Brake System

Service
Workshop Manual
Audi TT 2007 ➤
Brake system
Edition 04.2009
Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2010 Audi AG, Ingolstadt A005TT00320

Audi TT 2007 ➤
Brake system - Edition 04.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Production code (PR No.) allocation: brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.5 Rear wheel brakes, front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.6 Rear wheel brakes, four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.7 Rear brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Four-wheel drive vehicles with Haldex coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Testing four-wheel drive vehicles with Haldex coupling on a conventional brake
dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1 General information on the anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Notes for repair work on ABS Mark 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Connecting VAS 505x and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Components and fitting locations on brake system ABS/ESP Mark 60 . . . . . . . . . . . . . . . . 10
4 Removing and installing parts of ABS/ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Removing and installing brake light switch (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5 Removing and installing brake servo vacuum sender G483 . Only on vehicles with (OHBV)
optimised hydraulic brake assistance/vacuum sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 ABS/ESP Mark 60 control unit -J104- and hydraulic unit -N55- . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Removing and installing ABS control unit -J104- and ABS hydraulic unit -N55- . . . . . . . . 20
6 TFSI engine: ABS control unit -J104- and ABS hydraulic unit -N55- . . . . . . . . . . . . . . . . . . 25
6.1 Removing and installing control unit -J104- with hydraulic unit -N55- (TFSI) . . . . . . . . . . . . 25
6.2 Removing and installing control unit -J104- with hydraulic unit -N55- (TT RS) . . . . . . . . . . 29
7 Vehicles with diesel particulate filter: Control unit -J104- with hydraulic unit -N55- . . . . . . 34
7.1 Removing and installing control unit -J104- with hydraulic unit -N55- (TDI) . . . . . . . . . . . . 34
7.2 Basic setting of inlet valves and separating valves (Mark 60EC) . . . . . . . . . . . . . . . . . . . . 39
8 ABS/ESP system components on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8.2 Removing and installing speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9 ABS/ESP system components on rear axle (front-wheel drive vehicles) . . . . . . . . . . . . . . 42
9.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.2 Removing and installing rear speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10 ABS/ESP system components on rear axle (four-wheel drive vehicles) . . . . . . . . . . . . . . 44
10.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.2 Removing and installing rear speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1 Servicing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Contents i
Audi TT 2007 ➤
1.1 Servicing front brakes 16" FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.2 Removing and installing brake pads - front brakes 16" FN3 . . . . . . . . . . . . . . . . . . . . . . . . 49
1.3 Removing and installing brake caliper - front brakes 16" FN3 . . . . . . . . . . . . . . . . . . . . . . 52
2 Servicing front brakes 17" FNR G57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Removing and installing brake pads - front brakes 17" FNR G57 . . . . . . . . . . . . . . . . . . . . 57
2.2 Removing and installing brake caliper - front brakes 17" FNR G57 . . . . . . . . . . . . . . . . . . 60
3 Servicing front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1 Removing and installing brake pads - front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Removing and installing brake caliper - front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . 67
3.3 Renewing brake caliper - front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.4 Removing and installing brake disc - front brakes (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . 71
4 Pressing back brake piston in front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5 Vibration damper on brake caliper - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.1 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6 Servicing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.1 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.2 Removing and installing rear brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.3 Removing and installing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.4 Detaching and attaching handbrake cable from/to brake caliper . . . . . . . . . . . . . . . . . . . . 83
6.5 Pressing back piston in rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.1 Handbrake - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.2 Removing and installing handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.3 Removing and installing handbrake switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.4 Removing and installing handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.5 Removing and installing guide tubes for handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.6 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.1 Brake pedal - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.2 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.3 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1 High-pressure and low-pressure tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.1 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2 Servicing front brake caliper FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.1 Front brake caliper FN3 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.2 Removing and installing piston for front brake caliper FN3 . . . . . . . . . . . . . . . . . . . . . . . . 97
3 Servicing front brake caliper FNRG57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.1 Front brake caliper FNRG57 - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.2 Removing and installing piston for front brake caliper FNRG57 . . . . . . . . . . . . . . . . . . . . 101
4 Servicing brake caliper (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5 Servicing rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.1 Rear brake caliper - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.2 Removing and installing piston for rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6 Bleeding brake system - ABS/ESP Mark 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.1 Bleeding brake system with brake filling and bleeding equipment VAS 5234 or upgrade kit
and extraction unit V.A.G 1869/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.2 Bleeding brake system without brake filling and bleeding equipment . . . . . . . . . . . . . . . . 111
7 Brake servo/brake master cylinder - left-hand drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . 113
7.1 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
7.2 Checking non-return valve (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.3 Removing and installing non-return valve (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
7.4 Removing and installing brake fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
ii Contents
Audi TT 2007 ➤
7.5 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

7.6 Removing and installing brake master cylinder (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.7 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7.8 Removing and installing brake servo (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
7.9 Removing and installing noise amplifier (TFSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
8 Exhauster pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8.1 Removing and installing exhauster pump (TDI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8.2 Removing and installing exhauster pump (TFSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
8.3 Removing and installing exhauster pump (TT RS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
9 Brake lines and brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
9.1 Removing and installing brake lines and brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Contents iii
Audi TT 2007 ➤
iv Contents
Audi TT 2007 ➤
00 – Technical data
1 Technical data
1.1 Production code (PR No.) allocation:

brakes
Which brakes are fitted on the vehicle can be determined from
the corresponding production code (PR No.) on the vehicle data
sticker.
The vehicle data sticker can be found in the spare wheel well and
in the Service Schedule.
The corresponding PR numbers are listed in the following tables.
They indicate the required combination of brake discs/calipers/
drums ⇒ Electronic parts catalogue (ETKA)
1.2 Brakes
Brake system
Diagonal dual-circuit brake system, anti-lock brake system (ABS) with electronic brake pressure distribution
(EBPD). Certain equipment versions or model production dates additionally feature electronic differential
lock (EDL), traction control system (ASR) and electronic stabilisation program (ESP).
1.3 Front brakes

Front axle
Brake caliper (PR No.) 1LJ 1LL 1LK 1LM 1LN
Front brake caliper FN3 FN3 FNR-G-57 FNR-G-57 FNR-G-57
Piston ∅ mm 54 54 57 57 57
Brake disc (PR No.) 1LJ 1LJ 1LK 1LK 1LK
Front brake disc ∅ mm 312 (16“) 312 (16“) 340 (17“) 340 (17“) 340 (17“)
Brake disc thickness mm 25 25 30 30 30
(ventilated)
Brake disc, wear limit mm 21 21 27 27 27
Brake pad
Pad thickness (new, mm 14 14 14 14 14
without backplate)
Pad wear limit (without mm 2 2 2 2 2
backplate)
1.4 Front brakes (TT RS)

Front axle, TT RS
Brakes (PR No.) 1LA
Front brake caliper Brembo (M4)
Piston ∅ 40 / 44 mm
Brake disc (PR No.) 1LK
Front brake disc ∅ 370 mm
Brake disc thickness (ventilated) 32 mm
Brake disc, wear limit 30 mm
1. Technical data 1
Audi TT 2007 ➤
Front axle, TT RS
Pad wear limit (without backplate) 2 mm
1.5 Rear wheel brakes, front-wheel drive

Rear wheel brakes, front-wheel drive
Brake caliper (PR No.) 2ED 1KZ
Rear brake caliper CII 38HR CII 38HR
Piston ∅ mm 38 38
Brake disc (PR No.) 2ED, 2EE 1KZ, 1KJ,
Rear brake disc ∅ mm 286 (16“) 286 (16“)
Brake disc thickness (non-ventilated) mm 12 12
Brake disc thickness (ventilated) mm ------ ------
Brake disc wear limit mm 9 9
Brake pad
Pad thickness (new, without backplate) mm 12 12
Pad wear limit (without backplate) mm 2 2
1.6 Rear wheel brakes, four-wheel drive

Rear wheel brakes, four-wheel drive
Brake caliper (PR No.) 1KJ 2EE 2EA 2EF 2EG
Rear brake caliper CII 41HR CII 41HR CII 41HR CII 41HR CII 41HR
Piston ∅ mm 41 41 41 41 41
Brake disc (PR No.) 1KJ, 1KZ 2EE, 2ED 2EA 2EF 2EG
Rear brake disc ∅ mm 286 (16“) 286 (16“) 310 (17“) 310 (17“) 310 (17“)
Brake disc thickness mm 12 12 ------ ------ ------
(non-ventilated)
Brake disc thickness mm ------ ------ 22 22 22
(ventilated)
Brake disc, mm 9 9 19 19 19
wear limit
Pad wear limit (without mm 2 2 2 2 2
backplate)
1.7 Rear brakes (TT RS)

Rear brakes (TT RS)
Rear brake caliper CII 41 HR
Piston ∅ mm 41
Rear brake disc ∅ mm 312
Brake disc thickness (ventilated mm 22
brake disc)
Brake disc, mm 19
wear limit
Pad wear limit (without back‐ mm 2
plate)
2 Rep. Gr.00 - Technical data

Audi TT 2007 ➤
2 Brake test
2.1 General notes

The wheels are driven by the test rollers.
During the test the gearbox must be in neutral on manual gear‐
boxes or
in position N on automatic gearboxes.
Follow the instructions provided by the manufacturer of the brake
test equipment when performing the test.
Note
Electronic brake control systems are inoperative when the ignition

is switched off.
2.2 Vehicles with front-wheel drive

Testing on a single-axle brake dynamometer
Perform brake test on a single-axle brake dynamometer.
The EDL control can activate the brakes if the rollers start at dif‐
ferent points in time.
Test speed must not exceed 6 km/h.
All brake test equipment approved by Audi meets these require‐
ments.
2.3 Four-wheel drive vehicles with Haldex

coupling
Testing on a single-axle brake dynamometer for four-wheel drive
vehicles
The rollers drive the wheels of one axle in opposite directions to
avoid transmitting torque to the other axle.
The EDL control can activate the brakes if the rollers start at dif‐
ferent points in time.
Test speed must not exceed 6 km/h.
All brake test equipment approved by Audi meets these require‐
ments.
2.4 Testing four-wheel drive vehicles with

Haldex coupling on a conventional
brake dynamometer
Proceed as follows to test brakes on a conventional brake dyna‐
mometer.
– Drive vehicle forward until front wheels are standing on rollers.
– Switch off engine and wait for 3 seconds.
– Perform brake test on front wheels.
– Allow engine to run for approx. 5 seconds after performing
brake test to build up sufficient vacuum in the servo.
– Drive vehicle forward until rear wheels are standing on rollers.
2. Brake test 3
Audi TT 2007 ➤
– Switch off engine and wait for 3 seconds.

– Perform brake test on rear wheels.
WARNING
The engine must not run and the ignition must be switched off
during the brake test, otherwise the rear wheels will be driven
by the Haldex coupling.
4 Rep. Gr.00 - Technical data

Audi TT 2007 ➤
3 Brake fluid
3.1 General notes

Brake fluid is hygroscopic, i.e. it has the tendency to absorb water
and moisture from the atmosphere
The boiling point decreases as the water content increases, which
means a considerable rise in brake fluid temperature can lead to
formation of vapour bubbles and reduced braking effect.
The colour of the brake fluid becomes darker over the course of
time. This is caused by a normal chemical reaction and is not an
indication of the condition of the fluid.
WARNING
Rubber parts of brake system (sleeves, seals) are not com‐

patible with mineral oil, fuel and cleaning agents. Even minute
quantities coming into contact with a sleeve or seal will affect
the component and could impair brake operation.
3. Brake fluid 5
Audi TT 2007 ➤
45 – Anti-lock brake system

1 General information on the anti-lock
brake system
1.1 Notes for repair work on ABS Mark 60
WARNING
The anti-lock brake system is basically maintenance-free.

