279A- .
Note
Use a 4 mm aluminium solid rivet if pressing out the old rivets created a hole.
– Secure to A-pillar with an M5 x 18 flange bolt.
4. Upper longitudinal member for wheel housing - Renewal (Coupé and Roadster identical) 53
Audi TT 2007 ➤
Note
♦ The new parts may not be provided with the holes for the bol‐
ted connections.
♦ In this case the new parts have to be drilled out for the bolted
connections.
Note
5.3 x 5 mm punch rivets were previously fitted in the area of the

suspension strut mounting. A stepped seam (stitch seam) must
be made here instead of the punch rivets.
– Make stepped seam (stitch seam) in area of suspension strut

mounting.

Audi TT 2007 ➤
RO: 50 74 55 50
5 Suspension strut mounting - Renew‐

al (Coupé and Roadster identical)
WARNING

5.1 Tools
5. Suspension strut mounting - Renewal (Coupé and Roadster identical) 55

Audi TT 2007 ➤
5.2 Procedure
Cutting locations
• Longitudinal member (top section) already removed
WARNING
Do not damage adjoining castings.
Note
Refer to General information on aluminium regarding punch rivets

with one-sided access.
– Make separating cut in plenum chamber flange using pneu‐

matic sabre saw -V.A.G 1523A- .
– Separate original joint at support for suspension strut mount‐
ing using rechargeable riveter -VAS 5279A- .
D14 .
E2 .

Audi TT 2007 ➤
Note
Refer to General information on aluminium regarding punch rivets with one-sided access.
– Separate punch rivet with one-sided access at A-pillar (inner).


Audi TT 2007 ➤
Replacement parts
♦ Pop rivets
♦ Punch rivets (self-piercing rivets)
♦ Suspension strut mounting
Note
Refer to General information on bonding.
Preparing new part

– Prepare flanges on body and new parts for riveting.
Welding in
– Fix new part on alignment bracket.

Audi TT 2007 ➤
Note
SG continuous weld seam can also be used in place of riveted

joints.
Riveting in
– Weld windscreen cross member to suspension strut mounting
using shielded arc welding equipment 250A -VAS 6388- : SG
continuous seam.
– Rivet suspension strut mounting to longitudinal member (top
section) using rechargeable riveter -VAS 5279A- .
– Rivet suspension strut mounting to longitudinal member using
rechargeable riveter -VAS 5279A- .
– Weld in new part using shielded arc welding equipment 250A
-VAS 6388- : SG continuous seam.

Audi TT 2007 ➤
– Weld in at separating cut on plenum chamber using shielded

arc welding equipment 250A -VAS 6388- : SG continuous
seam.
Rivet in remaining joint using rechargeable riveter -VAS 5279A- .


Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 50 52 55 50
6 Longitudinal member for wheel hous‐

ing, upper, inner - Renewal (Coupé
WARNING

6.1 Tools

Audi TT 2007 ➤
6.2 Procedure
Cutting locations
D14 .
E2 .
VAS 5167- .
Replacement part
♦ Upper wheel housing longitudinal member
6. Longitudinal member for wheel housing, upper, inner - Renewal (Coupé and Roadster identical) 63
Audi TT 2007 ➤
Note
Riveted/bonded joint can also be used in place of weld seam.
Welding in
– Weld in upper wheel housing longitudinal member using shiel‐
ded arc welding equipment 250A -VAS 6388- : SG continuous
seam.

Audi TT 2007 ➤
RO: 50 79 55 00
7 Front longitudinal member - Renewal

(Coupé and Roadster identical)
WARNING

7.1 Tools
7. Front longitudinal member - Renewal (Coupé and Roadster identical) 65

Audi TT 2007 ➤
7.2 Procedure
Cutting locations
– Separate original joint using compact angle grinder -VAS
5167- .
VAS 5167- .

5167- .
VAS 5167- .

Audi TT 2007 ➤
Replacement part
♦ Longitudinal member
Preparing new parts
Welding in
– Weld in longitudinal member using shielded arc welding equip‐

Audi TT 2007 ➤
– Weld in new part on bracket set using shielded arc welding

equipment 250A -VAS 6388- : SG continuous seam.
– Weld in connecting bracket using shielded arc welding equip‐
ment 250A -VAS 6388- ; re-establish original joint: SG contin‐
uous seam.

Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 50 79 55 02
8 Front longitudinal member - Partial

renewal (Coupé and Roadster iden‐
tical)
WARNING

8.1 Tools

Audi TT 2007 ➤
8.2 Procedure
Cutting locations
5167- .
VAS 5167- .
8. Front longitudinal member - Partial renewal (Coupé and Roadster identical) 71

Audi TT 2007 ➤
Replacement part
♦ Longitudinal member (bottom section): part section
Preparing new parts
Welding in
– Weld in longitudinal member at front using shielded arc weld‐
ing equipment 250A -VAS 6388- : SG continuous seam.

