SM 12

Service
Body repairs
Audi TT 1999 ➤
Edition 09.1999
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service 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 A008NKI0120

Audi TT 1999 ➤
Body repairs - Edition 09.1999
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Vehicle identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Type plate and vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Body dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Floor group, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Floor group, centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Floor group, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Body - centre (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.8 Body - rear (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Body panel gaps/shut lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Body (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Corrosion protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Foam-filled cavities . . . . . . . . .permitted
. . . . . unless
. . . .authorised
. . . . . .by. AUDI
. . . AG.. . .AUDI
. . .AG
. .does
. . .not
. .guarantee
. . . . . or
. .accept
. . . .any
. .liability
.. 18
5.1 A-pillar . . . . . . . . . . . . . . . . . . . with
. . .respect
. . . .to. the
. . correctness
. . . . . . of. .information
. . . . . .in.this
. .document.
. . . . . .Copyright
. . . . .by. AUDI
. . . AG.
... 18
6 Aluminium panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7 Strengthened body panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8 Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1 Bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.2 Spot-welded bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.3 Inspecting and repairing bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.4 Repair methods for replacing body parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.5 Repair methods for bonded joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.6 Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.7 Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.8 Body - centre (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8.9 Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9 Straightening jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.2 Supplement for quattro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.3 Portal gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
50 - Body - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1 Engine console (right) - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Intermediate piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3 Upper wheel housing longitudinal member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4 Front wheel housing - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5 Front wheel housing - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6 Front longitudinal member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Contents i
Audi TT 1999 ➤
7 Front longitudinal member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

7.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8 Impact absorber mounting with towing eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
51 - Body - centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1 Roof - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2 Roof side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3 Cross panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4 Outer roof frame - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5 Front roof cross member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6 Rear roof frame - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7 Side frame - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8 A-pillar - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9 A-pillar - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10 Reinforcement tube and inner A-pillar - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11 Outer side member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
12 Outer side member - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
12.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
13 Seat cross member - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
13.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
14 Floor panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
14.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
15 Side member reinforcement - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
15.1 Procedure . . . . . . . . . . . . . .Protected
. . . . . by. .copyright.
. . . . .Copying
. . . . .for. private
. . . .or. commercial
. . . . . . .purposes,
. . . . .in. part
. . .or.in. whole,
. . . .is.not
. . 101
53 - Body - rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1 Rear cross panel (top section) - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2 Rear cross panel (inner section) - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3 Tail light mounting - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4 Rain channel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5 Side frame connecting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6 Luggage compartment floor - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7 Luggage compartment floor - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
7.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
ii Contents
Audi TT 1999 ➤
8 Rear longitudinal member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

8.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
9 Side panel - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
9.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
10 Side panel - Renewal (Roadster) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
10.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
11 Rear wheel housing - Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
11.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Contents iii
Audi TT 1999 ➤
iv Contents
Audi TT 1999 ➤
00 – Technical data
1 Vehicle identification data
1.1 Type plate and vehicle identification

number
The vehicle identification number -A- (chassis number) is stam‐
ped on the rear bulkhead in the engine compartment. It can be
seen through an opening in the plenum chamber cover.
The type plate -B- is attached to the plenum chamber behind the
right suspension turret.
1.2 Vehicle data sticker

The vehicle data sticker is located in the spare wheel well at the
rear of the vehicle.
This page is currently not used.
1. Vehicle identification data 1

Audi TT 1999 ➤
2 Body dimensions
2.1 Floor group, front
a - 956 ± 2mm
Distance between front longi‐
tudinal members (front)
b - 949 ± 2mm
Diagonal distance between
front longitudinal member and
attachment points of front axle
c - 753 ± 2mm
Distance between front attach‐
ment points of front axle
d - 772 ± 2mm
Diagonal distance between at‐
tachment points of front axle
e - 610 ± 2mm
Distance between rear attach‐
ment points of front axle
2 Rep. Gr.00 - Technical data

Audi TT 1999 ➤
2.2 Floor group, centre
f - 1620 ± 2mm
rear attachment points of front
axle and rear axle mounting
g - 1360 ± 2mm
rear attachment points of front
axle and rear axle mounting
h - 1360 ± 2mm
Distance between side mem‐
bers
j - 830 ± 2mm
tudinal members (rear)
2. Body dimensions 3
Audi TT 1999 ➤
2.3 Floor group, rear
k - 1270 ± 2mm
Distance between axle mount‐
ings
l - 1753 ± 2mm
axle mounting and longitudinal
member
m - 1853 ± 2mm
rear axle rear attachment point
and rear longitudinal member
n - 962 ± 2mm
production mounting and lon‐
gitudinal member

Audi TT 1999 ➤
2.4 Body - front
a - 867 ± 2mm
tudinal members
Audi TT 1999 ➤
b - 1480 ± 2mm
Distance between rear wing
panel mountings
c - 1310 ± 2mm
Distance between wing panel
mountings
d - 1320 ± 2mm
wing panel mountings and
strut holders
e - 1130 ± 2mm
Distance between strut hold‐
ers

Audi TT 1999 ➤
2.5 Body - centre
f - 1400 ± 2mm
Distance between A-pillars
g - 1100 ± 2mm
Distance between A-pillar and
B-pillar
h - 1320 ± 2mm
Distance between B-pillars
j - 870 ± 2mm
Height of door opening
Audi TT 1999 ➤
2.6 Body - centre (Roadster)
p - 777 ± 2mm
Distance between A-pillar and
B-pillar