Testing, removing, installing and repair work may only be per‐
formed by qualified personnel.
Failure to observe the information described in this Workshop
Manual may result in damage to the system and could make
the vehicle unsafe.
Note
Malfunctions in the ABS system do not influence the brake system

itself. However, a change in braking behaviour must be reckoned
with.
Vehicles equipped with the ABS Mark 60 do not have a mechan‐

ical brake pressure regulator. A specially matched software in the
control unit controls the rear axle brake pressure regulation.
♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the problem using self-diagnosis.
♦ Always switch off ignition before unplugging the connector at
hydraulic control unit.
♦ If a new hydraulic control unit has been fitted, it must be en‐
coded. Vehicle diagnostic, testing and information system -
VAS 505x-
♦ Bleed brake system after performing work involving opening
of brake system: ABS/ESP Mark 60 ⇒ page 109 . To do so,
use for example the brake filling and bleeding equipment -
V.A.G 1869- or brake filling and bleeding equipment -VAS
5234- .
♦ Absolute cleanliness is required when working on the anti-lock
brake system; avoid any products that contain mineral oil,
such as oil, grease, etc.
♦ Thoroughly clean all connections and the adjacent areas be‐
fore loosening; do not use harsh cleaning agents such as
brake cleaner, fuel, thinners or similar.
♦ Place removed parts on a clean surface and cover them up.
♦ Carefully cover or seal open components if repairs are not to
be carried out immediately. Use plugs from repair kit; Part No.
⇒ ETKA .
♦ When the brake system is open do not work with compressed
air and do not move the vehicle.
♦ Only use lint-free cloths.
♦ Only use genuine spare parts from original packaging.
6 Rep. Gr.45 - Anti-lock brake system

Audi TT 2007 ➤
♦ Only remove replacement parts from packaging immediately

prior to installation.
♦ During the final road test, ensure that at least one ABS-con‐
trolled braking operation is performed (pulsations must be felt
at the brake pedal).
♦ During painting operations, the electronic control unit can be
exposed to a maximum temperature of 95 °C for only a short
period, and to a maximum of 85 °C for longer periods (approx.
2 hours).
♦ Before carrying out welding work with an electric welding unit,
refer to ⇒ General notes; Body repairs; Safety notes .
1. General information on the anti-lock brake system 7

Audi TT 2007 ➤
2 Connecting -VAS 505x- and select‐

ing functions
Special tools and workshop equipment required
♦ Vehicle diagnostic, testing and information system -VAS 505x-
WARNING
♦ Test equipment must always be secured to the rear seat

when road-testing the vehicle.
♦ While the vehicle is moving this equipment must be oper‐
ated by a second person; NOT by the driver.
– Attach the diagnosis cable connector to the diagnosis con‐

nection.

Audi TT 2007 ➤
– Switch on tester -arrow-.

The tester is ready as soon as a picture of a car appears in the
display.
– Switch on ignition.
– Press the Guided Fault Finding button on the display screen.
– Select the following:
♦ Make
♦ Model
♦ Model year
♦ Version
♦ Engine code letters
– Confirm the entered information.
Wait until the tester has interrogated all the control units in the
vehicle.
– Press the Go to button and select the option “Function/com‐
ponent selection”.
Follow the instructions in the display to begin with the desired
functions.
2. Connecting VAS 505x and selecting functions 9

Audi TT 2007 ➤
3 Components and fitting locations on brake system ABS/ESP Mark 60
1 - ESP and TCS warning lamp

-K155-
❑ Fitting location: in rev.
counter.
❑ Flashes when the vehi‐
cle is in motion and the
ESP/TCS control is in
operation
❑ Lights up when the igni‐
tion is switched on and
goes out after a short
self-test has been com‐
pleted
❑ Lights up if there is a
malfunction in the ESP
❑ Lights up if there is a
malfunction in the ABS,
since the ESP works in
conjunction with the
ABS
❑ Lights up when the ESP
is switched off
❑ Lights up during auto‐
matic self-adaption of
the sensor systems
when:
♦ the battery has been dis‐
connected and then re-con‐
nected
♦ the vehicle has been jump-
started
♦ the battery charge level is
very low
❑ The warning lamp goes
out after the vehicle has
been in motion for a
short time as soon as the learning procedure of the sensor systems is finalised.
2 - Brake pad warning lamp -K32-
❑ Fitting location: in centre display zone
❑ Lights up when wear limit of the brake pads is reached ⇒ page 1
3 - Brake system warning lamp -K118-
❑ Fitting location: in speedometer
❑ Lights up when the handbrake is applied.
❑ Lights up if there is a malfunction in the ABS system.
❑ Flashes if brake fluid level is too low
4 - ABS warning lamp -K47-
❑ Fitting location: in speedometer
❑ Lights up for a few seconds when the ignition is switched on and goes out after the automatic ABS self-
test has been completed, providing no faults have been detected in the ABS.
❑ There is a malfunction of the ABS if the warning lamp:
♦ does not light up when the ignition is switched on,
♦ does not go out again after a few seconds,

Audi TT 2007 ➤
♦ lights up while the vehicle is in motion.

❑ Malfunctions in the ABS system do not influence the brake system itself. However, a change in braking
behaviour must be reckoned with.
❑ The ESP warning lamp will light up as well as the ABS warning lamp if there is a malfunction in the ABS,
since the two systems work in conjunction.
5 - TCS and ESP button -E256-
❑ Fitting location: on the centre console
6 - Rear left speed sensor -G44- , rear right speed sensor -G46- -
❑ 8 Nm
7 - Steering angle sender -G85-
❑ Fitting location: on steering column between steering wheel and steering column switch
❑ Removing and installing ⇒ page 16
8 - Diagnostic connection
❑ Fitting location: cover in driver's footwell
9 - Brake pedal
10 - Front left speed sensor -G45- , front right speed sensor -G47-
❑ 8 Nm
11 - Brake servo
Note
♦ On vehicles with TTS engine the

noise amplifier must be removed
and installed ⇒ page 129 .
♦ The noise amplifier is located in
the engine compartment in front
of the brake servo.
❑ With integrated brake vacuum sender -G 483
❑ Brake vacuum sender -G 483 is not fitted on all models
❑ Removing and installing brake servo vacuum sender -G 483 ⇒ page 17
Note
The brake vacuum sender -G 483 is

only installed on vehicles with
OHBV.
12 - Brake master cylinder

❑ With brake light switch attached
Note

of the brake servo.
3. Components and fitting locations on brake system ABS/ESP Mark 60 11

Audi TT 2007 ➤
13 - Brake light switch

❑ Removing and installing (TT RS) ⇒ page 13
❑ The brake light switch is not adjustable.
❑ Location: On brake master cylinder
❑ 5 Nm
14 - ABS control unit (with ESP) -J104-
❑ Fitting location: on hydraulic unit -N55 on right-side of engine compartment.
❑ Do not unplug connector before completing self-diagnosis. Switch off ignition before detaching connector.
❑ Removing and installing (TFSI engine) ⇒ page 25
❑ Removing and installing (vehicles with diesel particulate filter) ⇒ page 34
Caution
ABS control unit -J104-
and ABS hydraulic unit -
N55- must not be sepa‐
rated.
15 - ABS hydraulic unit -N55-

❑ Fitting location: in engine compartment (right-side) on control unit -J104-.
❑ The ABS hydraulic pump -V64- , the ABS hydraulic unit -N55- and the ABS control unit (with ESP) -J104-
together make up the hydraulic control unit.
❑ With integrated brake pressure sender -G201-
❑ The brake pressure sender -G201- cannot be renewed separately.
❑ Allocation ⇒ ETKA
16 - ESP sensor unit -G419-
❑ 9 Nm
❑ Fitting location: on centre console in front of gear lever.
❑ Combined lateral acceleration sender -G200- and yaw rate sender -G202-
❑ Longitudinal acceleration sender -G251- (only four-wheel drive vehicles)
❑ Removing and installing ESP sensor unit ⇒ page 15
Note
The ABS sensor ring / rotor is incorporated in the corresponding

wheel bearing unit and cannot be renewed.

Audi TT 2007 ➤
4 Removing and installing parts of

ABS/ESP system
4.1 Removing and installing brake light

switch
Removing
Note
♦ The brake light switch is located on the brake master cylinder.

♦ The brake light switch is not adjustable.
– Unplug electrical connector -1-.

– Remove securing bolt for brake light switch -2- from brake
master cylinder.
– Pull brake light switch at bottom out of brake master cylinder
and lift switch out of retaining tab at top.
Installing
– Installation is carried out in the reverse sequence. Ensure
proper seating of switch in retaining tab at top.
Note
The brake light switch is not adjustable.
4.2 Removing and installing brake light

switch (TT RS)
Removing
Note
♦ The brake light switch is located on the brake master cylinder.

♦ The brake light switch is not adjustable.
– Lift off engine cover panel -1-.
4. Removing and installing parts of ABS/ESP system 13

Audi TT 2007 ➤
– Unscrew bolts -arrows- and detach air duct.
– Unscrew bolts -arrows- and detach air cleaner housing.

– Remove securing bolt for brake light switch -2- from brake
master cylinder.
– Pull brake light switch at bottom out of brake master cylinder
and lift switch out of retaining tab at top.
Installing
– Installation is carried out in the reverse sequence. Ensure
proper seating of switch in retaining tab at top.
Note
The brake light switch is not adjustable.
– Insert air cleaner housing and tighten bolts -arrows-.

Audi TT 2007 ➤
– Insert air duct and tighten bolts -arrows-.

– Install engine cover panel.
4.3 Removing and installing ESP sensor

unit -G419-
WARNING
The ESP sensor unit is sensitive to impact. The ESP sensor

unit can be damaged if subjected to impact. If the ESP sensor
unit has been dropped by mistake it may not work properly and
must not be installed in the vehicle.
– After renewing ESP sensor unit -G419-, a basic setting (cali‐

bration) for
♦ Lateral acceleration sender -G200-
♦ Yaw rate sender -G202-
♦ Longitudinal acceleration sender -G251- (on four-wheel drive
vehicles)
– must be performed
Removing
Note
ESP sensor unit -G419 is fitted on centre console under trim in

front of gear lever / selector lever.
– Remove centre console trim ⇒ Rep. Gr. 68 .

– Unplug connector.
– Remove bolts.
– Lift out ESP sensor unit -G419-.
Installing
Installation is performed in reverse sequence; note the following:
Calibrate lateral acceleration sender -G200 and longitudinal ac‐
celeration sender -G251 on vehicles with four-wheel drive. To do
so, use the vehicle diagnosis, testing and information system -
VAS 505x- .
– Select on the display:
♦ Running gear
♦ Brake system (Repair group 01; 45)
♦ 01 - Self-diagnosis compatible systems

Audi TT 2007 ➤
♦ 03 - Brake electronics ABS/ESP Mark 60

– Select the function you require on the display.
♦ Calibrate lateral acceleration sender -G200-
♦ Calibrate longitudinal acceleration sender -G251- (only on
four-wheel drive vehicles)
– Carry out ESP road test and system test.
4.4 Removing and installing steering angle

sender -G85-
Removing
– Turn wheels to straight ahead position.
– Remove airbag unit and steering wheel ⇒ Rep. Gr. 48 .
Item -1-: Return ring with slip ring
- Clipped to switch for turn signal indicator, main beam, dipped
beam and headlight flasher
Item -2- Steering angle sender -G85-
- Clipped to return ring with slip ring
WARNING
The return ring with slip ring must not be rotated following re‐
moval.
– Remove driver's storage compartment ⇒ Rep. Gr. 68 .

– Remove steering column switch module ⇒ Rep. Gr. 94 .
Installing
Installation is carried out in the reverse sequence.
– Install airbag unit and steering wheel. ⇒ Rep. Gr. 48
Calibrate steering angle sender -G85.
To do this, use vehicle diagnosis, testing and information system
-VAS 505x- .
♦ Running gear
– Select the function you require on the display.
♦ J104 - Control unit for ABS/TCS/ESP, Functions
♦ G-85 - Calibrate steering angle sensor ⇒ Vehicle diagnosis,
testing and information system -VAS 505x- .

Audi TT 2007 ➤
4.5 Removing and installing brake servo

vacuum sender -G483- . Only on vehi‐
cles with (OHBV) optimised hydraulic
brake assistance/vacuum sender
Note
♦ On vehicles with TTS engine the noise amplifier must be re‐

moved and installed ⇒ page 129 .
♦ The noise amplifier is located in the engine compartment in
front of the brake servo.
Note
Vehicles on which the brake vacuum is supplied entirely by the

intake manifold and vehicles with mechanical vacuum pump are
not fitted with brake servo vacuum sender -G483.

♦ Vehicle diagnostic, testing and information system -VAS 505x-
Note
♦ Brake servo vacuum sender -G483- does not have to be cali‐

brated after renewal.
♦ The "Guided Fault Finding" contains a description of the elec‐
trical check.
Removing
Note

– Unplug electrical connector -1- for vacuum sender -2-.

Audi TT 2007 ➤
– Pull back retaining ring -1- on OHBV and remove sender -

G483 -2- from brake servo.
Installing
Note

Installation is carried out in reverse sequence.

