Audi TT Platform 2009 User manual

2009
TT Platform
Quick Reference
Specification Book

Audi TT Quick Reference Specication Book • May 2009 i
2009 Audi TT Platform
Quick Reference Specification Book
TABLE OF CONTENTS
General Information ...................................................... 1
Decimal and Metric Equivalents ...........................................1
Tightening Torque .................................................................2
Warnings and Cautions ........................................................4
Maintenance .........................................................................9
Vehicle Identication................................................... 10
VIN on Lower Edge of Front Window ....................................10
VIN on Suspension Strut Mount ............................................10
VIN Decoder ..........................................................................11
Type Plate – Location ............................................................12
Vehicle Data Sticker ..............................................................12
Sales Codes ................................................................. 13
Engine Codes ........................................................................13
Transmission Codes ..............................................................13
Vehicle Lifting .............................................................. 14
Lifting Points for Lifting Platform and Trolley Jack.................14
Engine Mechanical, Fuel Injection & Ignition ........... 15
General, Technical Data .....................................................15
Engine Number – Location – 2.0L – CCTA............................15
Engine Number – Location – 3.2L – CBRA ...........................16
Engine Data...........................................................................16
Engine – Removing and Installing .....................................18
Engine to Transmission – Tightening Torques – CBRA.........18
Manual Transmission to Engine ............................................18
Direct Shift Automatic Transmission to Engine Mounting ......19
Assembly Mountings – Tightening Torques ...........................20
Crankshaft/Cylinder Block – 4-Cylinder – Turbo Engine –
2.0L – CCTA .......................................................................21
Accessory Assembly Bracket Tightening Sequence..............21
Assembly Attachments Mounting – Tightening Torques ........22
Sealing Flange – Tightening Sequence.................................23
Flywheel/Drive Plate – Tightening Torques ...........................23
Crankshaft Assembly – Tightening Sequence .......................24
Crankshaft Dimensions .........................................................25
Identication on Crankshaft Bearing, Top ..............................25
Piston and Connecting Rod – Tightening Torques ................25

ii Audi TT Quick Reference Specication Book • May 2009
Crankshaft/Cylinder Block – 4-Cylinder – Turbo Engine –
2.0L – CCTA (continued) ....................................................26
Piston Ring End Gaps ...........................................................26
Piston Ring Clearance...........................................................26
Piston and Cylinder Dimensions............................................26
Crankshaft/Cylinder Block – 6-Cylinder – 3.2L – CBRA ....27
Accessory Assembly Bracket Tightening Sequence..............27
Sealing Flange Tightening Sequence....................................28
Assembly Attachments Mounting – Tightening Torques ........28
Drive Chain – Tightening Torques .........................................29
Brake Booster Vacuum Pump – Tightening Torques .............29
Sealing Flanges and Vibration Damper – Tightening
Torques ...........................................................................30
Crankshaft Assembly – Tightening Torques ..........................30
Crankshaft Dimensions .........................................................30
Piston and Connecting Rod – Tightening Torques ................30
Piston Ring End Gaps ...........................................................30
Piston Ring Clearance...........................................................31
Piston and Cylinder Dimensions............................................31
Cylinder Head – 2.0L Engine – CCTA ................................31
Crankcase Ventilation – Tightening Sequence ......................31
Cylinder Head – Tightening Torques .....................................32
Cylinder Head – Loosening Sequence ..................................32
Cylinder Head – Tightening Sequence ..................................33
Cylinder Head (Valve) Cover – Loosening Sequence ...........34
Cylinder Head (Valve) Cover – Tightening Sequence ...........35
Compression Pressures ........................................................35
Cylinder Head – 3.2L Engine – CBRA................................36
Cylinder Head – Tightening Torques .....................................36
Cylinder Head – Removal Sequence ....................................36
Cylinder Head – Tightening Sequence ..................................37
Cylinder Head Cover – Tightening Sequence .......................38
Compression Pressures ........................................................38
Valvetrain – 2.0L Engine – CCTA .......................................38
Valvetrain – Tightening Torques.............................................38
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 Specication Book • May 2009 iii
Engine Lubrication – 2.0L – CCTA......................................42
Oil Pan Upper Section – Tightening Sequence .....................42
Oil Pan Lower Section – Tightening Sequence .....................43
Oil Separator – Tightening Torques .......................................44
Lubrication System Components – Tightening Torques ........44
Oil Filter Bracket – Tightening Torques..................................45
Engine Lubrication – 3.2L – CBRA .....................................45
Lubrication System Components – Tightening Torques ........45
Oil Filter Bracket – Tightening Torques..................................45
Engine Cooling – 2.0L – CCTA...........................................45
Cooling System Components – Tightening Torques..............45
After Run Coolant Pump V51 – Tightening Torques..............46
Coolant Pump – Tightening Sequence ..................................46
Coolant Pump – Tightening Torques .....................................46
Recommended Coolant Mixture Ratios.................................46
Engine Cooling – 3.2L – CBRA...........................................47
Cooling System Components (on Engine) – Tightening
Torques ...........................................................................47
Cooling System Components (on Body) – Tightening
Torques ...........................................................................47
Recommended Coolant Mixture Ratios.................................47
Fuel Storage and Supply – 2.0L – CCTA, 3.2L – CBRA.....47
Fuel Pump – Tightening Torques ...........................................47
Fuel Tank – Tightening Torques.............................................48
Accelerator Pedal Module – Tightening Torques ...................48
EVAP Canister System – Tightening Torques........................48
Turbocharger – 2.0L – CCTA..............................................49
Turbocharger – Tightening Sequence ...................................49
Turbocharger – Tightening Torques.......................................50
Charge Air Cooler – Tightening Torques................................51
Noise Booster – Tightening Torques......................................51
Fuel Injection – 2.0L – CCTA..............................................51
Fuel Injection System Data....................................................51
Engine Cover/Air Filter – Tightening Torques ........................52
Intake Manifold – Tightening Torques ....................................52
High Pressure Pump – Tightening Torques ...........................52
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