Audi TT 2007 ➤
RO: 50 80 55 00
9 Longitudinal member (front section) -

Renewal (Coupé and Roadster iden‐
tical)
WARNING

9.1 Tools
9. Longitudinal member (front section) - Renewal (Coupé and Roadster identical) 73

Audi TT 2007 ➤
9.2 Procedure
– Detach part.
WARNING
Take care not to damage aluminium node castings.
Replacement parts
♦ Front longitudinal member
♦ Connecting collar with bolts

Audi TT 2007 ➤
Bolting on
– Match length if necessary. Distance from node casting at least
1 mm.
Preparing new parts
Note
Threads must be free of paint and grease.
– Insert longitudinal member with connecting collar in node cast‐

ing.
Note
Align longitudinal member with bolted-on parts.
– Hand-tighten bolts.
– Tighten bolts 1 - 5. (Tightening torque 24 Nm).
– Seal joint between longitudinal member and node casting.
9. Longitudinal member (front section) - Renewal (Coupé and Roadster identical) 75

Audi TT 2007 ➤

Audi TT 2007 ➤
51 – Body - centre
RO: 51 03 55 00
1 Roof - Renewal
WARNING

1.1 Tools
♦ Drill -VAS 5830-
♦ Grinder -VAS 5170-

♦
1. Roof - Renewal 77
Audi TT 2007 ➤
♦ Tensioning strap -T10038-
1.2 Procedure
Cutting locations
– Roughly cut out roof using pneumatic sabre saw -V.A.G
1523A- .
D14 .
E2 .
– Carefully bend open half-sections of roof until brazed joint
breaks.
– Remove remaining material.
78 Rep. Gr.51 - Body - centre

Audi TT 2007 ➤
– Remove remaining material on roof frame using compact an‐

gle grinder -VAS 5167- .
Caution
Take care not to damage the roof frame when removing remain‐
ing material with the compact angle grinder -VAS 5167- .
Audi TT 2007 ➤
Replacement parts
♦ Roof
♦ 4 Clamping bolts
♦ Silicone remover LSE 020 100 A3
Note
♦ It is important to keep to the following procedure to ensure a

satisfactory and effective roof repair.
♦ Bonded areas must not be treated with filler coat before bond‐
ing in centre roof section.
Reference for dimensions A + B is edge of roof.

Dimension A = 311 mm
Dimension B = 571 mm
Dimension C = 11.3 mm from inner roof frame

Audi TT 2007 ➤
– Press out rivets at this location with rechargeable riveter -VAS

5279A- .
D14 .
E2 .
– Drill holes for roof support using drill -VAS 5830- , ∅6.5 mm.
Preparing new part

– Clean roof side members and new roof panel (replacement
part) with silicone remover LSE 020 100 A3.
Bonding in roof
– Mask off roof side members with adhesive tape at joint with
roof panel to avoid unnecessary sanding.
– Mask off replacement roof panel with adhesive tape at joint
with roof side members to avoid unnecessary sanding.
Audi TT 2007 ➤
– Apply body adhesive -DA 001 730 A2- to roof cross members
at front and rear.
– Prepare adhesive cartridges required for bonding.

– Cut static mixer from body adhesive set -DA 001 730 A2- down
to 4th notch to obtain required bead cross-section.
– Apply adhesive beads to roof side members with pneumatic

glue gun -V.A.G 2005 B- .

Audi TT 2007 ➤
– Tension two tensioning straps -T10038- across the roof.

– Use a plastic wedge to obtain the required depth.
Note
To avoid damage to the centre roof section or side panel frame, the tensioning straps should not be too tight.
Audi TT 2007 ➤
– Rivet in roof at front using rechargeable riveter -VAS 5279A- .


Audi TT 2007 ➤
– Rivet in roof at rear using rechargeable riveter -VAS 5279A- .

Audi TT 2007 ➤
Note
♦ After completing the riveted joint, the vehicle must be left

standing for 8 hours on a level surface at a room temperature
of 15° C to allow the adhesive components to harden (curing
time).
♦ Do not continue working on the vehicle until the curing time
has elapsed.
Fit roof support in pre-drilled holes.

Audi TT 2007 ➤
Audi TT 2007 ➤
RO: 51 35 55 00
2 Roof side member - Renewal
WARNING

The repair “Foam-filling roof side member” must be entered in the
Service record section of the Service Schedule under Workshop
remarks.
2.1 Tools
WARNING
When renewing the roof side member, a structural foam must

be applied on vehicles up to chassis number
TRUZZZ8JZ81044000 to provide reinforcement for a roof car‐
rier.
It is important to keep exactly to the specified sequence.
Note
♦ After applying the foam fill, the vehicle must be left standing
on a flat surface for 24 hours at a room temperature of 15° C
to allow the epoxy hard foam to harden (curing time).
has elapsed.


Audi TT 2007 ➤
2.2 Procedure
Left roof side member foam-filled: yes / no
Right roof side member foam-filled: yes / no
Cutting locations
D14 .
E2 .
– Make separating cuts using pneumatic sabre saw -V.A.G
1523A- .
2. Roof side member - Renewal 89

Audi TT 2007 ➤
Replacement part
♦ Roof side member (sub-part)
Preparing new part
Prepare new part for riveting.
Riveting in
– Rivet in roof side member using rechargeable riveter -VAS
5279A- .
– Weld in roof side member using shielded arc welding equip‐

Audi TT 2007 ➤
2.3 Foam-filling roof side member
2.3.1 Procedure
The repair “Foam-filling roof side member” must be entered in the
Service record section of the Service Schedule under Workshop
remarks.
Left roof side member foam-filled: yes / no
Right roof side member foam-filled: yes / no
Note
♦ After riveting in, the vehicle must be left standing on a flat sur‐
face for 24 hours at a room temperature of 15° C to allow the
bonded components to harden (curing time).
has elapsed.