Audi TT 1999 ➤
2.7 Body - rear
k - 1048 ± 2mm
Distance between rear longitu‐
dinal members
l - 1245 ± 2mm
Distance between rear cross
panel flange and flange on win‐
dow cross member
Audi TT 1999 ➤
m - 1080 ± 2mm
Distance between tail light
mountings
n - 995 ± 2mm
Distance between side panels
(bottom)
o - 1068 ± 2mm
(top)

Audi TT 1999 ➤
2.8 Body - rear (Roadster)
q - 992 ± 2mm
(bottom)
r - 1050 ± 2mm
(top)
s - 988 ± 2mm
Distance between
Protected gas-filled
by copyright. Copying for private or commercial purposes, in part or in whole, is not
strut mounting points
Audi TT 1999 ➤
t - 538 ± 2mm
Height of luggage compart‐
ment opening

Audi TT 1999 ➤
3 Body panel gaps/shut lines
3.1 Body - front
C - 1.5 mm
F - 3.0 mm
H - 4.0 mm
K - 5.0 mm
Use special tool 3371 for adjusting or checking.
3. Body panel gaps/shut lines 13

Audi TT 1999 ➤
3.2 Body - centre
A - 1.0 mm
D - 2.0 mm
G - 3.5 mm
H - 4.0 mm
J - 4.5 mm

Audi TT 1999 ➤
3.3 Body - rear
C - 1.5 mm
D - 2.0 mm
E - 2.5 mm
F - 3.0 mm
G - 3.5 mm
J - 4.5 mm
K - 5.0 mm
3. Body panel gaps/shut lines 15

Audi TT 1999 ➤
3.4 Body (Roadster)
N - 0.0 mm
D - 2.0 mm
E - 2.5 mm
F - 3.0 mm
G - 3.5 mm
Hpermitted
- 4.0 mm unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
M - 6.0 mm (hard top only)
K - 5.0 mm
O - 8.0 mm

Audi TT 1999 ➤
4 Corrosion protection
The body is manufactured from panels galvanised on both sides.

Certain areas are cavity-sealed and have to be re-sealed after
completing repair work.
4. Corrosion protection 17
Audi TT 1999 ➤
5 Foam-filled cavities
5.1 A-pillar
a - Foam-filling hole
b - Foam-filling hole
These parts of the body are foam-filled for acoustic reasons.

Audi TT 1999 ➤
6 Aluminium panels
Aluminium panels are used on the following parts of the car body:
Bonnet ⇒ Workshop Manual, General notes; chapter on Repair
procedures
6. Aluminium panels 19
Audi TT 1999 ➤
7 Strengthened body panels
Strengthened body panels are used in the following areas:

Roof and reinforcement for side frame, A-pillar hinge and belt
guide bracket. ⇒ Workshop Manual, General notes; chapter on
Repair procedures

Audi TT 1999 ➤
8 Bonded joints
The body of the Audi TT features bonded joints and spot-welded
bonded joints for increased rigidity and strength.
8.1 Bonded joints

In the case of bonded joints, the panel sections are only joined 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. ⇒ Workshop Manual, General notes; chapter on Bon‐
ded body joints
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.
8. Bonded joints 21
Audi TT 1999 ➤
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 spotbywelding.
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
Ensure good root penetration at all joints.
Seal off repaired joint flanges and apply cavity sealing.
8.5 Repair methods for bonded joints

8.6 Body - front
A - Bottom of inner A-pillar to

outside of side frame
Additional 4 x SG plug weld
seam at flange. ⇒ Workshop
Manual, General notes; chap‐
ter on Bonded body joints

Audi TT 1999 ➤
8.7 Body - centre
1 - Outside of front side frame

to top of inner A-pillar
SG continuous seam in notch‐
es instead of bonded joint.
2 - Inside of rear side frame to

hinge reinforcement
Bottom of rear lid: 2 x 10 mm
SG seam at flange.
3 - Roof to outside of inner side

frame: Same as original joint
Apply body adhesive and
make spot welds, but leave 15
mm either side of spot welds
free of adhesive.

outside of front side frame
8. Bonded joints 23
Audi TT 1999 ➤
5 - Front floor to frame base

plate
4 x 20 mm SG continuous
seam instead of bonded joint.
6 - Front floor to frame base

plate
7 - Outside of front side frame

to inner A-pillar

Audi TT 1999 ➤
8 - Outer side to sill


10 - Outside of rear wheel

housing to sill
Additionally double the num‐
ber of spot welds instead of
bonded joint.
11 - Sill connecting piece to sill

bonded joint.
12 - Outside of side frame to

outer side
bonded joint.
8. Bonded joints 25
Audi TT 1999 ➤
13 - Roof to rear roof frame

3 x SG plug weld seam instead
of bonded joint.
14 - Roof to outside of inner

side frame: Same as original
joint
Apply body adhesive and
make spot welds, but leave 15
mm either side of spot welds
free of adhesive.
15 - Lower to upper hinge re‐

inforcement
of bonded joint
16 - Hinge reinforcement to
side frame
Additionally 3 x SG plug weld
17 - Hinge reinforcement to
roof frame
of bonded joint.
18 - Roof to rear roof frame:

Same as original joint
Insert butyl cord and fit roof.
19 - Roof to rear roof frame:

Same as original joint
Insert butyl cord and fit roof.