iv Audi TT Quick Reference Specication Book • May 2009
Exhaust System – 3.2L – CBRA.........................................54
Exhaust System – Tightening Torques ..................................54
Secondary Air Injection (AIR) System – Tightening
Torques ...........................................................................55
Ignition System – 2.0L – CCTA, 3.2L – CBRA....................55
Ignition – Tightening Torques.................................................55
Spark Plug Data ....................................................................55
Manual Transmission .................................................. 56
General, Technical Data .....................................................56
02E Transmission Identication.............................................56
02Q Manual Transmission Specications..............................58
Clutch – 02Q.......................................................................59
Pedal Cluster – Tightening Torques.......................................59
Over-Center Spring – Tightening Torques .............................59
Hydraulic System – Tightening Torques ................................59
Slave Cylinder – Tightening Torques .....................................59
Clutch (Sachs) – Tightening Torques.....................................59
Clutch (LuK) – Tightening Torques ........................................59
Cable Retainer Dimensions...................................................60
Shift Cable Retainer – Tightening Torques ............................60
Manual Transmission – Installing – 02Q.............................61
02Q Selector Mechanism – Tightening Torques ....................61
02Q Transmission To Engine – Tightening Torques ..............61
02Q Transmission – Tightening Torques ...............................61
O2Q Transmission Pendulum Support ..................................62
02Q Transmission Housing and Shift Mechanism –
Tightening Torques..........................................................62
02Q Installation Position of Shafts and Selector Rods in
Transmission ...................................................................63
02Q Input Shaft, Output Shaft (Pinion Shaft), Differential
and Shift Forks – Tightening Torques..............................63
02Q Transmission Housing and Clutch Housing –
Tightening Torques..........................................................63
Automatic Transmission............................................. 64
General, Technical Data .....................................................64
02E Transmission Identication.............................................64
02E Transmission Specications...........................................65
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 Specication Book • May 2009 v
02E Transmission Input Speed (RPM) Sensor G182 and
Clutch Oil Temperature Sensor G509 – Tightening
Torques ...........................................................................68
02E Direct Shift Gearbox (DSG) Mechatronic J743 –
Tightening Torques..........................................................69
02E Direct Shift Gearbox (DSG) Mechatronic J743 –
Tightening Sequence ......................................................69
02E Oil Pan – Tightening Torques .........................................70
02E Drain Plug and Filter housing – Tightening Torques ......70
Automatic Transmission Installing – 02E............................71
02E Transmission To 2.0L TFSI Engine – Tightening
Torques ...........................................................................71
02E Transmission To 3.2L MPI Engine – Tightening Torques72
02E Oil Cooler – Tightening Torques .....................................72
02E Oil Pump – Tightening Torques ......................................72
02E Transmission Mount – Tightening Torques.....................73
Rear Final Drive ........................................................... 74
Identication ..........................................................................74
Identication Code Letters, Allocation, Gear Ratios and
Capacities .......................................................................77
Rear Final Drive – Tightening Torques ..................................78
Suspension, Wheels, Brakes, Steering ..................... 79
Front Suspension ...............................................................79
Front Axle – Curb Weight Data..............................................79
Subframe – Tightening Torques.............................................79
Control Arm – Tightening Torques .........................................80
Stabilizer Bar – Tightening Torques .......................................80
Pendulum Support – Tightening Torques ..............................80
Suspension Strut – Tightening Torques .................................80
Drive Axle – Tightening Torques ............................................81
Wheel Bearing Housing – Tightening Torques ......................81
Rear Suspension – Front Wheel Drive ...............................82
Rear Axle – Curb Weight Data...............................................82
Subframe – Tightening Torques.............................................82
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