Audi TT 2007 ➤
Note
The instructions listed here apply to the left side of the vehicle.
The procedure for the right side is similar.
It is important to keep exactly to the procedure as described:

Heat the cartridge of structural foam material for 30 minutes in a
water bath at a constant temperature of approx. 60 °C.
The cartridge can also be heated at 60° C in a suitable oven, if
available.
Remove inner A-pillar trim.
Remove roof trim strips.
Mask rivet holes with commercially available adhesive tape.
Prepare static mixer for foaming operation.
Fill holes with foam and then immediately re-fit bolts.
Install inner A-pillar trim.
Install roof trim strips.
Replacement parts
♦ 4 x 2-component epoxy hard foam -D 506 110 A2-
♦ 22x pop rivet N 910 197 01
♦ Removal wedge -3409-
♦ Hand-cartridge gun -V.A.G 1628-

Audi TT 2007 ➤
♦ Pop rivet pliers -VAS 5072-
– Heat the cartridge of structural foam material for 30 minutes in

a water bath at a constant temperature of approx. 60 °C.
The cartridge can also be heated at 60° C in a suitable oven, if
available.
1 - Cartridge of 2-component
structural foam material
– Open cap.
2 - Static mixer
3 - Extension hose
4 - Adapter
Note
5 - Union nut
– Screw onto structural
foam cartridge -1- to‐
gether with static mixer
-2-.
Removing upper A-pillar trim


Audi TT 2007 ➤
♦ Removal wedge -3409-
Removing
– Unclip C-pillar trim -1- in area adjacent to upper A-pillar trim
-2-.
– Starting at top, unclip upper A-pillar trim -2- using removal
wedge -3409- .
– Lift out upper A-pillar trim -2-.
Installing
Install in reverse sequence. Note the following:
Note
♦ If any trim clips remain seated in the body mounting points,

they should be removed and re-fitted in the trim.
♦ Check the clips for damage or deformation and renew if nec‐
essary.
– Start by inserting upper A-pillar trim -1- in ribbed section of

dash panel -2- in direction of -arrow-.
– Clip upper A-pillar trim -2- into place and fold lip of door seal
-3- over upper A-pillar trim -2-.
Removing roof trim strip

Audi TT 2007 ➤
Note
Removal of the roof trim strip does not involve removing the side window.
1 - Roof trim strip
Note
– Detach door seals from

body flange in area ad‐
jacent to roof trim strip.
– Drill off heads of pop riv‐

ets, knock out rivets and
detach roof trim strip.
❑ Carefully prise roof trim
strip out of retaining
clips and detach.
2 - Pop rivet
❑ 11x
3 - Side panel
4 - Retaining clip
❑ 4x
End piece for roof trim strip

– When fitting, first slide roof trim strip -1- into moulding on side
window and then press into retaining clip -2-.

Audi TT 2007 ➤
2.3.2 Injecting structural foam
Note
Use 1 static mixer tube for all 4 openings.
Remove screws -b- from roof side member.

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

Audi TT 2007 ➤
1 - Remove hose -3- (supplied

with cartridge) from nozzle.
2 - Screw nozzle -4- into static
mixer tube -2-.
– Apply hand cartridge gun -V.A.G 1628- perpendicular to roof

side member.

Audi TT 2007 ➤
– Inject the contents of one 2-component epoxy hard foam car‐

tridge into each bolt hole.

Audi TT 2007 ➤

Audi TT 2007 ➤
1 - Re-fit bolts immediately af‐

ter filling with foam.

Audi TT 2007 ➤
1 - After filling, rivet in roof trim

strip using pop rivet pliers -
VAS 5072- .
Note
♦ After riveting in, the vehicle must be left standing on a flat sur‐
face for 24 hours at a room temperature of 15° C to allow the
bonded components to harden (curing time).
has elapsed.

Audi TT 2007 ➤
RO: 51 06 55 00
3 Outer roof frame - Renewal (Road‐

ster)
WARNING

3.1 Tools

Audi TT 2007 ➤
3.2 Procedure
Cutting locations
D14 .
E2 .
Replacement part
♦ Outer roof frame
3. Outer roof frame - Renewal (Roadster) 103

Audi TT 2007 ➤
Preparing new part

– Use a brush to apply aluminium primer DA 009 801 to bonding
locations.
area.
Riveting in
Rivet in roof frame at front using rechargeable riveter -VAS
5279A- .

Audi TT 2007 ➤
Rivet in roof frame using rechargeable riveter -VAS 5279A- .

3. Outer roof frame - Renewal (Roadster) 105

Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 51 07 55 50
4 Front roof cross member - Renewal
WARNING

4.1 Tools
4.2 Procedure
Cutting locations
• Roof already removed
– Roughly cut out cross member using pneumatic sabre saw -
V.A.G 1523A- .
D14 .
E2 .
– Remove remaining material.
4. Front roof cross member - Renewal 107

Audi TT 2007 ➤
Replacement parts
♦ Roof cross member
locations.
area.
Riveting in
– Match up and fix new part in position.
– Rivet in roof cross member using rechargeable riveter -VAS
5279A- .

Audi TT 2007 ➤
4. Front roof cross member - Renewal 109

Audi TT 2007 ➤
RO: 51 09 55 50
5 Rear roof frame - Renewal
WARNING

5.1 Tools
5.2 Procedure
Cutting locations
• Roof already removed
D14 .
E2 .
– Roughly cut out rear roof frame using pneumatic sabre saw -
V.A.G 1523A- .
VAS 5167- .

Audi TT 2007 ➤
Replacement parts
♦ Roof frame
5. Rear roof frame - Renewal 111

Audi TT 2007 ➤

locations.
area.
Riveting in
– Match up and fix new part in position.
– Rivet in roof frame using rechargeable riveter -VAS 5279A- .

Audi TT 2007 ➤
5. Rear roof frame - Renewal 113

Audi TT 2007 ➤
RO: 51 37 55 00
6 Outer A-pillar - Renewal
WARNING

6.1 Tools
♦ Laser weld seam grinder -VAS 6319-

♦ When using the rechargeable riveter -VAS 5279A- , the at‐
tachment set -VAS 5279/2 - is also required.

Audi TT 2007 ➤
♦ Alternatively, you can use the new rechargeable riveter -VAS

5279B- . This is a complete set.
6.2 Procedure
Cutting locations
D14 .
E2 .
VAS 5167- .
6. Outer A-pillar - Renewal 115

Audi TT 2007 ➤

D14 .
E2 .
– Make separating cuts as shown using pneumatic sabre saw -
V.A.G 1523A- .
VAS 5167- .
– Grind open laser weld seams in area around side member us‐
ing laser weld seam grinder -VAS 6319- .