Audi TT 2007 ➤
5 ABS/ESP Mark 60 control unit -J104-

and hydraulic unit -N55-
5.1 Exploded view
1 - Brake lines
♦ Marking - DK - Brake mas‐
ter cylinder/primary piston
circuit to hydraulic unit.
♦ Marking - HL - To rear left
brake caliper.
♦ Marking - VR - To front right
brake caliper.
♦ Marking - VL - To front left
brake caliper.
♦ Marking - HR - To rear right
brake caliper.
♦ Marking - SK - Brake mas‐
ter cylinder/secondary pis‐
ton circuit to hydraulic unit.
❑ 14 Nm
❑ Perform final control di‐
agnosis after securing
brake lines to hydraulic
unit. To do this, use ve‐
hicle diagnosis, testing
and information system
-VAS 505x- .
2 - ABS control unit (with ESP)
-J104-
❑ Fitting location: on hy‐
draulic unit -N55 on
right-side of engine
compartment.
❑ Removing and installing
⇒ page 20
(TFSI engine)
⇒ page 25
Caution
ABS control unit -J104-
and ABS hydraulic unit -
N55- must not be sepa‐
rated. Control unit and
hydraulic unit must be re‐
newed as one unit.
3 - ABS hydraulic unit -N55-

❑ Fitting location: in engine compartment (right-side) on control unit -J104-
5. ABS/ESP Mark 60 control unit -J104- and hydraulic unit -N55- 19

Audi TT 2007 ➤

4 - Bracket
❑ Removing and installing together with hydraulic unit -N55- and control unit -J104- ⇒ page 20
5 - Bolt
❑ Bracket to hydraulic unit
❑ 8 Nm
6 - Mounting bracket
❑ With rubber buffer
7 - Nut
5.2 Removing and installing ABS control

unit -J104- and ABS hydraulic unit -N55-
Caution
ABS control unit -J104- and ABS hydraulic unit -N55- must not
be separated.
Removing hydraulic unit with control unit

– Read out control unit version and note down.
– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 (note
radio code).
– Insert brake pedal actuator -V.A.G 1869/2- between brake
pedal and driver's seat (depress brake pedal at least 60 mm).
– Connect hose of bleeder bottle to bleeder screws of front left
and rear left brake calipers.
– Open bleeder screws of rear left and front left brake calipers
to release pressure in hydraulic unit.
– Close bleeder screws of front left and rear left brake calipers.
– Do not remove brake pedal actuator -V.A.G 1869/2- .

Audi TT 2007 ➤
– Release connector at control unit -arrow 1- and unplug

-arrow 2-.
Note
♦ Make sure brake fluid does not get into connector housing of
control unit. This can result in corrosion of the contacts and
failure of the system.
♦ Use compressed air to carefully clean connector housing if
necessary.
– To protect against escaping brake fluid, place a sufficient

number of lint-free cloths in area beneath control unit and hy‐
draulic unit.
– Mark brake lines ⇒ Item 1 (page 19) .
WARNING
Do not bend or kink brake lines.
– Unscrew brake lines from hydraulic unit -2- to brake master

cylinder and tie in place.
– Disconnect remaining brake lines -3- on hydraulic unit.
Note
Hydraulic pump -1- must not be separated from hydraulic unit.
– Seal brake lines and threaded holes using sealing plugs from
repair kit.

Audi TT 2007 ➤
– Carefully pull hydraulic unit -2- together with control unit and
bracket -4- out of rubber buffers on mounting bracket -6-.
– Take hydraulic unit out of vehicle.
– Unscrew bolts -5- from bracket -4- and detach bracket.
WARNING
Severe shocks or jolts can damage the control unit. The control
unit must not be re-installed if it has been damaged in any way.
– Place hydraulic unit on a clean flat surface with control unit

facing downwards.
Seal threaded holes and brake lines using sealing plugs -
1H0.698.311.A after removing control unit and hydraulic unit.
WARNING
Hydraulic pump must not be separated from hydraulic unit.
Installing
Note
♦ The hydraulic unit supplied as a replacement is filled with

brake fluid.
♦ Do not remove sealing plug of corresponding brake line before
fitting, otherwise brake fluid will escape. Proper bleeding is
then no longer ensured.

Audi TT 2007 ➤
– Secure bracket -4- by tightening bolts -5- to 8 Nm.

– Carefully insert hydraulic unit -2- together with control unit and
bracket -4- in rubber buffers on mounting bracket -6-.
Make sure that rubber buffers are not pressed through mounting
bracket when inserting unit.
– Connect brake lines as previously marked.
WARNING
Interchanging brake line connections will result in ESP system

malfunction.
– Connect brake lines to hydraulic unit.

– Attach connector to control unit and lock connector.
– Bleed brake system ⇒ page 109 .
– Perform final control diagnosis after securing brake lines to
hydraulic unit.
-VAS 505x- .
Note
Final control diagnosis can be used to establish whether line con‐

nections have been interchanged.
If a new ABS control unit -J104- has been fitted, it must be enco‐
ded.
-VAS 505x- .
♦ Running gear
– Select required function on the display.
♦ J104 - Control unit for ABS/TCS/ESP Mark 60
♦ J104 - Encoding control unit
Also calibrate the following senders after renewing control unit -
J104-.
♦ Steering angle sender -G85-
♦ Brake pressure sender 1 -G201-
♦ Longitudinal acceleration sender -G251- (only on four-wheel
drive vehicles)
-VAS 505x- .

Audi TT 2007 ➤
♦ Running gear
♦ Brake system
– Then carry out ESP road test and system test.
WARNING
Before driving vehicle for the first time, make sure function of
brakes is OK.

Audi TT 2007 ➤
6 TFSI engine: ABS control unit -J104-

and ABS hydraulic unit -N55-
6.1 Removing and installing control unit -

J104- with hydraulic unit -N55- (TFSI)
Caution
be separated.

radio code).
– Lower vehicle.
– Detach engine cover panel.

– Using suitable pliers, unfasten clamp at air hose to air duct and
detach hose
– Using suitable pliers, unfasten clamps of air duct and detach.
– Remove air duct to turbocharger from bracket.
– Take air duct out of vehicle.
6. TFSI engine: ABS control unit -J104- and ABS hydraulic unit -N55- 25
Audi TT 2007 ➤

-arrow 2-.
Note
necessary.

draulic unit.
WARNING

repair kit.
Note
The hydraulic pump must not be separated from the hydraulic

unit.

Audi TT 2007 ➤
facing downwards.
WARNING

WARNING
Installing
Note

brake fluid.
♦ If sealing plugs are removed before fitting corresponding
brake line, brake fluid will escape. Proper bleeding is then no
longer ensured.
Audi TT 2007 ➤

– Connect brake lines as previously marked
⇒ Item 1 (page 19) .
WARNING

malfunction.

– Insert air duct for turbocharger and use suitable pliers to fasten
clamps.
– Secure air duct for turbocharger at bracket.
– Connect air hose and use suitable pliers to fasten clamp.
hydraulic unit.
-VAS 505x- .
Note

ded.
-VAS 505x- .
♦ Running gear
J104-.

Audi TT 2007 ➤

drive vehicles)
-VAS 505x- .
♦ Running gear
♦ Brake system
WARNING
brakes is OK.

J104- with hydraulic unit -N55- (TT RS)
Caution
be separated.

radio code).
Audi TT 2007 ➤

– Lower vehicle.
– Using suitable pliers, unfasten clamp at air hose to air duct and
detach hose.
– Using suitable pliers, unfasten clamps of air duct and detach.
– Remove air duct to turbocharger from bracket.
– Take air duct out of vehicle.
– Unclip coolant line to coolant expansion tank from bulkhead.
– Carefully press coolant line to one side.

-arrow 2-.
Note
necessary.
– Unfasten cable tie for electrical wiring to connector and move

wiring clear to one side.
draulic unit.
WARNING

Audi TT 2007 ➤

repair kit.
Note
The hydraulic pump must not be separated from the hydraulic

unit.
facing downwards.
WARNING

WARNING
Installing
Note

brake fluid.
longer ensured.
Audi TT 2007 ➤

– Connect brake lines as previously marked
WARNING

malfunction.

– Secure electrical wiring for connector to body using a cable
tie.
– Clip coolant line to coolant expansion tank into retainers in
bulkhead.
Note
Fasten retainers at bulkhead.
– Insert air duct for turbocharger and use suitable pliers to fasten
clamps.
– Secure air duct for turbocharger at bracket.
– Connect air hose and use suitable pliers to fasten clamp.
hydraulic unit.
-VAS 505x- .
Note

ded.
-VAS 505x- .
♦ Running gear

Audi TT 2007 ➤

J104-.
drive vehicles)
-VAS 505x- .
♦ Running gear
♦ Brake system
WARNING
brakes is OK.
Audi TT 2007 ➤
7 Vehicles with diesel particulate filter:

Control unit -J104- with hydraulic unit
-N55-

J104- with hydraulic unit -N55- (TDI)
Note
The diesel particulate filter must be removed ⇒ Rep. Gr. 26 .
Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1410-
♦ Brake pedal actuator -
V.A.G 1869/2-

Audi TT 2007 ➤
Sealing plug repair kit, Part no. 1H0 698 311 A

No warranty can be assumed for hydraulic units without transport
protection.
1 - Transport protection for valve domes (foam)
2 - Sealing plugs M10 for brake lines and tapped holes
3 - Sealing plugs M12 for brake lines and tapped holes
Caution
be separated.

radio code).

pedal and driver's seat. Depress the brake pedal at least
60 mm.
and rear left brake calipers and open bleeder screws.
Note
This will release the pressure in the hydraulic unit.
– Close front left and rear left bleeder screws.

– Lower vehicle.
– Remove engine cover panel.

– Remove diesel particulate filter ⇒ Rep. Gr. 26 .
7. Vehicles with diesel particulate filter: Control unit -J104- with hydraulic unit -N55- 35
Audi TT 2007 ➤

-arrow 2-.
Note
necessary.
– As protection against escaping brake fluid, place a sufficient

draulic unit.
– Mark brake lines.

WARNING
Do not bend or kink the brake lines in the vicinity of the hy‐
draulic unit.
– Seal brake lines and tapped holes with sealing plugs from re‐
pair kit.

Audi TT 2007 ➤
bracket -4- out of rubber buffers -6-.
facing downwards.
WARNING
Seal threaded holes and brake lines using sealing plugs

WARNING
Installing
Note

brake fluid.
longer ensured.
Audi TT 2007 ➤
– Secure mounting bracket -4- with bolts -5-. Tightening torque:

8 Nm.
– Connect brake lines as previously marked.
WARNING
Interchanging brake lines will result in ESP system malfunc‐

tion.

– Install diesel particulate filter ⇒ Rep. Gr. 26 .
hydraulic unit.
-VAS 505x- .
Note

ded.
-VAS 505x- .
♦ Running gear
J104-.
drive vehicles)

Audi TT 2007 ➤

-VAS 505x- .
♦ Running gear
♦ Brake system
WARNING
brakes is OK.
7.2 Basic setting of inlet valves and sepa‐

rating valves (Mark 60EC)
The basic setting of the inlet valves should only be performed if
the ABS control unit -J104- has been renewed.
To do so, use the vehicle diagnosis, testing and information sys‐
tem -VAS 505x- or -VAS 5052- .
Note
If the basic setting of the inlet valves has to be performed, you

must then perform the basic setting of the separating valves.
♦ Running gear
♦ Brake system
♦ 03 ABS control unit J104 MK60EC
♦ 03 Functions ABS MK60EC J104
♦ Basic setting of inlet valves
♦ Basic setting of separating valves
Please follow the instructions on the display exactly.
Audi TT 2007 ➤
8 ABS/ESP system components on

front axle
8.1 Exploded view
Note

wheel bearing unit ⇒ Rep. Gr. 42 and cannot be renewed.
1 - Speed sensor
⇒ page 40
2 - Hexagon socket head bolt
❑ 8 Nm
8.2 Removing and installing speed sensor

Removing
– Release connector -1- at speed sensor and unplug.
– Remove bolt -2-.
– Pull speed sensor -1- out of wheel bearing housing.