Audi TT 1999 ➤
20 - Floor sill closure plate to

side frame
Same as original joint: Apply
body adhesive and make spot
welds, but leave 15 mm either
side of spot welds free of ad‐
hesive.
21 - Rear section of rear floor

to rear wheel housing longitu‐
dinal member
2 xProtected
20 mm SG continuous
seam with respect to of

instead bonded ofjoint.
the correctness information in this document. Copyright by AUDI AG.
22 - Rear floor to fastening ring

reinforcement
23 - Rear section of rear floor

to rear cross panel reinforce‐
ment
24 - Floor cross member to

rear floor
25 - Front section of rear floor /

rear section of rear floor to rear
wheel housing longitudinal
member
8. Bonded joints 27
Audi TT 1999 ➤
26 - Outer side to outside of

side frame
bonded joint.
27 - Panel section to inside of

side frame
Additional 2 x RP spot weld
28 - Outer side to outside of

side frame
Additional 8 x RP spot weld
outside of rear side frame
es instead of bonded joint. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi TT 1999 ➤
8.8 Body - centre (Roadster)
30 - Longitudinal member to
front floor
8. Bonded joints 29
Audi TT 1999 ➤


33 - Outside of rear wheel

housing to sill
bonded joint.

Audi TT 1999 ➤
8.9 Body - rear
A - Same as original joint: Ap‐

ply adhesive and bead over
edge of wheel housing. Repair
as follows if bond is damaged:
Brush area, apply paint finish,
seal and apply cavity sealing.
If bond is damaged over a
length of more than 100 mm,
make a 10 mm SG seam every
50 mm. Rework wheel housing
liner if necessary.
B - Rear wheel housing liner to

rear wheel housing
Additional 4 x 30 mm SG
seam.
C - Rear wheel housing liner to

rear floor
Twice the number of RP spot
weld seams.
D - Rear longitudinal member

to rear wheel housing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Twice the number of RP spot permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
weld seams.
E - Rear wheel housing liner to

rear wheel housing
RP spot weld seam with 25 mm
spacing.
F - Rear wheel housing liner to

rear wheel housing
2 additional spot welds.
8. Bonded joints 31
Audi TT 1999 ➤
G - Tail light mounting insert to

rear cross panel
of bonded joint.

Audi TT 1999 ➤
9 Straightening jig
9.1 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 for
checking the body with and without mechanical units are
marked with a circle.
♦ Check the freedom of movement of the alignment brackets
before placing them on the straightening jig. Any obstructing
components are to be unfastened or removed.
♦ The required basic set size is given for the alignment bracket
mountings.
Alignment bracket set Alignment bracket set Audi A3 -VAS 5020/-
9. Straightening jig 33
Audi TT 1999 ➤
Alignment bracket set Alignment bracket set supplement Audi TT

-VAS 5020/6-
2 - MZ 200 and TV 400

64 - MZ 200 and alignment
bracket mounting -2-
6 - MZ 142
8 - MZ 260
10 - MZ 200
13 - Left and right centring
piece identical
14 - MZ 601
piece identical
18 - MZ 140
20 - Bracket without MZ and
alignment bracket mounting
-22-
26 - MZ 140
28 - MZ 080
30 - MZ 080 and mounting
plate -31-
32 - MZ 602
30 - MZ 200
66 - Packing plate.
34 - MZ 200
67 - Packing plate.

Audi TT 1999 ➤
2 - MZ 200 and TV 400

6 - MZ 142
8 - MZ 260
10 - MZ 200
14 - MZ 601
18 - MZ 140
24 - MZ 080 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
26 - MZ 140 with respect to the correctness of information in this document. Copyright by AUDI AG.
28 - MZ 080
30 - MZ 080
32 - MZ 602
34 - MZ 200
66 - Packing plate.
67 - Packing plate.
Overview and locations of MZ elements
Audi TT 1999 ➤
6 - MZ 142
12 - MZ 080
18 - MZ 080
piece identical
26 - MZ 140
28 - MZ 080
30 - MZ 080
34 - MZ 200
66 - Packing plate.
67 - Packing plate.
Overview of alignment bracketsProtected

with MZ elements for vehicles
with mechanical units installed. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 1999 ➤
2 - Front longitudinal member

When checking, bolt on MZ
last, as the longitudinal posi‐
tion of the impact absorber
mounting can vary by
several mm due to production
tolerances - if necessary do not
bolt down.
64 - Front longitudinal mem‐

ber / top of wheel housing
Overview of front alignment brackets
Audi TT 1999 ➤

Audi TT 1999 ➤
8 - Engine carrier mounting

9 - Engine carrier mounting
Audi TT 1999 ➤

Audi TT 1999 ➤
6 - Front longitudinal member

10 - Mounting for subframe
14 - Strut holder
Audi TT 1999 ➤
Overview of centre alignment brackets

Audi TT 1999 ➤

22 - Front production mounting
May have been forced up‐
wards by handling vehicle in
factory: when checking dimen‐
sions, pack with spacer up to 4
mm if necessary.
26 - Drilling in floor panel

28 - Drilling in longitudinal
member
66 - Packing plate.
Audi TT 1999 ➤
Overview of rear alignment brackets

Audi TT 1999 ➤
30 - Mounting for rear axle

Do not insert pin until after fit‐
ting body on jig.
31 - Left and right spacer iden‐

tical
Only use with rear axle re‐
moved.
66 - Packing plate.
32 - Strut holder
member
The drilling is covered over
with fabric-backed tape and
sprayed over with underseal.
Re-seal drilling after checking.
67 - Packing plate.
Audi TT 1999 ➤
9.2 Supplement for quattro
78 - MZ 140
80 - MZ 080
82 - MZ 260 and TV 400
84 - MZ 260
86 - MZ 200
88 - MZ 260
90 - MZ 200
When setting up the alignment
bracket mountings -22- to -27-
and -31- to -36-, spacers -93-
and -94- are to be placed
under the transverse module.
The mountings -26- -25- and

-28- -27- are identical to front-
wheel drive.