Audi TT 2007 ➤
– Carefully separate A-pillar from vehicle using a flat chisel.

– Take A-pillar out of vehicle.
Caution
Avoid making excessively deep cuts. Components remaining

in the vehicle could otherwise be damaged or broken off.
Preparing new part

– With no load on vehicle, position and match up new part and
clamp in place.
– Detach new part.
– Grind new part down to bare metal in welding area.
– Clean new part.
Preparing body
– Grind body down to bare metal in welding area.
– Make weld pool backing and insert at cutting locations.

Audi TT 2007 ➤
Inserting new part

– Prepare bonding area with silicate stone DA 009 800 and
clean.
locations.
area and wheel housing.
– Position new part and fix in place with portal gauge.
– Working outwards, make suitable 5 mm holes in area of alu‐
minium solid rivets.
– Countersink holes, working inwards from outside. Use re‐
chargeable riveter -VAS 5279A- with attachments D15 and
D16 from -VAS 5279/2 - or rechargeable riveter -VAS 5279B-
with attachments D15 and D16 .
– Flatten riveting areas. Use rechargeable riveter -VAS 5279A-
with attachments D8 or D17 from -VAS 5279/2 - or recharge‐
able riveter -VAS 5279B- with attachments D8 or D17 .
Riveting on new part -arrows- with 6 x 12 mm solid rivets

Audi TT 2007 ➤

Caution
If the roof frame is also being renewed, repair work is per‐

formed entirely with 5.3 x 7.5 punch rivets.
Welding in new part

– Weld in at separating cuts using shielded arc welding equip‐

Audi TT 2007 ➤
– Weld in A-pillar using shielded arc welding equipment 250A -

VAS 6388- : SG continuous seam (staggered - with gaps).

Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 51 38 55 50
7 Reinforcement tube and inner A-pillar

- Renewal (Roadster)
WARNING

7.1 Tools

Audi TT 2007 ➤
7.2 Procedure
Cutting locations
• Outer roof frame already removed
• Inner roof frame already removed
• Outer A-pillar already removed
• Wing mounting flange already removed
– Grind down weld seams using grinder -VAS 5170- .
D14 .
E2 .
– Remove remaining material using grinder -VAS 5170- .
7. Reinforcement tube and inner A-pillar - Renewal (Roadster) 123

Audi TT 2007 ➤
Replacement part
♦ A-pillar with reinforcement tube

Audi TT 2007 ➤
Preparing new part

– Prepare new part for riveting and welding.
Welding in
Fix A-pillar on portal gauge.

Audi TT 2007 ➤
Riveting in

Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 51 38 55 50
8 Inner A-pillar - Renewal (Coupé and

Roadster)
WARNING

8.1 Tools

Audi TT 2007 ➤
8.2 Procedure
Cutting locations
• Outer A-pillar already cut out.
• Longitudinal member (top section) already removed
Remove large punch rivets. Use rechargeable riveter -VAS
D14 .
Remove small punch rivets. Use rechargeable riveter -VAS
5279A- with attachments S1 and E2 from -VAS 5279/2 - or re‐
chargeable riveter -VAS 5279B- with attachments S1 and E2 .
– Knock out bolts from outside.
8. Inner A-pillar - Renewal (Coupé and Roadster) 129

Audi TT 2007 ➤
Replacement part
♦ Inner A-pillar
Preparing new part
Drill holes for rivets using drill -VAS 5830- .

Audi TT 2007 ➤
Reinforcement for inner A-pillar: prepare elongated holes for SG

continuous seam.

Audi TT 2007 ➤
Weld in inner A-pillar at A-pillar reinforcement using shielded arc

welding equipment 250A -VAS 6388- : SG continuous seam.
– Fit pop rivet nuts (M5) in bolt holes.

Audi TT 2007 ➤
Riveting in
Rivet in new part using rechargeable riveter -VAS 5279A- .

Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 51 42 55 50
9 Inner B-pillar - Renewal (Roadster)
WARNING

9.1 Tools
9. Inner B-pillar - Renewal (Roadster) 135

Audi TT 2007 ➤
9.2 Procedure
Cutting locations
• Side panel already removed
– Roughly cut out B-pillar using pneumatic sabre saw -V.A.G
1523A- .
D14 .
– Separate weld seams using compact angle grinder -VAS
5167- .
– Detach part.

Audi TT 2007 ➤

VAS 5167- .

Audi TT 2007 ➤
Replacement part
♦ B-pillar
♦ Pop rivets
♦ Punch riveting
Preparing new part
– Drill holes for rivets using drill -VAS 5830- .

Audi TT 2007 ➤
Riveting in
– Rivet in new part.
Note
Rivet in new part with 4.8 x 9 mm aluminium pop rivets.


Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 51 45 55 00
10 Outer side member - Renewal
WARNING

10.1 Tools

♦ When using the rechargeable riveter -VAS 5279A- , the at‐
tachment set -VAS 5279/2 - is also required.
10. Outer side member - Renewal 141

Audi TT 2007 ➤

10.2 Procedure
Cutting locations
D14 .
E2 .
Note
♦ For inaccessible locations use C-bracket from rechargeable

riveter -VAS 5279A- or rechargeable riveter -VAS 5279B- .
♦ Move the C-bracket into position before fitting the extension.

Audi TT 2007 ➤
– Mark out and make separating cuts using pneumatic sabre

saw -V.A.G 1523A- .
Caution

– Carefully separate side member from vehicle using flat chisel.
– Take side member off vehicle.
Welding in new part
Rivet in new part with 6 x 12 mm aluminium rivets.
Note
♦ The standard rivets are replaced with 12 mm solid rivets.