Audi TT 2007 ➤
Installing
– Before inserting speed sensor, clean inner surface of hole and
coat speed sensor thoroughly with lubricating paste
G 000 650.
– Turn steering completely to left and right and check clearance
of speed sensor wire.
8. ABS/ESP system components on front axle 41

Audi TT 2007 ➤

rear axle (front-wheel drive vehicles)
9.1 Exploded view
Note


❑ 8 Nm
2 - Speed sensor
⇒ page 42
9.2 Removing and installing rear speed sen‐

sor
Removing

Audi TT 2007 ➤
Installing
– Before inserting speed sensor, clean inner surface of fitting
hole and coat speed sensor thoroughly with grease -G 000
650- .
9. ABS/ESP system components on rear axle (front-wheel drive vehicles) 43

Audi TT 2007 ➤

rear axle (four-wheel drive vehicles)
10.1 Exploded view
Note

1 - Speed sensor
⇒ page 44
❑ 8 Nm
10.2 Removing and installing rear speed sen‐

sor
Removing

Audi TT 2007 ➤
Installing
– Before inserting speed sensor, clean inner surface of hole and
coat speed sensor thoroughly with lubricating paste
G 000 650.
10. ABS/ESP system components on rear axle (four-wheel drive vehicles) 45

Audi TT 2007 ➤
46 – Brakes - mechanism
1 Servicing front brakes
Observe general notes before servicing.
Note
♦ Use the brake filling and bleeding equipment -VAS 5234- to

extract brake fluid from brake fluid reservoir.
♦ Before removing brake caliper or disconnecting brake hose
from brake caliper, insert brake pedal actuator -V.A.G 1869/2-
to prevent brake fluid reservoir from emptying completely.
♦ To draw off brake fluid from brake fluid reservoir use a bleeder
bottle which is used only for brake fluid.
♦ Make sure that no brake fluid escapes, otherwise components
and paintwork will be damaged.
♦ Always install all parts supplied in repair kit.
WARNING
Brake fluid is poisonous and must NOT be sucked through a

hose with the mouth.
1.1 Servicing front brakes 16" FN3

♦ Install all parts supplied in repair kit.
♦ After replacing brake pads, depress brake pedal firmly several
times with vehicle stationary so that the pads are properly
seated in their normal operating position.
Observe general notes ⇒ page 46 .
46 Rep. Gr.46 - Brakes - mechanism

Audi TT 2007 ➤
1 - Wheel bearing unit with in‐

tegrated ABS sensor wheel
⇒ Rep. Gr. 40
2 - Speed sensor
⇒ page 40
❑ 8 Nm
4 - Splash plate
5 - Bolt
❑ 10 Nm
6 - Brake disc
❑ Allocation, dimensions
and wear limit ⇒ page 1
❑ To remove, unbolt brake
caliper housing
❑ Do not force brake discs
off wheel hub; if neces‐
sary, use rust remover,
otherwise brake discs
could be damaged.
❑ Always renew on both
sides of axle
7 - Bolt
❑ Do not loosen unless re‐
moving brake disc
❑ 4 Nm
8 - Brake carrier
❑ Bolt to wheel bearing
housing
❑ 200 Nm
❑ Renew protective caps if they have been damaged (repair kit); use grease sachet supplied to lubricate
the guide pins
9 - Brake pads
❑ With wear indicator (on inner brake pad on left-side only)
❑ Pad thickness, wear limit ⇒ page 1
❑ Always renew on both sides of axle
Before fitting pads, clean guide surfaces and apply a thin coating of grease ⇒ ETKA .
❑ Checking pad thickness: ⇒ Maintenance ; Booklet 808
Note
Clean the brake caliper thoroughly

(grease-free) before inserting new
brake pads. It is particularly impor‐
tant to ensure that contact surfaces
for brake pads are clean.
10 - Retaining spring
❑ Insert in both holes in brake caliper housing
1. Servicing front brakes 47

Audi TT 2007 ➤
11 - Brake caliper housing

❑ Piston diameter ⇒ page 1 ; versions available ⇒ ETKA
❑ Unscrew from brake carrier to replace brake pads
❑ Servicing ⇒ page 96
Brake line connection to brake caliper, 19 Nm
Brake line connection to brake hose, 12 Nm
Counterhold at hexagon flats on brake hose when connecting brake line to brake hose.
❑ Brake caliper with vibration damper ⇒ page 74
12 - Bracket
13 - Bolt
❑ Bracket to brake caliper
14 - Protective cap
15 - Guide pin
❑ Brake caliper to brake carrier
❑ 30 Nm
16 - Bearing bush
17 - Protective cap
18 - Bolt
❑ Brake carrier to wheel bearing housing
❑ Always renew if removed
❑ 200 Nm
Brake hose connection with locating pin

Tightening torque for brake hose to brake caliper for 16" FN-3
brakes: 35 Nm
– Make sure groove in banjo union of brake hose is inserted on
locating pin -arrow-.

Audi TT 2007 ➤
1.2 Removing and installing brake pads - front brakes 16" FN3

♦ Torque wrench -V.A.G 1331-
♦ Brake pedal actuator -V.A.G 1869/2-
♦ Piston resetting appliance -T10145-
Removing
– Raise vehicle.
– Remove wheels.
Note
Mark brake pads when removing them if they are to be reinstalled.

Reinstall in their original position to prevent uneven braking.

Audi TT 2007 ➤
– Unplug connector -1- of brake pad wear indicator at left brake.

– Do not loosen bolt -2-.
– Lever off brake pad retaining spring from brake caliper housing
with a screwdriver -arrow- and remove.
– Remove brake caliper. ⇒ page 52
– Remove brake caliper and secure such that the weight of the
caliper does not damage the brake line.
Note
Brake hose/line must not be twisted or kinked.
– Take brake pads out of brake caliper housing or from brake

carrier.
– Clean brake caliper housing; in particular the bonding surface
for the brake pad must be free of any traces of adhesive and
grease.
Only use methylated spirits to clean the brake caliper housing.
Installing
Before fitting pads, clean guides and apply a thin coating of
grease ⇒ ETKA .
Press back brake pistons using piston resetting appliance -
T10145- when fitting new brake pads ⇒ page 73 .
Make sure that no brake fluid escapes from brake fluid reservoir;
otherwise components and paintwork will be damaged.
To draw off brake fluid from brake fluid reservoir use a bleeder
WARNING

hose with the mouth. On account of its corrosive effect it must
also not be allowed to come into contact with paintwork.
Perform further installation in reverse order; note the following:

– Insert brake pads in brake carrier, paying attention to fitting
location:

Audi TT 2007 ➤
When properly installed, arrow on backplate of brake pad must

face downwards.
1 - Right-side brake pad (facing piston)
2 - Left-side brake pad (facing piston)
Note
The wear indicator is located on inner brake pad on front left brake
caliper.
– Pull protective foil off outer brake pad backplate.

– Fit brake caliper onto brake carrier and brake disc.
– Secure brake caliper with both guide pins to brake carrier
⇒ page 52 . Note tightening torque ⇒ Item 15 (page 48) .

Audi TT 2007 ➤
– Insert retaining spring -arrow- in brake caliper housing.
Note
Make sure not to twist or stretch brake hose when installing.
– Fit both protective caps onto guide pins.

– Insert retaining spring into brake caliper housing.
– Press in spring clip.
– Plug in connector for wear indicator.
– Press connector for wear indicator into bracket and insert wire.
– Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .
WARNING
♦ The retaining spring must be pressed under the brake

carrier after inserting into both holes. If incorrectly instal‐
led, the wear of the outer pad cannot be adjusted, and the
pedal travel will be increased as a result.
♦ After installing the brake pads and bleeding brake system,
depress pedal firmly several times with the vehicle sta‐
tionary, so that the brake pads are properly seated in their
normal operating position.
– Check brake fluid level and top up if necessary.

–
WARNING
After installing the brake pads, depress pedal firmly several

times with the vehicle stationary, so that the brake pads are
properly seated in their normal operating position.
WARNING
brakes is OK.
1.3 Removing and installing brake caliper -

front brakes 16" FN3

Audi TT 2007 ➤
Removing
Note
This closes the valves in the brake master cylinder and stops the
brake fluid reservoir from running empty.
– Connect hose of bleeder bottle to bleeder screw of removed

brake caliper.
– Open bleeder screw.
– Close bleeder screws.
– Disconnect brake hose from brake caliper.
– Remove protective caps from guide pins -arrows-.

Audi TT 2007 ➤
– Remove guide pins -arrows-.

– Pull both guide pins out of brake caliper and bearing bushes.
– Remove brake pads ⇒ page 49 .
Installing
– Remove brake pedal actuator -V.A.G 1869/2- .
WARNING

– Install brake pads ⇒ page 49 .

– Secure brake caliper with both guide pins to brake carrier
⇒ page 52 . Note tightening torque ⇒ Item 15 (page 48) .
– Secure brake hose to brake caliper.

Tightening torque for brake hose to brake caliper for 16" FN-3
brakes: 35 Nm
– Bleed brake system ABS/ESP Mark 60 ⇒ page 109 .
WARNING

WARNING
brakes is OK.

Audi TT 2007 ➤
2 Servicing front brakes 17" FNR G57

Observe general notes ⇒ page 46 .
1 - Brake disc
sides of axle
❑ Detach brake caliper
prior to removing
❑ Lubricate contact surfa‐
ces between brake disc
and wheel hub with pol‐
ycarbamide grease -G
052 142 A2- . ⇒ Rep.
Gr. 44
and wear limit ⇒ page 1
❑ Checking thickness
⇒ Maintenance ; Book‐
let 808
❑ Ensure correct installa‐
tion position
❑ Piston diameter
⇒ page 1 ⇒ ETKA
❑ Unscrew from brake
carrier to replace brake
pads
⇒ page 60
❑ Servicing brake caliper
⇒ page 100
❑ Brake caliper with vibra‐
tion damper
⇒ page 74
4 - Bearing bush
❑ Insert into brake caliper
housing
5 - Guide pin
❑ 30 Nm
6 - Protective cap
7 - Cable retainer for wear indicator
8 - Bolt
❑ Cable retainer to brake caliper
❑ 25 Nm
9 - Protective cap
10 - Bolt
❑ Bracket for brake line to brake caliper
2. Servicing front brakes 17" FNR G57 55

Audi TT 2007 ➤
❑ 15 Nm
11 - Bracket for brake line
❑ Bolt to brake caliper housing
❑ Attach brake line
12 - Brake line
❑ Screw into brake caliper housing with ⇒ Item 11 (page 56)
❑ Do not twist hose when fitting
♦ Brake line connection to brake caliper, 14 Nm
♦ Brake line connection to brake hose, 14 Nm
♦ Counterhold at hexagon flats on brake hose when connecting brake line to brake hose.
13 - Spring clip
❑ Secures brake line in bracket ⇒ Item 11 (page 56)
14 - Brake pads
❑ With wear indicator (on inner brake pad on left-side only)
❑ Pad thickness, wear limit ⇒ page 1
Note
Clean the brake caliper thoroughly

(grease-free) before inserting new
brake pads. It is particularly impor‐
tant to ensure that contact surfaces
for brake pads are clean.
15 - Brake carrier
❑ Bolt to wheel bearing housing
❑ 200 Nm
16 - Bolt
❑ 200 Nm

Audi TT 2007 ➤
2.1 Removing and installing brake pads - front brakes 17" FNR G57

Removing
Note
♦ Mark brake pads when removing them if they are to be rein‐

stalled. Reinstall in their original position to prevent uneven
braking.
♦ When installing brake discs, note direction of travel -indicated
by arrow on brake disc- and fitting location -left or right-.
– Raise vehicle.

Audi TT 2007 ➤
– Remove wheels.
– Lever brake pad retaining spring out of brake caliper housing
with a screwdriver and remove.
Loosen bolt -1- only when removing brake disc (4 Nm).
– Unplug connector for brake pad wear indicator -1-.

– Do not loosen bolt -2-.
– Unplug connector for brake pad wear indicator from bracket
and detach wire.

Audi TT 2007 ➤
– Take spring clip -arrow- out of bracket for brake line.

– Detach brake line from bracket.
– Remove bolt and detach bracket for brake line.
– Remove brake caliper ⇒ page 60 .
– Remove brake caliper and secure such that the weight of the
caliper does not damage the brake line.
Note
Brake hose/line must not be twisted or kinked.
– Take brake pads out of brake caliper housing or from brake

carrier.
grease.
Installing
Before fitting pads, clean guide surfaces and apply a thin coating
of grease ⇒ ETKA .
WARNING

Note
The wear indicator is located on inner brake pad on front left brake
caliper.
– Insert brake pad with retaining spring and wear indicator into
brake caliper housing (piston).

Audi TT 2007 ➤
– Fit outer brake pad -2- in brake caliper.

– The wear indicator wire is fitted to the inner pad -1- at front left
wheel.
– Fit brake caliper together with inserted brake pads onto brake
carrier and brake disc.
– Secure brake caliper housing with both guide pins to brake
carrier. ⇒ page 60 Note specified tightening torque.
⇒ Item 5 (page 55)
Note
– Fit both protective caps.

– Secure bracket for brake line.
– Insert retaining spring into brake caliper housing.
– Attach brake line to bracket.
– Press in spring clip.
– Plug in connector for wear indicator.
– Press connector for wear indicator into bracket and insert wire.
Note
The retaining spring must be pushed under the brake carrier after
engaging onto both studs. If incorrectly installed, the wear of the
outer pad cannot be adjusted, and the pedal travel will be in‐
creased as a result.
Note
Check that the brake caliper moves freely by moving it from side
to side.
WARNING

WARNING
brakes is OK.

front brakes 17" FNR G57

Audi TT 2007 ➤
Removing
Note

brake caliper.
– Remove protective caps from guide pins -arrows-.

Audi TT 2007 ➤
– Remove guide pins -arrows-.