vi Audi TT Quick Reference Specication Book • May 2009
Rear Suspension – All Wheel Drive....................................84
Rear Axle – Curb Weight Data...............................................84
Subframe – Tightening Torques.............................................84
Left Rear Level Control System Sensor G76 – Tightening
Torques ...........................................................................84
Wheel Bearing Housing – Tightening Torques ......................85
Trailing Link – Tightening Torques .........................................85
Shock Absorbers – Tightening Torques .................................85
Stabilizer Bar – Tightening Torques .......................................85
Drive Axle – Tightening Torques ............................................86
Wheels, Tires, Wheel Alignment.........................................86
Wheel Bolts – Tightening Torques .........................................86
Tire Pressure Sensor – Tightening Torques ..........................86
Wheel Alignment Data ...........................................................87
Light Alloy Wheels with Metal Valve – Tightening Torques ...88
Brake System .....................................................................88
Front Brakes – Technical Data...............................................88
Rear Brakes Front Wheel Drive – Technical Data .................89
Hydraulic Unit, Brake Booster/Brake Master Cylinder – ABS
Mark 70 (ABS/ASR) and 60 (ABS/EDL/ASR/ESP) –
Tightening Torques..........................................................90
ABS System Components on Front and Rear Axles –
Tightening Torques..........................................................90
ESP Sensor Unit G419 – Tightening Torques........................91
Front Wheel Brakes – Brake Caliper FN3/FNR-G –
Tightening Torques..........................................................91
Rear Brakes (Disc Brakes) – Rear Brake CII/CII 38 –
Tightening Torques..........................................................91
Parking Brake Lever – Tightening Torques............................91
Hydraulic Components – Front Brake Caliper FN3/FNR-G –
Tightening Torques..........................................................92
Hydraulic Components – Rear Brake Caliper CII/CII 38 –
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 Specication Book • May 2009 vii
Body.............................................................................. 94
Body Dimensions................................................................94
Front Dimensions ..................................................................94
Center Dimensions ................................................................95
Rear Coupe Dimensions .......................................................96
Rear Roadster Dimensions ...................................................98
Body Exterior ......................................................................98
Lock Carrier Service Position – Tightening Torques ..............98
Front Fender – Tightening Torques .......................................98
Noise Insulation Panel – Tightening Torques ........................99
Underbody Trim – Tightening Torques...................................99
Front Hood – Tightening Torques ..........................................99
Rear Lid – Tightening Torques...............................................99
Tank Flap Unit – Tightening Torques .....................................99
Front and Rear Door – Tightening Torques .........................100
Sunroof – Tightening Torques..............................................100
Front Bumper – Tightening Torques ....................................100
Rear Bumper – Tightening Torques .....................................100
Front and Rear Door Window – Tightening Torques ...........101
Front Wheel Housing Liner – Tightening Torques ...............101
Rear View Mirror – Tightening Torques ...............................101
Radiator Grille – Tightening Torques ...................................101
Strips and Trim – Tightening Torques ..................................101
Body Interior .....................................................................101
Storage Compartment – Tightening Torques .......................101
Passenger Protection – Tightening Torques ........................102
Interior Trim – Tightening Torques .......................................102
Seat Frames – Tightening Torques......................................103
Heating and Air Conditioning................................... 104
Refrigerant R134a – Capacity .............................................104
Refrigerant (PAG) Oil Identication......................................104
Refrigerant (PAG) Oil Capacities .........................................104
Refrigerant Oil Distribution ..................................................104
Refrigerant R134a Vapor Pressure Table ............................105
Heating and A/C Components – Tightening Torques...........106
A/C System – Tightening Torques .......................................106
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