♦ At the A-pillar the two cast shells are additionally joined with
two punch rivets before fitting the side member.

Audi TT 2007 ➤
Preparing new part

clamp in place.
– Transfer cutting lines from new part to body and mark.
Note
This prevents a gap forming between the two components.

– Clean new part.
– Make final separating cuts on body as previously marked.
Caution


Audi TT 2007 ➤
Preparing body
– Make backing plate of same material and insert at cutting lo‐
cations.
Inserting new part
Note
At the A-pillar the two cast shells are additionally joined with two
punch rivets before fitting the side member.

locations.
Rivet in new part with 6 x 12 mm aluminium rivets.

Audi TT 2007 ➤
Note
At the A-pillar the two cast shells are additionally joined with two
punch rivets before fitting the side member.
Note
Countersink the holes.
Note


Audi TT 2007 ➤
Welding in new part
Note
As an alternative to welding, rivet on the new part at the separat‐

ing cuts with 4.8 x 9 mm aluminium pop rivets.
WARNING
The body consists of a combination of steel and aluminium

panels. In areas where the two materials meet, the aluminium
parts must be carefully covered and protected when welding.
This prevents contact corrosion caused by weld spatter and
dust particles on the aluminium sections.
Note
As an alternative to welding, rivet on the new part at the separat‐

ing cuts with 4.8 x 9 mm aluminium pop rivets.
Making stepped seam (stitch seam) in area of side member

– Weld in new part at separating cuts using shielded arc welding

Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 51 47 55 50
11 Inner side member - Partial renewal

(old part section)
WARNING

11.1 Tools
11. Inner side member - Partial renewal (old part section) 149
Audi TT 2007 ➤
11.2 Procedure
Cutting locations
• Outer side member already removed
V.A.G 1523A- .

V.A.G 1523A- .

Audi TT 2007 ➤
– Prepare sub-part for welding.

Replacement part
♦ 2-component body adhesive -DA 180 A00 A2-
♦ Inner side member (sub-part)
– Apply 2-component adhesive -DA 180 A00 A2- using pneu‐
matic glue gun -V.A.G 2005 B- .
Audi TT 2007 ➤
Welding in
– Weld in inner side member (sub-part) using shielded arc weld‐

Audi TT 2007 ➤
Audi TT 2007 ➤
RO: 51 47 55 50
12 Inner side member - Renewal (Road‐

ster)
WARNING

12.1 Tools

Audi TT 2007 ➤
12.2 Procedure
Cutting locations
• Outer side member already removed
• Outer A-pillar already removed
• Inner A-pillar already removed
• Inner floor panel already removed
• Outer floor panel already removed
• Side panel already removed
• B-pillar already removed
– Separate original joint at side member using grinder -VAS
5170- .
12. Inner side member - Renewal (Roadster) 155

Audi TT 2007 ➤
– Separate original joint at inner side member using grinder -

VAS 5170- .

Audi TT 2007 ➤

VAS 5170- .

Audi TT 2007 ➤

VAS 5170- .

Audi TT 2007 ➤
– Detach part.

Audi TT 2007 ➤
Replacement part
♦ Side member
Welding in
• Fix new part on alignment bracket.
– Weld in lower inner side member using shielded arc welding

Audi TT 2007 ➤


Audi TT 2007 ➤


Audi TT 2007 ➤


Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 51 73 55 00
13 Floor panel - Renewal (Coupé and

Roadster identical)
WARNING

13.1 Tools
– Detach bolted joints.
13. Floor panel - Renewal (Coupé and Roadster identical) 165

Audi TT 2007 ➤
Replacement part
♦ Front floor panel
Installing
Match up and fix new part in position.
– Secure new part with screws (torque: 8 Nm).

Audi TT 2007 ➤
13. Floor panel - Renewal (Coupé and Roadster identical) 167

Audi TT 2007 ➤
53 – Body - rear
RO: 53 05 55 00
1 Rear cross panel (top section) - Re‐

newal (Coupé and Roadster identi‐
cal)
WARNING

1.1 Tools
♦ Resistance spot welder -VAS 6239 A- or
♦ Resistance spot welder -VAS 6525- or
♦ Resistance spot welder -VAS 6545-
♦ Shielded arc welding equipment 250A -VAS 6045A-
♦ Spot weld breaker -V.A.G 1731-
168 Rep. Gr.53 - Body - rear

Audi TT 2007 ➤
1.2 Procedure
Cutting locations
Note
Protect adjacent aluminium parts adequately against sparks from

welding and grinding operations; cover up or mask with adhesive
tape as necessary.
– A - Detach riveted joint at rain channel using rechargeable riv‐

eter -VAS 5279A- .
D14 .
– Separate original joint using spot weld breaker -V.A.G 1731- .
– Detach part.
1. Rear cross panel (top section) - Renewal (Coupé and Roadster identical) 169
Audi TT 2007 ➤
Note
Partial renewal is possible with the separating cuts illustrated. SG

continuous butt weld in the separated area.
Replacement part
♦ Rear cross panel, top section
Preparing new part
Drill 7 mm ∅ holes for SG plug weld seam.
Welding in
– Weld in cross panel using resistance spot welder -VAS 6239
A- : RP spot weld seam.
– Weld in cross panel using shielded arc welding equipment
250A -VAS 6045A- : SG plug weld seam.