– Pull both guide pins out of brake caliper and bearing bushes.
Installing
WARNING


– Push both guide pins through bearing bushes into brake cali‐
per.
– Secure brake caliper housing with both guide pins to brake
carrier. Note specified tightening torque ⇒ Item 5 (page 55) .
Tightening torque for brake hose to brake caliper for 17" FNR-
G57 brakes: 14 Nm
Note
♦ Check that the brake caliper moves freely by moving it from

side to side.
♦ Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .
– Lower vehicle.
WARNING

WARNING
brakes is OK.

Audi TT 2007 ➤
3 Servicing front brakes (TT RS)

1 - Bleeder screw
❑ 10 Nm
Note
2 - Bolt
❑ Unscrew for removal of
brake caliper
❑ 200 Nm
Note
3 - Speed sensor
4 - Bolt
❑ For speed sensor
❑ 8 Nm
5 - Brake caliper
Note

⇒ page 67
❑ Renewing ⇒ page 69
6 - Brake disc
❑ Wear limit ⇒ page 1
Note

⇒ page 71
7 - Bolt
❑ For securing brake disc
❑ 4 Nm
Note
8 - Brake pads
❑ With brake pad wear cable (only in left brake caliper)
❑ Wear limit ⇒ page 1
Before fitting pads, clean guides and apply a thin coating of grease ⇒ ETKA .
Before fitting pads, peel off adhesive foil
9 - Brake pad wear cable

❑ Only installed in left brake caliper
3. Servicing front brakes (TT RS) 63

Audi TT 2007 ➤
10 - Retaining clip
❑ Ensure correct installation position
Note
11 - Brake pad retaining pins
Note
12 - Bolt
❑ For bracket
❑ 18 Nm
13 - Brake hose
❑ Screw into brake caliper
❑ Insert in bracket
❑ 35 Nm
Tightening torque for brake hose to brake caliper for TT RS: 35 Nm
Note
14 - Bracket
❑ For brake hose and brake pad wear cable
3.1 Removing and installing brake pads -

front brakes (TT RS)
Note

Removing
– Raise vehicle.
– Remove wheels.
Note
The brake pad wear cable is only installed at the left brake caliper.

Audi TT 2007 ➤
– Unclip brake pad wear cable -9- from bracket.
Note
Do not loosen bolts -2-.
– Unplug electrical connector from brake pad wear cable.

– Press brake pistons at brake pads slightly back into brake cal‐
iper using a suitable tool.
Note
Take care not to scratch or damage brake caliper.

Audi TT 2007 ➤
– Pull brake pad wear cable -9- out of retaining clip -10-.
– Pull one brake pad retaining pin -11- out of brake caliper. While
doing so, press down retaining clip -10-.
– Pull second brake pad retaining pin -11- out of brake caliper.
– Take brake pads out of brake caliper.
WARNING

Installing
If provided, peel adhesive foil off back of brake pads.
Before fitting pads, clean guides and apply a thin coating of
grease ⇒ ETKA .
WARNING


– Insert brake pads into brake caliper.
Note
♦ Make sure that brake pads are seated correctly.

♦ The brake pads with the brake pad wear cable are only fitted
in the left brake caliper.
♦ The brake pad wear cable is fitted in the left brake caliper in
both brake pads.

Audi TT 2007 ➤
– Slide one brake pad retaining pin -11- through brake caliper
and brake pads from inside to outside.
– Insert retaining spring -10- underneath retaining pin -11-.
– Slide second retaining pin through brake caliper and brake
pads from inside to outside. While doing so, press down re‐
taining spring -10-.
WARNING
Both brake pad retaining pins must be pressed through the

brake caliper and the brake pads as far as the stop so that the
spring is seated at the retaining pin in the brake caliper.
– Insert brake pad wear cable -9- in retaining spring -10-.

– Connect brake pad wear cable.
– Insert brake pad wear cable in bracket.
Fit wheels ⇒ Wheels and tyres; Rep. Gr. 44 .
– Lower vehicle.
WARNING

WARNING
brakes is OK.

Removing
– Raise vehicle.
– Remove wheels.
Note

Audi TT 2007 ➤
– Unclip brake pad wear cable -9- from bracket.

– Unplug electrical connector from brake pad wear cable.
– Unclip brake hose -13- from bracket.
– Press brake pistons at brake pads slightly back into brake cal‐
iper using a suitable tool.
Note
Take care not to scratch or damage brake caliper.
– Remove bolts -2-.

– Detach brake caliper.
Note
Do not suspend the brake caliper from the brake hose. Secure it
to the body with a suitable wire.
Installing
Note
Renew bolts -2-.
– Carefully slide brake caliper (with brake pads fitted) over brake
disc and install.

Audi TT 2007 ➤
– Secure brake caliper with new bolts -2-. 200 Nm

– Fit brake hose -13- in bracket.
– Connect brake pad wear cable -9-.
– Insert brake pad wear cable in bracket.
– Lower vehicle.
WARNING
Firmly depress the brake pedal several times with the vehicle
stationary, so that the brake pads are properly seated in their
WARNING
brakes is OK.
3.3 Renewing brake caliper - front brakes

(TT RS)
Note

Removing
– Raise vehicle.
– Remove wheels.
Note

Audi TT 2007 ➤

Note

brake caliper.
– Disconnect brake hose -13- from brake caliper.

– Remove bolts -2-. Hold brake caliper in position while doing
so.
– Detach brake caliper.
Installing
Note
Renew bolts -2-.

– Install brake caliper.
– Secure brake caliper with new bolts -2-. 200 Nm

WARNING


Audi TT 2007 ➤
– Attach brake hose -13- to caliper and tighten connection.

Tightening torque for brake hose to brake caliper for TT RS:
35 Nm
– Bleed brake system at all bleeder screws.
– Lower vehicle.
WARNING

WARNING
brakes is OK.
3.4 Removing and installing brake disc -

Note

Removing
– Raise vehicle.
– Remove wheels.
Note
– Remove brake caliper ⇒ page 67 .
Note
Do not suspend the brake caliper from the brake hose. Secure it
to the body with a suitable wire.

Audi TT 2007 ➤

– Pull brake disc off wheel hub.
Note
Keep brake disc straight while detaching it.
Installing
Note
Always renew bolt -7-.
– Clean contact surfaces on wheel hub and brake disc.

– Fit brake disc onto wheel hub.
Note
Keep brake disc straight while installing it.
– Secure brake disc with new bolt -7- (4 Nm).

– Install brake caliper ⇒ page 67 .
– Lower vehicle.
WARNING
Firmly depress the brake pedal several times with the vehicle
stationary, so that the brake pads are properly seated in their
WARNING
brakes is OK.

Audi TT 2007 ➤
4 Pressing back brake piston in front

brake caliper
Note
Before inserting new brake pads, press brake piston back into
cylinder with resetting appliance. Before pressing the piston back,
draw off brake fluid from the reservoir with a bleeder bottle, oth‐
erwise components can be damaged by escaping brake fluid.

T10145- ⇒ page 73 .
WARNING

Pressing piston back
Pressing piston back
4. Pressing back brake piston in front brake caliper 73

Audi TT 2007 ➤
5 Vibration damper on brake caliper -

front brakes
The vibration damper is not fitted with all models. This has no
influence on removal, installation and servicing of the brake cali‐
per.
1 - Dust cap
2 - Bolt
❑ Always renew
❑ 10 Nm
3 - Vibration damper
⇒ page 74
4 - Washer
5 - Brake caliper
5.1 Removing and installing vibration damp‐

er
Removing
– Raise vehicle.
– Remove front wheels.
– Remove dust cap.

Audi TT 2007 ➤

– Detach vibration damper -3- and washer -4- from brake cali‐
per.
Installing
– Clean brake caliper in area of vibration damper.
– Insert washer -4- and vibration damper -3- in brake caliper.
– Insert new bolt -2- and tighten to 10 Nm.
– Insert and press home the dust cap -1-.
5. Vibration damper on brake caliper - front brakes 75

Audi TT 2007 ➤
6 Servicing rear brakes
Note
♦ Use the brake filling and bleeding equipment -VAS 5234- or

the upgrade kit and extraction unit -V.A.G 1869/4- to extract
brake fluid from brake fluid reservoir.
♦ Before removing brake caliper or disconnecting brake hose
from brake caliper, insert brake pedal actuator -V.A.G 1869/2-
to prevent brake fluid reservoir from emptying completely.
WARNING

6.1 Rear brakes

General notes ⇒ page 76
1 - Brake disc
and wear limit (front-
wheel drive) ⇒ page 2
and wear limit (four-
and wear limit (TT RS)
⇒ page 2
❑ Do not force brake discs
off wheel hub; if neces‐
sary, use rust remover,
otherwise brake discs
could be damaged.
❑ Remove brake caliper
prior to removing
sides of axle
2 - Brake caliper
❑ Do not disconnect brake
hose when changing
brake pads
❑ Piston diameter (front-
❑ Piston diameter (four-
❑ Piston diameter (TT RS)
⇒ page 2
⇒ page 80
❑ Servicing ⇒ page 105
❑ The handbrake must be
adjusted following re‐

Audi TT 2007 ➤
pair or replacement
⇒ page 89 .
3 - Brake line
❑ Do not disconnect brake hose and brake line when changing brake pads
❑ Tightening torque for brake line (all models): 14 Nm
4 - Brake hose
❑ Do not disconnect brake hose when changing brake pads
❑ Tightening torque for brake hose (all models): 14 Nm
5 - Protective cap
6 - Bolt
❑ Remove when changing brake pads
❑ Brake caliper to brake carrier
❑ Self-locking
❑ When loosening and tightening, counter-hold on guide pin
❑ 35 Nm
Note
7 - Bleeder screw
❑ 10 Nm
8 - Protective cap
9 - Return spring for handbrake
10 - Nut
❑ Secures handbrake linkage to brake caliper
❑ Do not loosen
11 - Handbrake cable
12 - Handbrake linkage
13 - Pad retaining spring
❑ Always renew when changing pads
14 - Speed sensor wire
15 - Brake pads
❑ Wear limit (front-wheel drive) ⇒ page 2
❑ Wear limit (four-wheel drive) ⇒ page 2
❑ Wear limit (TT RS) ⇒ page 2
❑ For correct version refer to ⇒ ETKA
Note
16 - Bolt
6. Servicing rear brakes 77

Audi TT 2007 ➤
❑ 90 Nm + 90°
Note
17 - Brake carrier
❑ Bolt to wheel bearing housing
6.2 Removing and installing rear brake pads
Note


Removing
– Raise vehicle.
– Remove wheels.
Do not detach handbrake cable from brake caliper.
– Detach brake caliper housing (counterhold at guide pin).
– Remove brake caliper housing from brake disc.
– Secure brake caliper housing with wire such that the weight of
the caliper does not damage the brake hose.
WARNING
Do not kink or bend brake lines and brake hose.

Audi TT 2007 ➤
– Remove brake pads and pad retaining springs from brake car‐
rier -arrows-.
Note


grease.
Installing
Before fitting pads, clean guide surfaces and apply a thin coating
of grease ⇒ ETKA .
WARNING


Audi TT 2007 ➤
– Insert brake pad retaining springs -arrows- and brake pads

into brake carrier.
– Pull protective foil off brake pad backplate.
Note
Fit brake caliper onto brake carrier and brake disc.
– Secure brake caliper housing with new self-locking bolts. Note

tightening torque ⇒ Item 6 (page 77) .
Note
The repair kit includes four self-locking hexagon bolts which must
be installed in all cases.

WARNING

WARNING
brakes is OK.
6.3 Removing and installing rear brake cal‐

iper

Audi TT 2007 ➤
Removing
– Raise vehicle.
– Remove wheels.
Only detach handbrake cable when brake caliper is being re‐
moved completely ⇒ page 83 .
Note

– Detach brake caliper housing (counterhold at guide pin).

– Remove brake caliper housing from brake disc.
– Secure brake caliper housing with wire such that the weight of
the caliper does not damage the brake hose.
WARNING
Do not kink or bend brake lines and brake hose.

Audi TT 2007 ➤

Note
– Connect hose of bleeder bottle to bleeder screw of rear brake

caliper (removed) and front brake caliper on same side of ve‐
hicle.
– Open both bleeder screws.
– Close front bleeder screw.
Installing
WARNING


– Secure brake caliper housing with new self-locking bolts. Note
tightening torque ⇒ Item 6 (page 77) .
Tightening torque for brake hose to brake caliper (all models):
14 Nm
Note
– After fitting a serviced or new brake caliper, the handbrake

must be adjusted ⇒ page 89 . Do not press the brake pedal
until after the handbrake has been adjusted.
– Bleed brake system: ABS/ESP Mark 60 ⇒ page 109 .
WARNING


Audi TT 2007 ➤
WARNING
brakes is OK.
6.4 Detaching and attaching handbrake ca‐

ble from/to brake caliper
Removing
– Press brake lever -2- in direction of arrow and disengage
handbrake cable -3-.
– Compress retaining tabs -1- and pull out handbrake cable
through guide.
Installing
– Insert handbrake cable through guide
– Compress retaining tabs -1- and engage. Make sure that both
retaining tabs are engaged.
– Press brake lever -2- in direction of arrow and attach hand‐
brake cable -3-.
6.5 Pressing back piston in rear brake cali‐

per
♦ Piston compressing tool -T 10165-

Audi TT 2007 ➤
Note
Before pressing the piston back, draw off brake fluid from the
reservoir. To draw off fluid, use a bleeder bottle or plastic bottle
kept specially for this purpose.
WARNING

hose with the mouth.
– Apply piston compressing tool -T 10165- on piston of brake

caliper housing.
– Screw in piston by turning knurled wheel of piston compress‐
ing tool -T 10165- clockwise, do not damage protective cap
when doing so.
Note
If piston will not move easily, a 13 mm open-ended spanner can

be applied at the appropriate flats -arrow-.