Audi TT 1999 ➤
Overview of alignment brackets for quattro

Audi TT 1999 ➤
28 - MZ 080 and packing plate

93
93
82 - MZ 260, TV 400 and pack‐
ing plate 93
94
94
94
94
93 - Position packing plates on
cross bars 22 to 27
cross bars 31 to 36
Overview and locations of MZ elements (quattro only)

– Mark out holes as permitted
shown.unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 1999 ➤

93
83 - Left and right spacer iden‐
tical
Only use with rear axle re‐
moved.

94
85 - Shim
94
94
cross bars 22 to 27
cross bars 31 to 36
Overview of alignment brackets with MZ elements for vehicles

with mechanical units installed.
– Mark out holes as shown.
Audi TT 1999 ➤
member
94 - Packing plate
78 - Mounting for propshaft

Audi TT 1999 ➤
80 - Mounting for rear axle

ting body on jig.

84 - Strut holder
ting body on jig.
member
Audi TT 1999 ➤
9.3 Portal gauge
A - Extension
B - Telescopic column
C - Cross bar 1200 mm
100 - Mounting for A-pillar
Coupe and Roadster identical.
100 - MZ 260
Portal gauge -VAS 5007-

Supplement for TT Coupe and Roadster portal gauge Supple‐
ment for portal gauge Audi TT/TT Roadster -VAS 5007/8- .

Audi TT 1999 ➤
A - Extension
102 - Mounting for front cross
member
102 - MZ 602
108 - Connecting piece
Audi TT 1999 ➤
A - Extension
104 - Mounting for B-pillar
Coupe and Roadster identical.
106 - Mounting for convertible

top holder
104 - MZ 602
106 - MZ 602

Audi TT 1999 ➤
50 – Body - front
RO: 50 40 55 00
1 Engine console (right) - Renewal
1.1 Procedure
1.1.1 Cutting locations
– Engine console separating cut

– Separate original joint.
– Remove front part section.
– Drill out spot welds -a- with dia. 7 mm bit.
– Remove remaining material.
1. Engine console (right) - Renewal 55

Audi TT 1999 ➤
1.1.2 Replacement part

♦ Engine console
Preparing new part
– Drill dia. 7 mm holes for SG plug weld seam.
1.1.3 Welding in
– Fix new part in position with alignment bracket.
– Weld in console: SG plug weld seam.
– Spot welds -a- from outside: SG plug weld seam.
56 Rep. Gr.50 - Body - front

Audi TT 1999 ➤
RO: 50 52 55 00
2 Intermediate piece
2.1 Procedure
– Separate original joint. Inner reinforcement must be drilled off.
Note:
♦ Partial replacement is possible with the separating cut indicated. SG continuous butt weld in the area of the
separating cut.
♦ On account of with
internal reinforcement, the separating cutCopyright
is onlybytoAUDI
beAG.
made at this location.
respect to the correctness of information in this document.

♦ Reinforcement plate
2. Intermediate piece 57
Audi TT 1999 ➤
Preparing new part

2.1.3 Welding in
– Reinforcement plate to wheel housing: RP spot weld seam.
– Reinforcement plate to wheel housing: SG plug weld seam.

Audi TT 1999 ➤
RO: 50 72 55 50
3 Upper wheel housing longitudinal

member - Renewal
3.1 Procedure
• Intermediate piece already removed

♦ Upper wheel housing longitudinal member
3. Upper wheel housing longitudinal member - Renewal 59

Audi TT 1999 ➤
3.1.3 Welding in
– Fix new part in position on alignment bracket.
– Spot weld upper wheel housing longitudinal member: RP spot
weld seam.

Audi TT 1999 ➤
RO: 50 74 55 00
4 Front wheel housing - Renewal
4.1 Procedure

• Longitudinal member (top section) already removed

♦ Front wheel housing
4. Front wheel housing - Renewal 61

Audi TT 1999 ➤
Preparing new part

4.1.3 Welding in
– Fix wheel housing in position on alignment bracket.
– Spot weld wheel housing to lower longitudinal member: RP
spot weld seam.
– Weld in remaining joint: SG plug weld seam.

Audi TT 1999 ➤
RO: 50 74 55 12
5 Front wheel housing - Partial renewal
5.1 Procedure
• Intermediate piece already removed Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Longitudinal member (top section) already
with removed
respect to the correctness of information in this document. Copyright by AUDI AG.
– Cut out wheel housing in front of strut holder.

– Detach part.
5.1.2 Replacement parts

♦ Wheel housing
5. Front wheel housing - Partial renewal 63

Audi TT 1999 ➤
Preparing new parts

– Transfer separating cut to new part plus 10 mm for overlap.
Cut off hatched area.
– Step separating cut at body.
5.1.3 Welding in
– Both sides of separating cut: SG continuous seam (stag‐
gered).
– Spot weld remainder of joint, RP spot weld seam.