Audi TT 2007 ➤
Riveting in
– Rivet in cross panel at rain channel using rechargeable riveter
-VAS 5279A- .
– Use rechargeable riveter -VAS 5279A- with attachments D17
and D17 from -VAS 5279/2 - or rechargeable riveter -VAS
5279B- with attachments D17 and D17 .
1. Rear cross panel (top section) - Renewal (Coupé and Roadster identical) 171
Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 53 09 55 50
2 Cross panel (inner section) - Renew‐

al (Coupé and Roadster identical)
WARNING

2.1 Tools
♦ Resistance spot welder -VAS 6239 A-
2.2 Procedure
Cutting locations
• Top section of cross panel already removed
2. Cross panel (inner section) - Renewal (Coupé and Roadster identical) 173
Audi TT 2007 ➤
Note

tape as necessary.
Partial renewal is possible with the separating cuts illustrated.

Replacement part
♦ Cross panel (inner section)
Welding in
– Weld at separating cuts using shielded arc welding equipment
250A -VAS 6045A- : SG continuous seam.

Audi TT 2007 ➤
– Weld in cross panel using resistance spot welder -VAS 6239

A- : RP spot weld seam.
2. Cross panel (inner section) - Renewal (Coupé and Roadster identical) 175
Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 53 14 55 50
3 Rain channel - Partial renewal
WARNING

3.1 Tools
3. Rain channel - Partial renewal 177

Audi TT 2007 ➤
3.2 Procedure
Cutting locations
Note

tape as necessary.

D14 .
V.A.G 1523A- .

Audi TT 2007 ➤

V.A.G 1523A- .

Audi TT 2007 ➤
Replacement part
♦ Metal insert for tail light
♦ Rain channel
♦ Rain channel reinforcement
Preparing new part
– Prepare new parts for bonding and welding.
Welding in
– Weld in rain channel using shielded arc welding equipment
– Weld in metal insert for tail light using shielded arc welding

Audi TT 2007 ➤
– Weld in rain channel reinforcement using shielded arc welding


Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 53 42 55 00
4 Rear suspension strut mounting - Re‐

cal)
WARNING

4.1 Tools
4. Rear suspension strut mounting - Renewal (Coupé and Roadster identical) 183
Audi TT 2007 ➤
4.2 Procedure
Cutting locations
Note

tape as necessary.

VAS 5167- .
Replacement part
♦ Rear suspension strut mounting
Welding in
– Weld in suspension strut mounting using shielded arc welding
equipment 250A -VAS 6045A- : SG continuous seam.

Audi TT 2007 ➤
– Weld in suspension strut mounting using resistance spot weld‐

er : RP spot weld seam.
4. Rear suspension strut mounting - Renewal (Coupé and Roadster identical) 185
Audi TT 2007 ➤
RO: 53 48 55 52
5 Rear longitudinal member - Partial re‐

cal)
WARNING

5.1 Tools
♦ Resistance spot welder -VAS 6239 A- or
5.2 Procedure
Cutting locations
• Rear cross panel sections and mounting plate already re‐
moved
– Cut out part section of longitudinal member using pneumatic
sabre saw -V.A.G 1523A- .

Audi TT 2007 ➤
Replacement part
♦ Longitudinal member part section
Welding in
– Locate and secure section of longitudinal member on align‐
ment bracket.
– Butt weld longitudinal member using shielded arc welding
equipment 250A -VAS 6045A- : SG continuous seam.
5. Rear longitudinal member - Partial renewal (Coupé and Roadster identical) 187
Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 53 55 55 00
6 Side panel - Renewal (Coupé)

Includes rain channel and tail light mounting.
WARNING

6.1 Tools
6. Side panel - Renewal (Coupé) 189

Audi TT 2007 ➤

6.2 Procedure
Cutting locations
WARNING

parts must be carefully covered and protected when grinding,
sawing, and welding etc. This prevents contact corrosion
caused by weld spatter and dust particles on the aluminium
sections.
Cutting locations
Note
Before deciding on the location of the separating cuts, measure

the replacement part to make sure it will fit in the body after re‐
moving the old part.
– Transfer separating cut to new part and cut to size using pneu‐

Audi TT 2007 ➤
Cutting locations at rear side panel

– Transfer separating cut to new part and cut to size using pneu‐

Audi TT 2007 ➤
Cutting locations
D14 .
E2 .
Note

Caution


Audi TT 2007 ➤
Note
Lubricate the blade of the pneumatic sabre saw -V.A.G 1523A-

with a cleaning block DA 009 802. This prevents clogging of the
saw teeth with aluminium.
– Mark separating cut approx. 80 mm -A- below edge of roof to

avoid damaging inner reinforcement.
– Grind through flanged seam of wheel arch using compact an‐
gle grinder -VAS 5167- .
Note
Apply adhesive tape parallel to marking to obtain a perpendicular separating cut.
– Make separating cut below edge of roof using pneumatic sa‐

bre saw -V.A.G 1523A- to avoid damaging inner reinforce‐
ment.

Audi TT 2007 ➤
Note
In the area of the internal foam inserts, heat the body with a hot air blower for 2 to 5 minutes to facilitate
separation from the side panel.
– Carefully separate side panel from vehicle using a flat chisel.

– Take side panel off vehicle.
VAS 5167- .
Preparing new part

– Mark out and make separating cuts using pneumatic sabre
saw -V.A.G 1523A- .
– Apply body adhesive DA 001 730 A1 in area of wheel housing
using pneumatic glue gun -V.A.G 2005 B- .

Audi TT 2007 ➤
Riveting in
WARNING

parts must be carefully covered and protected when grinding,
sawing, and welding etc. This prevents contact corrosion
caused by weld spatter and dust particles on the aluminium
sections.
Note
The standard rivets are replaced with 10 mm solid rivets.
– Rivet on new part in area of side panel with 6 x 10 mm solid

rivets -arrows-.
– Rivet on new part in area of side member and A-pillar with 6 x
12 mm solid rivets -arrows-.