Audi TT 2007 ➤
7 Handbrake
7.1 Handbrake - exploded view
1 - Handbrake lever
❑ Available as replace‐
ment part complete with
pull rod, pawl, push rod,
push-button, compres‐
sion spring and locking
segment
⇒ page 85
❑ Switch for warning lamp
is located under hand‐
brake lever
handbrake lever trim
2 - Handbrake switch
⇒ page 86
❑ For handbrake warning
lamp in instrument clus‐
ter
3 - Hexagon nut
❑ 15 Nm
4 - Compensator
❑ With adjustment nut to
adjust handbrake cable
5 - Handbrake cable (left and
right)
7.2 Removing and installing handbrake lev‐

er
Removing
– Release handbrake.
– Loosen adjustment nut on compensator -4- until handbrake
cables -5- can be unhooked from compensator on left and right
sides.
– Remove handbrake switch -2- ⇒ page 86 .
– Remove nuts -3-.
– Remove handbrake lever from vehicle.
7. Handbrake 85
Audi TT 2007 ➤
Installing
– Installation is carried out in reverse sequence.
– Install handbrake switch ⇒ page 86 .
– Pretension handbrake cable with adjustment nut on compen‐
sator -4-.
Note
The handbrake must be adjusted after installing handbrake cable

⇒ page 89 .
7.3 Removing and installing handbrake switch
1 - Locking knob
2 - Trim, one-piece
❑ Depending on type of
equipment
3 - Trim (left-side)
equipment
4 - Handbrake switch
❑ For handbrake warning
lamp in instrument clus‐
ter
5 - Trim (right-side)
equipment
6 - Protective cap
7 - Bolt
❑ 0.7 Nm
Removing
– Detach locking knob -1-.

Audi TT 2007 ➤
Note
Note different versions of handbrake trim.
– One-piece trim for handbrake -2-: release and pull off to front.
– Two-piece trim for handbrake: release handle and pull off to
front.
– Remove two-piece trim for handbrake lever.
– Unclip handbrake switch -4-.
– Unplug connector.
Installing
– Installation is carried out in the reverse sequence.
The handbrake does not have to be adjusted after installing the
handbrake switch.
7.4 Removing and installing handbrake cable
1 - Guide tube (bottom right) for

handbrake cable (right-side)
2 - Clip for guide tube (bottom
right)
3 - Nut for clip (bottom right)
❑ Do not loosen when re‐
moving handbrake ca‐
ble and guide tube
❑ 12 Nm
4 - Bolt (left and right)
❑ 4 Nm
5 - Bracket for handbrake ca‐
ble on axle beam (left and
right)
❑ On some versions it is
necessary to detach
skid plate
right)
7 - Rubber grommet (left and
right)
right)
9 - Retainer for handbrake ca‐
ble (left and right)
10 - Clip for guide tube (bottom
left)
11 - Guide tube (bottom left)
7. Handbrake 87
Audi TT 2007 ➤
Removing
– Use hook to release cover in storage compartment in centre
console (rear) and remove cover.
– Loosen adjustment nut on handbrake cable until the hand‐
brake cables -3- can be unhooked from the compensator -4-
(left and right sides).
– Raise vehicle.
– Detach handbrake cables from brake calipers ⇒ page 83 (left
and right).
– Unfasten bolt (right-side) on axle beam (right-side) and detach
bracket with handbrake cable.
– Detach handbrake cable (right-side) from compensator.
– Unclip guide tube (right-side) ⇒ Item 1 (page 87) from bracket
⇒ Item 2 (page 87) , do not loosen nut ⇒ Item 3 (page 87) .
– Carefully pull out handbrake cable (right-side) from guide tube
(right-side).
– Unfasten bolt (left-side) on axle beam (left-side) and detach
bracket with handbrake cable.
– Detach handbrake cable left-side) from compensator.
– Unclip guide tube (left-side) ⇒ Item 11 (page 87) from bracket
(left-side) ⇒ Item 10 (page 87) .
– Carefully pull out handbrake cable (left-side) from guide tube
(left-side).
Installing
Note
Install handbrake cable free of tension and stress.
– Installation is carried out in the reverse sequence.

– Carefully push handbrake cables (left and right) through cor‐
responding guide tubes and into vehicle interior.
– Engage handbrake cables on brake calipers ⇒ page 83 (left
and right).
– Lower vehicle.

Audi TT 2007 ➤
– Pull handbrake cables (left and right) -3- out of front end of
relevant guide tube -2-.
– Engage handbrake cables (left and right) -3- in compensator
-4-.
– Pretension handbrake cable with adjustment nut on compen‐
sator -4-.
Note
The handbrake must be adjusted after installing handbrake cable

⇒ page 89 .
7.5 Removing and installing guide tubes for

handbrake cable
Removing
– Remove handbrake cable ⇒ page 87 .
– Unclip guide tubes from vehicle floor.
– Pull guide tubes -2- out of opening in vehicle floor from below.
– Take care not to damage rubber grommets -1-.
Installing
– Push guide tubes -2- through opening into vehicle interior from
below.
– Take care not to damage rubber grommets -1-.
– Clip guide tubes into retainers on vehicle floor.
7.6 Adjusting handbrake
Note
Adjustment is only necessary if handbrake cables, brake calipers

or brake discs have been replaced.
♦ Both rear wheels must turn freely when handbrake lever is not
pulled (released position).
♦ The handbrake lever must return by itself to released position
if not pulled up to the first catch.
♦ The adjustment nut on the compensator must be screwed past
the end of the pull rod.
7. Handbrake 89
Audi TT 2007 ➤
– Use hook to release cover in storage compartment in centre
console (rear) and remove cover.
– The handbrake cable -5- must be routed free of stress.
Do not pull up the handbrake lever -1- more than 2 degrees when
adjusting the handbrake.
– Tighten adjustment nut on compensator -2- until levers on
brake caliper -4- lift away from stop -3-.
– The sum of distances -a- between lever on brake caliper -4-
and stop -3- on both sides of vehicle must be at least 1 mm
(with handbrake lever in released position).
– The distance on one side must not exceed 4 mm.
– The distance -a- to stop -3- on one side must be greater than
0 mm, however not greater than 4 mm.
– Apply handbrake firmly 3 times and then release.
– With handbrake released, check whether both wheels turn
freely. Check whether the distances -a- meet specifications.
– If the handbrake lever is pulled up to the first catch, there must
be a slight brake effect on the rear wheels.
If necessary, adjust via the adjustment nut.
Note
Due to the automatic adjustment of the rear brake, it is no longer

necessary to adjust the handbrake after performing initial adjust‐
ment.
WARNING
brakes is OK.

Audi TT 2007 ➤
8 Brake pedal
8.1 Brake pedal - exploded view
WARNING
The brake pedal travel must not be restricted by additional floor

coverings.
1 - Brake servo
⇒ page 122
2 - Brake light switch on brake
master cylinder
3 - Mounting bracket
❑ With crash bar
4 - Bearing bush
❑ Before installing, lubri‐
cate pivot points with
polycarbamide grease -
G 052 142 A2- .
5 - Hexagon nut
❑ 25 Nm
6 - Hexagon nut
❑ 25 Nm
7 - Brake pedal
⇒ page 91
❑ Separating from brake
servo ⇒ page 92
❑ Before installing, lubri‐
cate pivot points with
polycarbamide grease -
G 052 142 A2- .
8 - Cap
9 - Hexagon bolt
8.2 Removing and installing brake pedal

Removing
– Remove driver's storage compartment: ⇒ Rep. Gr. 68
– Separate brake pedal from brake servo ⇒ page 92 .
8. Brake pedal 91
Audi TT 2007 ➤
– Unscrew nut -5-.

– Pull hexagon bolt -9- out of brake pedal and bearing bush.
Installing
– Push hexagon bolt -9- through brake pedal and bearing bush.
– Use new nut -5- and tighten. Note tightening torque
Note
Before installing, lubricate pivot points with polycarbamide grease

-G 052 142 A2- .
Clip brake pedal to ball head of brake servo push rod.

– Hold ball head of push rod in front of mounting and push brake
pedal in direction of brake servo so that the ball head audibly
locks into place ⇒ page 92 .
WARNING
brakes is OK.
8.3 Separating brake pedal from brake ser‐

vo
♦ Release tool -T 40024-
Separating
– Remove driver's storage compartment: ⇒ Rep. Gr. 68

Audi TT 2007 ➤
– Use release tool -T 40024- to separate brake pedal from brake

servo.
– Position release tool -T 40024- and press handles together
while simultaneously pulling the brake pedal towards driver's
seat. (The brake pedal is thereby detached from ball head of
push rod).
Installing
Clip brake pedal to ball head of brake servo push rod.

– Hold ball head of push rod in front of mounting and push brake
pedal in direction of brake servo so that the ball head audibly
locks into place.
– Install storage compartment on driver's side: ⇒ Rep. Gr. 68
WARNING
brakes is OK.
8. Brake pedal 93
Audi TT 2007 ➤
47 – Brakes - hydraulics
1 High-pressure and low-pressure
tests
1.1 Tests
♦ Tester for brake pressure regulator -V.A.G 1310A-
High-pressure test:
Note
Make sure that the brake system (master cylinder, brake hoses,
brake lines and brake calipers) works properly and is free of leaks.
– Screw out bleeder screw at one of the front brake calipers.

Connect tester for brake pressure regulator -V.A.G 1310 A-
and bleed.
pedal and driver's seat. Apply pressure to brake pedal until the
gauge indicates a pressure of 50 bar. The pressure must not
drop by more than 4 bar during the test period of 45 seconds.
Renew brake master cylinder if drop in pressure exceeds the
specification.
Low-pressure test:
– Move the brake pedal actuator back until the pressure gauge
indicates a pressure of 6 bar.
94 Rep. Gr.47 - Brakes - hydraulics

Audi TT 2007 ➤
– The pressure should not drop by more than 1 bar within the
test period of 3 minutes.
Renew brake master cylinder if drop in pressure exceeds the
specification.
1. High-pressure and low-pressure tests 95

Audi TT 2007 ➤
2 Servicing front brake caliper FN3
Note
♦ Install complete repair kit when servicing.

♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ Apply thin coat of lithium grease -G 052 150 A2- to brake cyl‐
inder, piston and seal.
2.1 Front brake caliper FN3 - exploded view
1 - Protective cap
❑ Fit onto bleeder valve
2 - Bleeder screw, 10 Nm
❑ Before screwing in,
grease thread with thin
coat of lithium grease -G
052 150 A2- .
3 - Protective caps
❑ Insert into bearing bush
4 - Guide pin, 30 Nm
5 - Bearing bush
housing
tion damper ⇒ page 74
7 - Brake carrier
❑ Bolt to brake caliper
housing
❑ Insert both ends in holes
in brake caliper housing
9 - Seal
❑ Do not damage when in‐
serting piston
⇒ page 97
10 - Piston
⇒ page 97
❑ Apply a thin coat of lithi‐
um grease -G 052 150 A2- to piston
11 - Protective cap
❑ Push outer sealing lip onto piston
❑ Do not damage when inserting piston

Audi TT 2007 ➤
2.2 Removing and installing piston for front

brake caliper FN3
♦ Removal wedge -3409-
♦ Piston resetting appliance -T 10145-
♦ Assembly tool for protective caps -T10146/6-
Removing
– Force piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damaging the pis‐
ton.
2. Servicing front brake caliper FN3 97

Audi TT 2007 ➤
– Lever off protective cap from brake caliper using removal

wedge -3409- .
– Remove seal using removal wedge -3409- .