Audi TT 1999 ➤
RO: 50 79 55 00
6 Front longitudinal member - Renewal
6.1 Procedure
– Separating cut for longitudinal member.


♦ Longitudinal member
♦ Impact absorber mounting
♦ Towing eye (right only)
6. Front longitudinal member - Renewal 65

Audi TT 1999 ➤
Preparing new part

– Transfer separating cut to new part and cut off hatched area.
6.1.3 Welding in
– Weld separating cut: SG continuous seam.
– Weld in front longitudinal member: SG plug weld seam.
– Weld in impact absorber with towing eye. ⇒ page 69

Audi TT 1999 ➤
RO: 50 79 55 12
7 Front longitudinal member - Partial

renewal
7.1 Procedure
– Make separating cut on longitudinal member according

by AUDI AG. to ex‐
permitted unless authorised AUDI AG does not guarantee or accept any liability
tent of damage. with respect to the correctness of information in this document. Copyright by AUDI AG.
Note:
Separating cut must be a straight line.

♦ Longitudinal member
7. Front longitudinal member - Partial renewal 67

Audi TT 1999 ➤
♦ Towing eye
♦ Closure plate for longitudinal member
Preparing new part
– Transfer separating cut to new part and cut off hatched area.
7.1.3 Welding in
– Fix longitudinal member sub-part in position
permitted on alignment
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
bracket. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Butt weld longitudinal member: SG continuous seam.

The spot welds must be parallel. It is important to keep to the
specified spacings.

Audi TT 1999 ➤
RO: 50 80 55 00
8 Impact absorber mounting with tow‐

ing eye
8.1 Procedure


♦ Towing eye
8. Impact absorber mounting with towing eye 69

Audi TT 1999 ➤
Preparing new part

8.1.3 Welding in
– Weld in impact absorber mounting: SG continuous seam.
– Weld in towing eye: SG plug weld seam. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Dimension a = 110 mm

Audi TT 1999 ➤
51 – Body - centre
RO: 51 03 55 00
1 Roof - Renewal
1.1 Procedure

– Drill 6 holes each at front and rear of roof for SG plug weld
seam instead of bonding.

♦ Roof
♦ Butyl adhesive sealing cord AKL 450 005 05
1. Roof - Renewal 71
Audi TT 1999 ➤
♦ Sealant
1.1.3 Welding in
– Clean bonding area (it must be free of dust and grease).
– Place 2 x 200 mm lengths of butyl cord centrally over rear lid
hinge cut-out and 2 x 360 mm on roof cross member.
– Apply sealant to top of rear roof frame.
– Fit roof and fix in place.
– Weld in roof: RP spot weld seam.

– Weld in roof: SG plug weld seam.
72 Rep. Gr.51 - Body - centre

Audi TT 1999 ➤
RO: 51 05 55 00
2 Roof side member - Renewal
2.1 Procedure
– Separate 5 spot welds from roof in area of both windscreen

and rear window.
– Cut out as shown. Take care not to damage inner reinforce‐
ment.
– Drill 6 holes each at front and rear of roof for SG plug weld
seam instead of bonding.
– Separate inner roof side member original joint.
– Detach part outwards.
2. Roof side member - Renewal 73

Audi TT 1999 ➤
– Remove adhesive remnants with knife and scraper.

♦ Side frame
Preparing new part
2.1.3 Welding in
– Place an additional thickness of the same material behind the
C-pillar separating cut.
– Insert new part between roof and side panel.
– Weld in roof side member: RP spot weld seam.
– Weld in roof: SG plug weld seam.
– Butt weld A-pillar separating cut: SG continuous seam.
– Weld in inner roof frame: SG plug weld seam.

Audi TT 1999 ➤
RO: 51 05 55 52
3 Cross panel - Renewal
3.1 Procedure
• A-pillar and inner A-pillar already removed.

– Make separating cut according to extent of damage.

♦ Cross panel
3. Cross panel - Renewal 75

Audi TT 1999 ➤
Preparing new part

– Make holes in outer joint surface of new part.
– Transfer separating cut to new part and cut to size.
3.1.3 Welding in
– At separating cut: SG continuous seam (staggered).
– Weld in new part: RP spot weld seam. with respect to the correctness of information in this document. Copyright by AUDI AG.

Audi TT 1999 ➤
RO: 51 06 55 00
4 Outer roof frame - Renewal (Road‐

ster)
4.1 Procedure


– Position of spot welds -a- visible from inside. Drill off spot
welds through outer A-pillar.
– Lift out part -arrow-.

♦ Outer roof frame
4. Outer roof frame - Renewal (Roadster) 77

Audi TT 1999 ➤
Preparing new part

4.1.3 Welding in
– Slide in new part between outer pillar and inner A-pillar.
– Weld in roof frame: RP spot weld seam.
– Weld in roof frame: SG plug weld seam.
– Pay attention to 2 metal thicknesses at A-pillar: SG plug weld
seam.
– Weld in top part of roof frame: SG continuous seam.

– Braze top part of roof frame. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Weld in new part: A-pillar to outer roof frame, 5 x 30 mm SG

continuous seam.