Audi TT 2007 ➤
Preparing body
– Grind body down to bare metal in welding area.
– Make weld pool backing and insert at cutting locations.
Inserting new part
clamp in place.
– Screw in securing nut for rear lid damper.

Audi TT 2007 ➤
Riveting in new part

locations.
– Apply 2-component filler foam D 506 KG1 A3 to remaining
material of expanded foam inserts.
Note
Always fit the expanded foam inserts and apply the 2-component
filler foam D 506 KG1 A3 before welding in.
• Locate and secure side panel on portal gauge.
Note

– Rivet on new part with 6 x 10 mm solid rivets -arrows-.

– Use rechargeable riveter -VAS 5279A- with attachments D17
and D17 from -VAS 5279/2 - or rechargeable riveter -VAS
5279B- with attachments D17 and D17 .

Audi TT 2007 ➤
Note
Always remove adhesive residue from the riveter attachment.
Note

Note
♦ Use new 3.35 x 4 mm punch rivets at intact holes in the rear

lid area.
♦ Use a 4 mm aluminium solid rivet if pressing out the old rivets
created a hole.
– Rivet in rain channel using rechargeable riveter -VAS 5279A- :

3.35 x 4 mm punch rivets.

Audi TT 2007 ➤
Welding in
WARNING

Note
Always fit the expanded foam inserts and apply the 2-component
filler foam D 506 KG1 A3 before welding in ⇒ page 4 . ⇒ page 4
– Weld in side panel at separating cuts using shielded arc weld‐

Weld in joint between side panel and side member using shielded
arc welding equipment 250A -VAS 6388- : SG stepped seam
(stitch seam) -arrow-.

Audi TT 2007 ➤
– Weld in components at rear end -arrow- using resistance spot

welder -VAS 6239 A- : RP spot weld seam.
– Rivet in rain channel using rechargeable riveter -VAS 5279A-
with attachments D17 and D17 from -VAS 5279/2 - or re‐
chargeable riveter -VAS 5279B- with attachments D17 and
D17 .

Audi TT 2007 ➤
– Bead over wheel housing flange using fold crimping tool -

V.A.G 1585- .
Note
After beading over the flange, spread the emerging 2-component adhesive to make a good seal.

Audi TT 2007 ➤
RO: 53 55 55 00
7 Side panel - Renewal (Roadster)

Includes rain channel and tail light mounting.
WARNING

WARNING

7.1 Tools

Audi TT 2007 ➤
7.2 Procedure
Cutting locations
– Roughly cut out side panel using pneumatic sabre saw -V.A.G
1523A- .
– Grind through outer edge of side panel (top) using compact
angle grinder -VAS 5167- .
– Grind through outer edge of wheel arch using compact angle
grinder -VAS 5167- .
– Take care not to damage inner reinforcement when making
separating cut in sill.
D14 .
7. Side panel - Renewal (Roadster) 203

Audi TT 2007 ➤

D14 .
– Detach part.
VAS 5167- .

Audi TT 2007 ➤
Replacement parts
♦ Side panel (sub-part)
Preparing new part
– Transfer separating cut to new part using pneumatic sabre
saw -V.A.G 1523A- .
– Clean beaded flange (it must be free of dust and grease).

Audi TT 2007 ➤
Note
Expanded foam inserts must be fitted before welding. Refer to

section on expanded foam inserts ⇒ page 4 .
Welding in
locations.
area and wheel housing using pneumatic glue gun -V.A.G
2005 B- .
– Apply adhesive to beaded flange. Two beads of adhesive:
3.5 mm diameter.
– Bead over wheel arch flange. Wipe off emerging adhesive and
seal joint.
– Bead over side panel flange. Wipe off emerging adhesive and
seal joint.

Audi TT 2007 ➤
• Locate and secure side panel on portal gauge.

– Align side panel with no load on vehicle and check panel gaps.
– Weld in at separating cut using shielded arc welding equip‐

Audi TT 2007 ➤
Riveting in
– Rivet in side panel using rechargeable riveter -VAS 5279A- .

Audi TT 2007 ➤
– Rivet in rain channel using rechargeable riveter -VAS 5279A- .


Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 53 65 55 50
8 Inner side panel - Renewal
WARNING

8.1 Tools
8. Inner side panel - Renewal 211

Audi TT 2007 ➤
8.2 Procedure
Cutting locations
• Outer side panel already removed
• Side panel reinforcement already removed
Note

tape as necessary.

D14 .
– Detach part.

Audi TT 2007 ➤
Make separating cuts as required.

D14 .
– Detach part.
VAS 5167- .

Audi TT 2007 ➤
Replacement parts
♦ Inner side panel
♦ Inner side panel reinforcement
Preparing new part
– Prepare new parts for bonding
locations.
area using pneumatic glue gun -V.A.G 2005 B- .
Riveting in
– Align side panel with no load on vehicle and check panel gaps.

Audi TT 2007 ➤
– Re-secure bolted joints.


Audi TT 2007 ➤

Audi TT 2007 ➤
RO: 53 69 55 52
9 Rear wheel housing - Partial renewal

WARNING

Note

tape as necessary.
9.1 Tools
♦ Pneumatic punch and offset tool -VAS 1996-
9. Rear wheel housing - Partial renewal (Coupé and Roadster identical) 217
Audi TT 2007 ➤
9.2 Procedure
Cutting locations
• Side panel already cut out
– Make separating cut with pneumatic sabre saw -V.A.G 1523A-
so that body side of joint can be prepared for joddle-joining.
– Make separating cut from below so that inner side panel does
not have to be drilled out.