When removing ensure that the bore of the cylinder is not dam‐
aged.
Installing
– The surface of the piston and seal should be cleaned using
only methylated spirits and then dried.
– Apply a thin coat of lithium grease -G 052 150 A2- to piston
and seal before inserting.
– Insert the seal into the brake caliper.
– Insert protective cap -A- into assembly tool T10146/6 -1-.
– Push protective cap onto brake caliper using assembly tool

-1- and piston resetting appliance -2- so that it is seated on the
brake caliper all round.
Checking correct seating of protective cap:

Audi TT 2007 ➤
– At this stage it should not be possible to remove the protective

cap from the brake caliper by hand.
– Press the piston lightly against the protective cap and lock in
position (e.g. with assembly wedge -2-).
– Inflate protective cap with compressed air (maximum 3 bar)

-1-. The protective cap will then locate around the piston.
Keep the piston straight to avoid damaging the seal.
– Press the piston into the brake caliper using piston resetting
appliance -1-.
The outer sealing lip of the protective cap will then lock in the
groove on piston.
2. Servicing front brake caliper FN3 99

Audi TT 2007 ➤
3 Servicing front brake caliper

FNRG57
Note

3.1 Front brake caliper FNRG57 - exploded view
1 - Brake carrier
❑ Bolt to brake caliper
housing
2 - Guide pin
❑ 30 Nm
3 - Protective caps
❑ Insert into bearing bush
4 - Protective cap
❑ Push onto bleeder valve
5 - Bleeder valve
052 150 A2- .
❑ 15 Nm
6 - Bearing bush
housing
tion damper ⇒ page 74
❑ Note correct installation
position.
❑ Engage onto both brake
caliper housing studs
and onto outer pad re‐
taining spring.
9 - Protective cap
❑ Do not damage when in‐
serting piston
❑ Apply a thin coat of lithium grease -G 052 150 A2-
10 - Piston
❑ Apply a thin coat of lithium grease -G 052 150 A2- to piston
11 - Seal
❑ Apply a thin coat of lithium grease -G 052 150 A2-

Audi TT 2007 ➤
3.2 Removing and installing piston for front

brake caliper FNRG57
♦ Lithium grease -G 052 150 A2-
♦ Assembly tool -T10146-

♦ Assembly tool for protective caps -T10146/2-
3. Servicing front brake caliper FNRG57 101

Audi TT 2007 ➤
Removing
– Force piston out of brake caliper housing using compressed
air.
Note
Place a piece of wood in the recess to prevent damaging the pis‐

ton.
– Take out seal.

– To do so, use removal wedge -3409- .
Note
When removing ensure that the bore of the cylinder is not dam‐
aged.
Installing
– Using the removal wedge -3409- , insert inner seal into groove
of brake caliper.
– Press in protective cap with special tool -1- and -2-.

– Item -1- Assembly tool for protective caps -T10146/2-
– Item-2- Piston resetting appliance -T10145-
Use jaw protectors

Audi TT 2007 ➤
– Push protective cap onto brake caliper housing and press it in

so that it is seated flush -arrow-.
– At this stage it should not be possible to remove the protective
cap from the brake caliper housing by hand.
– Lift up piston with standard extension and ratchet attachment

as shown in illustration and press lightly onto protective cap.
Keep the piston straight to avoid damaging the seal.
– Inflate protective cap with compressed air (maximum 3 bar).
The protective cap will then locate around the brake piston.
Use jaw protectors
– Press piston into brake caliper housing by hand.
Note
The inner sealing lip on the protective cap will then locate in the
piston groove.
3. Servicing front brake caliper FNRG57 103

Audi TT 2007 ➤
4 Servicing brake caliper (TT RS)
Note
There is no provision for servicing the brake caliper on the TT RS.

Audi TT 2007 ➤
5 Servicing rear brake calipers
Note

♦ Use only methylated spirits to clean the brake caliper
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ When carrying out repairs it is essential to appropriately pre-
bleed the brake calipers (without brake pads) before installing
in the vehicle ⇒ page 107 .
5.1 Rear brake caliper - exploded view
1 - Bolt
❑ Self-locking
❑ Always renew if re‐
moved
❑ When loosening and
tightening, counter-hold
on guide pin
❑ 35 Nm
2 - Bleeder screw
052 150 A2-
❑ 10 Nm
3 - Protective cap
4 - Guide pin
❑ Lubricate before instal‐
ling protective cap
5 - Protective cap
❑ Insert onto brake carrier
and guide pin
6 - Brake carrier with guide
pins and protective caps
❑ Replacement carriers
are supplied assembled
and with sufficient
grease on guide pins
❑ If protective caps or
guide pins are dam‐
aged, renew using re‐
pair kit. Use grease sa‐
chet supplied to lubri‐
cate the guide pins.
7 - Protective cap
❑ Push outer sealing lip onto piston
8 - Piston with automatic adjustment
5. Servicing rear brake calipers 105

Audi TT 2007 ➤
❑ Apply a thin coat of lithium grease -G 052 150 A2- to piston

9 - Seal
❑ Do not damage when inserting piston
10 - Brake caliper housing with lever for handbrake cable
❑ Renew the brake caliper housing if there is a leak at the lever for handbrake cable
❑ After repairing, pre-bleed brake caliper housing ⇒ page 107
5.2 Removing and installing piston for rear

brake caliper
♦ Piston compressing tool -T10165-
Removing
– Screw piston out of brake caliper by turning knurled wheel anti-
clockwise.
Insert piston compressing tool (make sure that the collar contacts
the piston).
♦ If piston will not move easily, a 13 mm open-end spanner can
be applied at the flats provided -arrow A-.

Audi TT 2007 ➤
– Remove seal using removal wedge -3409- .

Installing
– Insert the seal into the brake caliper housing.
– Place outer sealing lip of protective cap on the piston
– Using the removal wedge -3409- , insert the inner sealing lip
into the groove of cylinder.
Note
When doing this hold piston in front of caliper housing.
– Apply piston compressing tool -T10165- on piston of brake

caliper housing.
– Screw in piston by turning knurled wheel clockwise.
Note
♦ If the piston is pushed back with a piston resetting tool, the

automatic adjustment in the brake caliper will be damaged.
♦ If piston will not move easily, a 13 mm open-ended spanner
can be applied at the appropriate flats -arrow-.
– Fit brake pads.

Pre-bleeding brake caliper
5. Servicing rear brake calipers 107

Audi TT 2007 ➤
– Open bleeder screw -arrow A- and fill with brake fluid from a
commercially available bleeder container until bubble-free flu‐
id emerges from hole (brake hose connection) -arrow B-.
Close bleeder screw.
Note
Position brake caliper as illustrated for pre-bleeding.

Audi TT 2007 ➤
6 Bleeding brake system - ABS/ESP

Mark 60
WARNING
♦ Do not under any circumstances allow brake fluid to come

into contact with fluids that contain mineral oils (e.g. oil,
petrol, cleaning agents). Mineral oils damage the plugs
and seals in the brake system.
♦ Brake fluid is poisonous and must NOT be sucked through
a hose with the mouth. On account of its corrosive effect
it must also not be allowed to come into contact with paint‐
work.
♦ Brake fluid is hygroscopic, i.e. it absorbs moisture from the
surrounding air, and should therefore always be stored in
airtight containers.
♦ Always observe the relevant environmental regulations for
disposal.
When topping up brake fluid with, for example, brake filling and
bleeding equipment -VAS 5234- or upgrade kit and extraction unit
-V.A.G 1869/4- , make sure the filling pressure does not exceed
1 bar.
The brake fluid pressure must be reduced to 1 bar on brake filling
and bleeding equipment ⇒ VAS 5234 or V.A.G 1869 operating
instructions .
Note
♦ Use only new brake fluid.

♦ Rinse off brake fluid spillages using plenty of water.
6.1 Bleeding brake system with brake filling

and bleeding equipment -VAS 5234- or
upgrade kit and extraction unit -V.A.G
1869/4-
♦ Brake filling and bleeding equipment -VAS 5234- or
6. Bleeding brake system - ABS/ESP Mark 60 109

Audi TT 2007 ➤
♦ Brake filling and bleeding equipment -V.A.G 1869-
♦ Upgrade kit and extraction unit -V.A.G 1869/4-

Procedure
– Connect brake filling and bleeding equipment -VAS 5234- or
upgrade kit and extraction unit -V.A.G 1869/4- .
– Detach protective cap on bleeder screw of brake caliper.
– Attach bleeder hose of bleeder bottle to bleeder valve of brake
caliper.
– With bleeder hose attached, leave bleeder screw open until
the brake fluid which emerges is clear and free from bubbles.
– Press brake pedal 5 times to assist bleeding process.
– Tighten bleeder screw to 10 Nm.
– Detach bleeder hose and attach protective cap to bleeder
screw.
– Perform same bleeding procedure on all brake calipers.
Bleeding sequence
1 - Front left-side brake caliper
2 - Front right-side brake caliper
3 - Rear left-side brake caliper
4 - Rear right-side brake caliper
– Fill brake fluid reservoir as far as max. marking and screw on
cap.
– Start engine to check brake pedal travel and brake pedal pres‐
sure.
– Check the brake system for leaks if the pedal travel is exces‐
sive or if the pedal is soft. Repeat bleeding procedure.
After bleeding brake system, zero position compensation must be
performed for brake pressure sender 1 -G201- .
Vehicle diagnosis, testing and information system -VAS 505x- .
⇒ Vehicle diagnosis, testing and information system -VAS 505x-
under the function "Guided Fault Finding".
Perform test drive after completion of bleeding. At least one ABS
control operation must be applied at all four wheels.
Changing brake fluid
⇒ Maintenance ; Booklet 808

Audi TT 2007 ➤
WARNING
brakes is OK.
6.2 Bleeding brake system without brake fill‐

ing and bleeding equipment
Note
A second person is required to bleed the brake system without

brake filling and bleeding equipment.
Make sure that the brake fluid reservoir does not drain completely.
– Detach protective cap on bleeder screw of brake caliper.
– Attach bleeder hose of bleeder bottle to bleeder valve of brake
caliper.
– Build up pressure in brake system by pumping brake pedal.
Note
Press brake pedal slowly to avoid formation of bubbles.
– Once pressure has built up, keep brake pedal depressed.

– Open bleeder screw with hose of bleeder bottle attached until
pressure has dissipated (pedal sags).
– Keep pedal depressed and close bleeder screw.
– Release brake pedal and wait approx. 2 seconds to allow
brake fluid to flow in from brake fluid reservoir.
– Repeat procedure until emerging brake fluid is clear and free
from bubbles.
– Tighten bleeder screw to 10 Nm.
– Detach bleeder hose and attach protective cap to bleeder
screw.
– Perform same bleeding procedure on all brake calipers.
Bleeding sequence
1 - Front left-side brake caliper
2 - Front right-side brake caliper
3 - Rear left-side brake caliper
4 - Rear right-side brake caliper
– Fill brake fluid reservoir as far as max. marking and screw on
cap.
– Start engine to check brake pedal travel and brake pedal pres‐
sure.
– Check the brake system for leaks if the pedal travel is exces‐
sive or if the pedal is soft. Repeat bleeding procedure.
Changing brake fluid
⇒ Maintenance ; Booklet 808
6. Bleeding brake system - ABS/ESP Mark 60 111

Audi TT 2007 ➤
WARNING
brakes is OK.

Audi TT 2007 ➤
7 Brake servo/brake master cylinder -

left-hand drive vehicles
7.1 Exploded view
Note
Complete master cylinder and brake servo can be replaced in‐

dependently of each other.
2 - Brake servo
❑ On some vehicle types,
the vacuum required is
taken exclusively from
the intake manifold
❑ Vehicles with OHBV are
fitted with brake servo
vacuum sender -G483
⇒ page 17
Checking function
♦ With the engine switched
off, firmly depress the brake
pedal several times (this re‐
duces the vacuum present
in the servo unit).
♦ Depress brake pedal and
hold.
♦ Start engine.
♦ If the brake servo unit is
working properly, the pedal
will give noticeably under
the foot.
❑ Separating from brake
pedal ⇒ page 92
⇒ page 122
(TT RS) ⇒ page 126
Note

of the brake servo.
❑ If faulty, renew complete.
1 - Gasket
❑ For brake servo
3 - Seal
❑ Renew
7. Brake servo/brake master cylinder - left-hand drive vehicles 113

Audi TT 2007 ➤
4 - Brake master cylinder

❑ With brake light switch attached ⇒ Item 13 (page 11)
❑ Cannot be repaired.
❑ If faulty, renew complete.
Note

of the brake servo.
5 - Heat shield
6 - Hexagon nut
❑ Self-locking
❑ 20 Nm
7 - Brake line
❑ Brake master cylinder/secondary piston circuit to hydraulic unit
❑ 14 Nm
8 - Brake line
❑ Brake master cylinder/primary piston circuit to hydraulic unit
❑ 14 Nm
9 - Sealing plug
❑ Lubricate with brake fluid and insert into brake master cylinder
10 - Brake fluid reservoir
❑ Lubricate with brake fluid and insert in sealing plugs in brake master cylinder
❑ With integrated warning contact for brake fluid level (gradual introduction)
❑ Brake fluid reservoir must be removed before renewing warning contact
❑ Press brake fluid reservoir into sealing plugs
11 - Filler cap
❑ With integrated float and warning contact for brake fluid level
12 - Vacuum pipe
❑ With non-return valve
13 - Sealing plug

Audi TT 2007 ➤
Checking inner bellows at brake servo

– Check that bellows has not slipped out of circumferential
groove as shown in illustration.
WARNING
brakes is OK.
7.2 Checking non-return valve (TT RS)

The non-return valve is installed in front of the brake servo.
Note
♦ Air must pass through non-return valve in direction of arrow.