Audi TT 1999 ➤
RO: 51 07 55 50
5 Front roof cross member - Renewal
5.1 Procedure
• Roof already removed

Note:
On account of the inner A-pillar reinforcement, the separating cut is only to be made at this location.
5. Front roof cross member - Renewal 79

Audi TT 1999 ➤

♦ Front roof cross member
♦ Upper roof cross member reinforcement
♦ Roof cross member
5.1.3 Welding in
– Fit new part and fix in position.
– Weld in front roof cross member: RP spot weld seam.
– Fix reinforcement in position and weld in: RP spot weld seam.

– Weld in reinforcement: SG continuous seam.
– Weld in reinforcement: SG plug weld seam.
– Weld in left and right reinforcement: RP spot weld seam.

Audi TT 1999 ➤
RO: 51 09 55 50
6 Rear roof frame - Renewal
6.1 Procedure
• Roof already removed


♦ Rear roof frame top section
♦ Rear roof frame bottom section
6. Rear roof frame - Renewal 81

Audi TT 1999 ➤
Preparing new part

6.1.3 Welding in Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Fit new part and fix in position. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Weld in roof frame bottom section: RP spot weld seam.
– Match up and fix new part in position.

– Weld in roof frame top section: RP spot weld seam.
– Weld in roof frame top section: SG plug weld seam.
– 4 x SG plug weld seam as replacement for adhesive.

Audi TT 1999 ➤
RO: 51 25 55 50
7 Side frame - Renewal
7.1 Procedure
• Side panel already cut out

• Outer side member already removed
– Cut out roof side member ⇒ page 73 .
– Cut out A-pillar ⇒ page 85 .

♦ Side frame
7. Side frame - Renewal 83

Audi TT 1999 ➤
Preparing new part

7.1.3 Welding in
– Weld in A-pillar ⇒ page 85 .
– Weld in roof side member ⇒ page 73 .

Audi TT 1999 ➤
RO: 51 37 55 00
8 A-pillar - Renewal
8.1 Procedure
• A-pillar fixed in position on portal gauge Alignment bracket set

supplement Audi TT -VAS 5020/6-
• Intermediate piece already removed.
• Outer side member part section already removed
– Make separating cut at top according to extent of damage. Not
in vicinity of inner reinforcement.
– Make separating cut in side member according to extent of
damage.
8. A-pillar - Renewal 85
Audi TT 1999 ➤

♦ Side frame
Preparing new part
– Transfer separating cuts to new part and cut off hatched area.
8.1.3 Welding in
– Weld in A-pillar: RP spot weld seam.
– Butt weld separating cuts: SG continuous seam.
– Weld in A-pillar: SG plug weld seam.

– A-pillar to wheel housing: SG plug weld seam.

Audi TT 1999 ➤
RO: 51 37 55 00
9 A-pillar - Renewal (Roadster)
9.1 Procedure
• A-pillar fixed in position on Alignment bracket set supplement

Audi TT -VAS 5020/6-
• Intermediate piece already removed.
– Make separating cut at side member according to extent of
damage.

♦ Inner side frame
9. A-pillar - Renewal (Roadster) 87

Audi TT 1999 ➤
Preparing new part

– Transfer separating cuts to new part and cut off hatched area.
9.1.3 Welding in
– Butt weld separating cut: SG continuous seam.
– Weld in A-pillar: SG plug weld seam.
– Weld in new part: A-pillar to outer roof frame, 5 x 30 mm SG
continuous seam.

Audi TT 1999 ➤
RO: 51 38 55 00
10 Reinforcement tube and inner A-pillar

- Renewal (Roadster)
10.1 Procedure

• Roof frame already removed
• Inner side frame part section already cut out.

♦ A-pillar reinforcement frame
10. Reinforcement tube and inner A-pillar - Renewal (Roadster) 89

Audi TT 1999 ➤
10.1.3 Welding in

Audi TT 1999 ➤
RO: 51 45 55 00
11 Outer side member - Renewal
11.1 Procedure

– Make separating cuts in side member according to extent of
damage.
11. Outer side member - Renewal 91

Audi TT 1999 ➤
Note:
♦ Before renewing, check whether the inner side member can be straightened.
♦ Deformation of up to 10 mm per 100 mm length is permissible.
♦ Cracks up to 100 mm long may be welded.
♦ Partial replacement is possible with the separating cuts indicated. Step in area of separating cut and SG
continuous seam.
♦ Set rivet nuts pop rivet nut pliers -V.A.G 1765/B- .

♦ Side member
♦ Rivet nuts
Preparing new part
– Drill side member for plug welding.
– Set rivet nuts with pop rivet nut pliers -V.A.G 1765/B- .
11.1.3 Welding in
– Weld in side member: RP spot weld seam.

Audi TT 1999 ➤
– Weld in side member: SG plug weld seam.

– 4 x 20 mm SG continuous seam instead of bonded joint.
11. Outer side member - Renewal 93

Audi TT 1999 ➤
RO: 51 45 55 00
12 Outer side member - Renewal (Road‐

ster)
12.1 Procedure

– Make separating cuts in side member according to extent of
damage.

Audi TT 1999 ➤
Note:
♦ Before renewing, check whether the inner side member can be straightened.
♦ Deformation of up to 10 mm per 100 mm length is permissible.
♦ Cracks up to 100 mm long may be welded.
♦ Set rivet nuts with pop rivet nut pliers -V.A.G 1765/B- .