viii Audi TT Quick Reference Specication Book • May 2009
Electrical Equipment (continued) ............................ 108
Generator 3.2L – Tightening Torques ..................................108
Starter – Tightening Torques ...............................................108
Front Wiper Motor – Tightening Torques .............................108
Washer Reservoir – Tightening Torques..............................108
Rear Wiper/Washer – Tightening Torques...........................108
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

General
Information
Audi TT Quick Reference Specication Book • May 2009 1
GENERAL INFORMATION
Decimal and Metric Equivalents
Distance/Length
To calculate: mm x 0.03937 = in.
mm in. mm in. mm in. mm in.
0.002 0.00008 0.01 0.0004 0.1 0.004 10.04
0.004 0.00016 0.02 0.0008 0.2 0.008 2 0.08
0.006 0.00024 0.03 0.0012 0.3 0.012 30.12
0.008 0.00031 0.04 0.0016 0.4 0.016 40.16
0.010 0.00039 0.05 0.0020 0.5 0.020 50.20
0.020 0.00079 0.06 0.0024 0.6 0.024 60.24
0.030 0.00118 0.07 0.0028 0.7 0.028 70.28
0.040 0.00157 0.08 0.0031 0.8 0.031 80.31
0.050 0.00197 0.09 0.0035 0.9 0.035 9 0.35
0.060 0.00236 0.10 0.0039 1.0 0.039 10 0.39
0.070 0.00276 0.20 0.0079 2.0 0.079 20 0.79
0.080 0.00315 0.30 0.0118 3.0 0.118 30 1.18
0.090 0.00354 0.40 0.0157 4.0 0.157 40 1.57
0.100 0.00394 0.50 0.0197 5.0 0.197 50 1.97
0.200 0.00787 0.60 0.0236 6.0 0.236 60 2.36
0.300 0.01181 0.70 0.0276 7.0 0.276 70 2.76
0.400 0.01575 0.80 0.0315 8.0 0.315 80 3.15
0.500 0.01969 0.90 0.0354 9.0 0.354 90 3.54
0.600 0.02362 1.00 0.0394 10.0 0.394 100 3.94
0.700 0.02756 2.00 0.0787 20.0 0.787
0.800 0.03150 3.00 0.1181 30.0 1.181
0.900 0.03543 4.00 0.1575 40.0 1.575
1.000 0.03937 5.00 0.1969 50.0 1.969
2.000 0.07874 6.00 0.2362 60.0 2.362
3.000 0.11811 7.00 0.2756 70.0 2.756
4.000 0.15748 8.00 0.3150 80.0 3.150
5.000 0.19685 9.00 0.3543 90.0 3.543
6.000 0.23622 10.00 0.3937 100.0 3.937
7.000 0.27559 20.00 0.7874
8.000 0.31496 30.00 1.1811
9.000 0.35433 40.00 1.5748
10.000 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