Audi TT 2007 ➤
Replacement part
♦ Wheel housing liner
Preparing new part
– Prepare joint on body side for joddle-joining using pneumatic
punch and offset tool -VAS 1996- .
– Transfer separating cut to new part plus 15 mm for overlap.
Cut off hatched area.
– Drill holes for SG plug weld seam using drill -VAS 5830- .
Audi TT 2007 ➤
Welding in
-VAS 6045A- : SG continuous seam.
– Weld in new part from inside using shielded arc welding equip‐
ment 250A -VAS 6045A- : SG plug weld seam.

Audi TT 2007 ➤
Audi TT 2007 ➤
RO: 53 69 55 52
10 Rear wheel housing - Renewal

WARNING

10.1 Tools
10.2 Procedure
Cutting locations
• Outer side panel already cut out.
• Inner side panel already cut out.

Audi TT 2007 ➤
Note

tape as necessary.
Replacement part
♦ Wheel housing liner
Preparing new part
– Drill holes for SG plug weld seam using spot weld breaker -
V.A.G 1731- .
10. Rear wheel housing - Renewal (Coupé and Roadster identical) 223
Audi TT 2007 ➤
Welding in
– Weld in wheel housing liner using resistance spot welder -VAS
6239 A- : RP spot weld seam.
– Weld in wheel housing liner using shielded arc welding equip‐

Audi TT 2007 ➤
10. Rear wheel housing - Renewal (Coupé and Roadster identical) 225
Audi TT 2007 ➤
RO: 53 80 55 50
11 Spare wheel well - Partial renewal

WARNING

Note

tape as necessary.
11.1 Tools
♦ Pneumatic punch and offset tool -VAS 1996-

Audi TT 2007 ➤
11.2 Procedure
Cutting locations
• Outer section of cross panel already cut out
• Inner section of cross panel already cut out
– Make separating cut with pneumatic sabre saw -V.A.G 1523A-
so that body side of joint can be prepared for joddle-joining.
11. Spare wheel well - Partial renewal (Coupé and Roadster identical) 227
Audi TT 2007 ➤
Replacement part
♦ Spare wheel well
Preparing new part
– Prepare joint on body side for joddle-joining using pneumatic
punch and offset tool -VAS 1996- .
– Transfer separating cut plus 15 mm for overlap to new part.
– Drill 7 mm ∅ holes for SG plug weld seam using drill -VAS
5830- .
Welding in
– Weld in spare wheel well using shielded arc welding equip‐
– Weld at separating cut using shielded arc welding equipment
250A -VAS 6045A- : SG continuous seam.

Audi TT 2007 ➤
11. Spare wheel well - Partial renewal (Coupé and Roadster identical) 229
Audi TT 2007 ➤
RO: 53 80 55 50
12 Spare wheel well - Renewal (Coupé

and Roadster)
WARNING

Note

tape as necessary.
12.1 Tools
12.2 Procedure
Cutting locations
• Upper section of cross panel already cut out
• Inner section of cross panel already cut out
– Detach bolted joints.

Audi TT 2007 ➤
Replacement part
♦ Spare wheel well
Preparing new part
– Drill 7 mm ∅ holes for SG plug weld seam using spot weld
breaker -V.A.G 1731- .
12. Spare wheel well - Renewal (Coupé and Roadster) 231

Audi TT 2007 ➤
Welding in
– Weld in spare wheel well using shielded arc welding equip‐
– Re-secure bolted joints: tightening torque 8 Nm.

Audi TT 2007 ➤
12. Spare wheel well - Renewal (Coupé and Roadster) 233

Body Repairs

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Body Repairs

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Service

Service Department. Technical Information

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Copyright © 2010 Audi AG, Ingolstadt A008JKI0120

53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

1.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

2 Vehicle identification data

2.1 Type plate and vehicle identification number

2 Rep. Gr.00 - Technical data

2.2 Vehicle data sticker

2. Vehicle identification data 3

3 Expanded foam inserts

The replacement foam inserts expand only after reaching

As the required temperatures cannot be achieved under normal

4 Rep. Gr.00 - Technical data

3. Expanded foam inserts 5

4 General notes on repairs to alumini‐

6 Rep. Gr.00 - Technical data

5 General notes on repairs to steel

We recommend that repairs should be performed in a specialist

5. General notes on repairs to steel parts 7

6.1 Aluminium panels

Extra-high-strength body panels are used in the following areas:

8 Rep. Gr.00 - Technical data

10 Rep. Gr.00 - Technical data

8.1 Bonded joints

8.2 Spot-welded/bonded joints

8.3 Inspecting and repairing bonded joints

8.4 Repair methods for replacing body parts

♦ If the instructions call for additional spot welds, these should

Ensure good root penetration at all joints.

9 Body panel gaps/shut lines

9.1 Body - front and centre

12 Rep. Gr.00 - Technical data

♦ Check that panel gaps are parallel with body lines

9.1.1 Body - rear

9. Body panel gaps/shut lines 13

♦ Check that panel gaps are parallel with body lines

14 Rep. Gr.00 - Technical data

10.1 Floor group, front

10. Body dimensions 15

10.2 Floor group, rear

16 Rep. Gr.00 - Technical data

10.3 Body - front

Distance between suspension strut mountings

10. Body dimensions 17

18 Rep. Gr.00 - Technical data

10.4 Body - centre

10. Body dimensions 19

10.5 Body - rear

20 Rep. Gr.00 - Technical data

Alignment bracket set Audi TT -VAS 6384-

11. Straightening jig 21

2 - MZ 142 and TV 400

22 Rep. Gr.00 - Technical data

2 - Front longitudinal member

11. Straightening jig 23

Overview of front alignment brackets

24 Rep. Gr.00 - Technical data

11. Straightening jig 25

26 Rep. Gr.00 - Technical data

11. Straightening jig 27

8 - Suspension strut mounting

28 Rep. Gr.00 - Technical data