♦ Side member
♦permitted
Rivetunless
nutsauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Lower hinge reinforcement.
Preparing new part
– Set rivet nuts with pop rivet nut pliers -V.A.G 1765/B- .
– Drill lower hinge reinforcement for plug welding.
12.1.3 Welding in
– Weld in side member: RP spot weld seam.
12. Outer side member - Renewal (Roadster) 95

Audi TT 1999 ➤
– Match up reinforcement and weld in: SG plug weld seam.


Audi TT 1999 ➤
RO: 51 87 55 02
13 Seat cross member - Renewal
13.1 Procedure

♦ Seat cross member
13. Seat cross member - Renewal 97

Audi TT 1999 ➤
Preparing new part

13.1.3 Welding in
– Weld in new part: SG plug weld seam.

Audi TT 1999 ➤
RO: 51 73 55 62
14 Floor panel - Renewal
14.1 Procedure
• Outer side member already removed

• Inner side member already removed
• Web plate already removed
• Reinforcement for side member already removed
• Seat cross member already removed
– Make separating cut as shown. Take care not to damage in‐
ternal reinforcement and longitudinal member.
14. Floor panel - Renewal 99

Audi TT 1999 ➤

♦ Floor panel
Preparing new part
14.1.3 Welding in
– Weld in floor panel: SG continuous seam.

Audi TT 1999 ➤
RO: 51 47 55 52
15 Side member reinforcement - Re‐

newal
15.1 Procedure

♦ Reinforcement for side member
15. Side member reinforcement - Renewal 101

Audi TT 1999 ➤
Preparing new part

15.1.3 Welding in
– Weld in new part as for original joint: SG continuous seam.
– RP spot weld seam in sill area.
– Weld in reinforcement plate: SG plug weld seam.

Audi TT 1999 ➤
53 – Body - rear
RO: 53 05 55 00
1 Rear cross panel (top section) - Re‐

newal
1.1 Procedure

– Detach part.
1. Rear cross panel (top section) - Renewal 103

Audi TT 1999 ➤
Note:
Partial replacement is possible with the separating cuts indicated. SG continuous butt weld in the area of the
separating cut.

♦ Rear cross panel
Preparing new part
1.1.3 Welding in
– Spot weld rear cross panel: RP spot weld seam.
– 3 x SG plug weld seam instead of bonding
104 Rep. Gr.53 - Body - rear

Audi TT 1999 ➤
RO: 53 05 55 50
2 Rear cross panel (inner section) - Re‐

newal
2.1 Procedure

– Grind off threaded rivets with angle grinder.
– Remove part downwards -arrow-.
2. Rear cross panel (inner section) - Renewal 105

Audi TT 1999 ➤
Note:
Set threaded rivets with pop rivet nut pliers -V.A.G 1765/B- .

♦ Rear cross panel
♦ Threaded rivets
Preparing new part
2.1.3 Welding in
– Guide in part from below between tail light mounting and bot‐
tom reinforcement.
– Spot weld rear cross panel: RP spot weld seam.

Audi TT 1999 ➤
RO: 53 10 55 00
3 Tail light mounting - Renewal
3.1 Procedure
• Top section of rear cross panel already removed

– Remove part downwards -arrow-.
Note:
The replacement part includes the inner reinforcement.
3. Tail light mounting - Renewal 107

Audi TT 1999 ➤

♦ Tail light mounting
Preparing new part
– Lever in new part

– Match up new part and fix in position.

Audi TT 1999 ➤
3.1.3 Welding in
– Weld in mounting panel: RP spot weld seam.
3. Tail light mounting - Renewal 109

Audi TT 1999 ➤
RO: 53 14 55 12
4 Rain channel - Renewal
4.1 Procedure


♦ Rain channel permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi TT 1999 ➤
Preparing new part

– Drill off spot welds and cut off hatched area.
4.1.3 Welding in
– Weld in sealing channel: SG plug weld seam.
4. Rain channel - Renewal 111

Audi TT 1999 ➤
RO: 53 17 55 50
5 Side frame connecting plate
5.1 Procedure
• Top section of rear cross panel already removed with respect to the correctness of information in this document. Copyright by AUDI AG.
• Rear cross panel already cut out.


♦ Side frame connecting plate

Audi TT 1999 ➤
Preparing new part

5.1.3 Welding in
– Weld in new part: RP spot weld seam.
5. Side frame connecting plate 113

Audi TT 1999 ➤
RO: 53 24 55 62
6 Luggage compartment floor - Partial

renewal
6.1 Procedure
• Rear cross panels and mounting panel already removed

– Make separating cut 20 mm in front of stamped area.

♦ Spare wheel well

Audi TT 1999 ➤
Preparing new part

6.1.3 Welding in
– Fit luggage compartment floor and fix in position.
– Weld overlap: SG plug weld seam.
– Weld in luggage compartment floor: SG plug weld seam.
6. Luggage compartment floor - Partial renewal 115

Audi TT 1999 ➤
RO: 53 24 55 56
7 Luggage compartment floor - Renew‐

al
7.1 Procedure


♦ Spare wheel well

Audi TT 1999 ➤
Preparing new part

7.1.3 Welding in
– With vehicle not subjected to load, align luggage compartment
floor and check panel gaps with rear cross panel and rear lid
in position.
– Weld in luggage compartment floor: SG continuous seam
(staggered).
– Weld in luggage compartment floor: SG plug weld seam.
7. Luggage compartment floor - Renewal 117

Audi TT 1999 ➤
RO: 53 48 55 62
8 Rear longitudinal member - Partial re‐

newal
8.1 Procedure

– Cut out longitudinal member.
– Grind off threaded rivets -a- with angle grinder.

Audi TT 1999 ➤
Note:
Set threaded rivets with pop rivet nut pliers -V.A.G 1765/B- .

♦ Longitudinal member part section
Preparing new part
8.1.3 Welding in
– Fix longitudinal member sub-part in position on alignment
bracket.
– Weld in longitudinal member: SG plug weld seam.
– Spot weld rear longitudinal member: RP spot weld seam.
– Butt weld longitudinal member: SG continuous seam.
8. Rear longitudinal member - Partial renewal 119

Audi TT 1999 ➤
RO: 53 55 55 00
9 Side panel - Renewal
9.1 Procedure
• Fix side panel in position on alignment bracket set supplement

Audi TT -VAS 5020/6- .
– Roughly cut out side panel.
– Grind through outer edge of wheel housing.
– Sand down brazed seam
– Detach part.

Audi TT 1999 ➤

♦ Side panel
♦ Brazing solder DA 008 000
♦ Body adhesive
Preparing new part
9.1.3 Welding in
– Weld in side panel, RP spot weld seam.
– Weld in side panel: SG plug weld seam.
– Apply adhesive to beaded area. Two beads of 3.5 mm diam‐
eter.
– Bead over wheel housing flange. Wipe off adhesive which
emerges and seal.
– Solder side panel to roof side member in the specified se‐
quence. Allow to cool for three minutes between soldering
operations.
9. Side panel - Renewal 121

Audi TT 1999 ➤
RO: 53 55 55 00
10 Side panel - Renewal (Roadster)
10.1 Procedure
• Side panel fixed in position on alignment bracket set supple‐

ment Audi TT -VAS 5020/6- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Roughly cut out side panel.

– Grind through outer edge of wheel housing.
– Grind through outer edge at top part of side panel.

Audi TT 1999 ➤
– Detach part.

♦ Side panel
♦ Body adhesive DA 001 730 A1
Preparing new part
– Make 8 additional holes in side member area.
10.1.3 Welding in
– Weld in side panel: RP spot weld seam.
– 4 x 20 mm SG continuous seam instead of bonded joint.
– Apply adhesive to beaded area. Two beads of 3.5 mm diam‐
eter.
– Bead over wheelpermitted
housing flange.
unless Wipe
authorised offAG.
by AUDI adhesive
AUDI AG does which
not guarantee or accept any liability
emerges and seal.with respect to the correctness of information in this document. Copyright by AUDI AG.
– Bead over wheel housing flange. Wipe off adhesive which
emerges and seal.
10. Side panel - Renewal (Roadster) 123

Audi TT 1999 ➤
RO: 53 68 55 50
11 Rear wheel housing - Renewal
11.1 Procedure

• Tail light mounting already cut out
Note:
Set rivet nuts with pop rivet nut pliers -V.A.G 1765/B- .

Audi TT 1999 ➤

♦ Wheel housing liner
♦ Rivet nuts
Preparing new part
11.1.3 Welding in
– Spot weld wheel housing liner: RP spot weld seam.
– Double the number of spot welds as replacement for adhesive.
– Weld in wheel housing: SG plug weld seam.

– Joint with longitudinal member is welded (SG plug weld seam)
instead of bonding.
11. Rear wheel housing - Renewal 125

SM 12

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM 12

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2010 Audi AG, Ingolstadt A008NKI0120

7 Front longitudinal member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

8 Rear longitudinal member - Partial renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

1.1 Type plate and vehicle identification

1.2 Vehicle data sticker

1. Vehicle identification data 1

2.1 Floor group, front

2 Rep. Gr.00 - Technical data

2.2 Floor group, centre

2.3 Floor group, rear

4 Rep. Gr.00 - Technical data

2.4 Body - front

6 Rep. Gr.00 - Technical data

2.5 Body - centre

2.6 Body - centre (Roadster)

8 Rep. Gr.00 - Technical data

2.7 Body - rear

10 Rep. Gr.00 - Technical data

2.8 Body - rear (Roadster)

12 Rep. Gr.00 - Technical data

3 Body panel gaps/shut lines

3.1 Body - front

Use special tool 3371 for adjusting or checking.

3. Body panel gaps/shut lines 13

3.2 Body - centre

14 Rep. Gr.00 - Technical data

3.3 Body - rear

3. Body panel gaps/shut lines 15

3.4 Body (Roadster)

16 Rep. Gr.00 - Technical data

The body is manufactured from panels galvanised on both sides.

These parts of the body are foam-filled for acoustic reasons.

18 Rep. Gr.00 - Technical data

7 Strengthened body panels

Strengthened body panels are used in the following areas:

20 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

The repair methods are shown in detail on the following pages.

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

8.5 Repair methods for bonded joints

A - Bottom of inner A-pillar to

22 Rep. Gr.00 - Technical data

8.7 Body - centre

1 - Outside of front side frame

2 - Inside of rear side frame to

3 - Roof to outside of inner side

4 - Inside of rear side frame to

5 - Front floor to frame base

6 - Front floor to frame base

7 - Outside of front side frame

24 Rep. Gr.00 - Technical data

8 - Outer side to sill

9 - Outer side to sill

10 - Outside of rear wheel

11 - Sill connecting piece to sill

12 - Outside of side frame to

13 - Roof to rear roof frame