Valve must remain closed in opposite direction.
♦ The non-return valve is open on the side of the brake servo.
Removing and installing non-return valve ⇒ page 115
7.3 Removing and installing non-return

valve (TT RS)
The non-return valve is installed in front of the brake servo.
Removing
– Detach vacuum hoses from non-return valve.
Installing
Make sure that non-return valve is installed in correct position.
Note
♦ Air must pass through non-return valve in direction of arrow.

Valve must remain closed in opposite direction.
♦ The non-return valve is open on the side of the brake servo.
– Press vacuum hoses onto connections of non-return valve.
Note
To make it easier to install vacuum hoses, slightly moisten con‐

nections on non-return valve with water prior to installation.
7.4 Removing and installing brake fluid res‐

ervoir
Removing
– TT RS: Lift off engine cover panel -1-.

Audi TT 2007 ➤
Engine cover panel (TT RS)

– Extract brake fluid from reservoir.
WARNING

– Detach and seal clutch hose.

– Unscrew bolt underneath brake fluid reservoir.
Note
Depending on the model, an additional securing pin may be

pressed through the mounting in the brake master cylinder and
the brake fluid reservoir.
– Pull securing pin out of mounting of brake master cylinder and

brake fluid reservoir.
– Detach brake fluid reservoir.
Installing
– Lubricate connections on brake fluid reservoir with brake fluid
and insert in sealing plugs in brake master cylinder.
Note
Depending on the model, an additional securing pin may be

pressed through the mounting in the brake master cylinder and
the brake fluid reservoir.
– Slide securing pin through mounting of brake master cylinder

and brake fluid reservoir.
– Screw in and tighten bolt underneath brake fluid reservoir.
– Connect clutch hose.
– Bleed clutch ⇒ Rep. Gr. 68 .
WARNING
brakes is OK.

Audi TT 2007 ➤
7.5 Removing and installing brake master

cylinder
Note

Removing
♦ Brake filling and bleeding equipment -VAS 5234-
♦ Sealing plug repair kit, Part No. -1H0 698 311 A-
– Unclip air duct leading to air cleaner housing -arrows- or unbolt
on both sides.
– Detach air duct from air cleaner.
– Lift off engine cover panel in direction of arrow.

Audi TT 2007 ➤
TFSI engine
– Depending on engine version, remove noise amplifier
⇒ page 129 .
– Remove brake light switch ⇒ page 13 .
number of lint-free cloths in area beneath brake master cylin‐
der.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment -VAS 5234-
or upgrade kit and extraction unit -V.A.G 1869/4- .
WARNING

work.
disposal.
– Detach connector for brake fluid level warning contact.
– Disconnect brake lines -3- from brake master cylinder and seal
brake lines with plugs from repair kit.
– Unscrew securing nuts -1- for brake master cylinder.
– Detach heat shield.
– Unclip brake fluid reservoir at position -2- and pull off upwards.
– Detach brake master cylinder from brake servo.
Installing
– Renew seal between brake master cylinder and brake servo.
– When fitting brake master cylinder, make sure that push rod
is correctly positioned in brake servo.

Audi TT 2007 ➤
– Use new nuts -1-. Note tightening torque

⇒ Item 6 (page 114) .
– Depress brake pedal slightly to make it easier to guide brake
master cylinder onto pushrod.
– Connect brake lines -3- to brake master cylinder. Note tight‐
ening torque ⇒ Item 7 (page 114) .
– Install brake light switch ⇒ page 13 .
– Install brake fluid reservoir ⇒ page 115 .
– Depending on engine version, install noise amplifier
⇒ page 129 .
– Initiate basic setting for brake pressure sender.
-VAS 505x- .
– See: Running gear
– Brake system (Repair group 01; 45)
– 01 - Self-diagnosis compatible systems
– 03 - Brake electronics ABS/ESP Mark 60 si
– J104 - Control unit for ABS/TCS/ESP, Functions
WARNING
brakes is OK.
7.6 Removing and installing brake master

cylinder (TT RS)
Removing

Audi TT 2007 ➤

– Remove brake light switch (TT RS) ⇒ page 13 .
number of lint-free cloths in area beneath brake master cylin‐
der.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment -VAS 5234-
or upgrade kit and extraction unit -V.A.G 1869/4- .
WARNING

work.
disposal.
– Detach connector for brake fluid level warning contact.

Audi TT 2007 ➤
– Disconnect brake lines -3- from brake master cylinder and seal
brake lines with plugs from repair kit.
– Unscrew securing nuts -1- for brake master cylinder.
– Detach heat shield.
– Unclip brake fluid reservoir at position -2- and pull off upwards.
– Detach brake master cylinder from brake servo.
Installing
– Renew seal between brake master cylinder and brake servo.
– When fitting brake master cylinder, make sure that push rod
is correctly positioned in brake servo.
– Use new nuts -1-. Note tightening torque

⇒ Item 6 (page 114) .
– Depress brake pedal slightly to make it easier to guide brake
master cylinder onto pushrod.
– Connect brake lines -3- to brake master cylinder. Note tight‐
ening torque ⇒ Item 7 (page 114) .
– Install brake light switch (TT RS) ⇒ page 13 .
– Install brake fluid reservoir ⇒ page 115 .

Audi TT 2007 ➤

-VAS 505x- .
– 03 - Brake electronics ABS/ESP Mark 60 si
WARNING
brakes is OK.
7.7 Removing and installing brake servo
Note


Audi TT 2007 ➤
1 - Brake servo
(TT RS) ⇒ page 126
❑ On brake servo
6 - Bolt
❑ 25 Nm
8 - Brake pedal
Removing
Note


– Release brake servo vacuum by pressing the brake pedal
several times.
– Depending on engine version, remove noise amplifier
⇒ page 129 .

Audi TT 2007 ➤
– Remove brake light switch ⇒ page 13 .

– Remove brake master cylinder ⇒ page 117 .
Note
Remove brake servo vacuum sender -G483 (depending on type

of vehicle) ⇒ page 17 .
– Unclip vacuum line from brake servo and detach.


Audi TT 2007 ➤
– Unscrew nuts -6-.

– Remove brake servo from vehicle.
Installing
Use new nuts.
– Note tightening torque ⇒ Item 6 (page 123) .
– Attaching brake pedal to brake servo ⇒ page 92 .
Note
Install brake servo vacuum sender -G483 (depending on type of

vehicle) ⇒ page 17 .
– Install brake master cylinder ⇒ page 117 ..

– Install brake light switch ⇒ page 13 .
– Depending on engine version, install noise amplifier
⇒ page 129 .
– Install driver's storage compartment ⇒ Rep. Gr. 68 .
-VAS 505x- .
– 03 - Brake electronics ABS/ESP Mark 60si
– On vehicles with ABS/ESP, start basic setting for brake pres‐
sure sender(s).
WARNING
brakes is OK.

Audi TT 2007 ➤
7.8 Removing and installing brake servo (TT RS)
1 - Brake servo
❑ On brake servo
– Remove brake light
switch (TT RS)
⇒ page 13 .
6 - Bolt
❑ 25 Nm
8 - Brake pedal
Removing
– Release brake servo vacuum by pressing the brake pedal
several times.
– Remove brake light switch (TT RS) ⇒ page 13 .
– Remove brake master cylinder (TT RS) ⇒ page 119 .

Audi TT 2007 ➤
Note
Remove brake servo vacuum sender -G483 (depending on type

of vehicle) ⇒ page 17 .

– Unclip vacuum line from brake servo and detach.
– Detach vacuum line from non-return valve.

Audi TT 2007 ➤
– Unscrew nuts -6-.

– Remove brake servo from vehicle.
Installing
Use new nuts.
– Note tightening torque ⇒ Item 6 (page 123) .
– Attaching brake pedal to brake servo ⇒ page 92 .
Note
Install brake servo vacuum sender -G483 (depending on type of

vehicle) ⇒ page 17 .
– Install brake master cylinder. ⇒ page 117 .

– Install brake light switch (TT RS) ⇒ page 13 .
– Install vacuum line.
– Connect vacuum line to non-return valve.
– Install driver's storage compartment ⇒ Rep. Gr. 68 .

Audi TT 2007 ➤

– Bleed brake system ABS/ESP Mark 60 ⇒ page 109 ..
-VAS 505x- .
– 03 - Brake electronics ABS/ESP Mark 60si
– On vehicles with ABS/ESP, start basic setting for brake pres‐
sure sender(s).
WARNING
brakes is OK.
7.9 Removing and installing noise amplifier

(TFSI)
The noise amplifier is located in the engine compartment in front
of the brake servo.
Removing
– Unclip air duct leading to air cleaner housing.
– Detach air duct from air cleaner.

Audi TT 2007 ➤

– Detach top air duct from noise amplifier.
– Pull noise amplifier out of 3 rubber buffers in bracket.
– Detach bottom air duct from noise amplifier.
– Remove noise amplifier from vehicle.
Installing
Note
♦ Connect bottom air hose before fitting noise amplifier.

♦ The air hose leading to the noise amplifier must not be kinked
when installing.
Note
Make sure the noise amplifier is clipped into all three rubber buf‐
fers on the bracket.

Audi TT 2007 ➤
8 Exhauster pumps
The exhauster pump is driven mechanically.
Removing and installing (TDI engine) ⇒ page 131
Removing and installing (TFSI engine) ⇒ page 133
Removing and installing (TT RS) ⇒ page 134
8.1 Removing and installing exhauster

pump (TDI)
Removing
The exhauster pump is fitted on the left side of the engine.
– Remove engine cover panel -1 and 2-.
– Carefully lift off engine cover panel.
– Release the catches -arrows- on the side and detach the air
duct cover.
– Release the catches on the left and right -arrow A- and unclip
the air duct at the bottom -2-.
– Swivel the air duct at the bottom slightly to the rear and dis‐
engage the air duct at the bottom at the mounts -3-.
– Disengage the air pipe -1- from the air duct -arrow B-.
8. Exhauster pumps 131

Audi TT 2007 ➤
– Unplug electrical connector -2- on air mass meter.

– Detach hose -1-.
– Unfasten clamp -3- and detach air hose.
– Remove bolt -4- and take off air cleaner housing.
Caution
Take care not to damage the vacuum hose. The vacuum hose
must be renewed if it is damaged.
– Unscrew bolts at air pipe -arrows-.
Note
The noise insulation at the bottom must be removed for the bolts
-bottom arrow-.
– Remove noise insulation (bottom) ⇒ Rep. Gr. 50 .

– Press air pipe to one side.
– Detach vacuum hose upwards from exhauster pump.
– Remove bolts from sealing flange of exhauster pump.
– Pull exhauster pump out of mounting and remove from vehicle.
Installing
Install in reverse order; note the following.
Note
Renew seal.
Make sure seal is correctly positioned with respect to exhauster

pump.
– Turn drive lugs of exhauster pump so they engage in slots in
camshaft when exhauster pump is installed.
– Fit exhauster pump in position.
– Fit all bolts to sealing flange of exhauster pump and tighten to
9 Nm.
– Push vacuum hose onto connection of exhauster pump.
Note
The vacuum hose must be pressed as far as possible onto con‐

nection of exhauster pump.
– Insert air pipe.

Audi TT 2007 ➤
– Screw in bolts -arrows- at air pipe.

– Install noise insulation ⇒ Rep. Gr. 50 .
– Install air cleaner housing ⇒ Rep. Gr. 23 .
– Plug in electrical connector -2- on air mass meter.
– Clip in the catches -arrows- on the side and fit the air duct
cover.

pump (TFSI)
– Remove engine cover panel.

Audi TT 2007 ➤
– Unplug electrical connector -1- on air mass meter.

– Disconnect breather hose -3-.
– Remove cover from air cleaner housing.
– Disconnect air duct at clamp -2-.
– Push air duct to one side.
– Detach vacuum hose from exhauster pump.
Caution
Take care not to damage the vacuum hose. The vacuum hose
must be renewed if it is damaged.
– Remove bolts from sealing flange of exhauster pump.

– Pull exhauster pump out of mounting and remove from vehicle.
Installing
Note
Renew seal.
Ensure that seal is seated correctly.

camshaft when exhauster pump is installed.
– Fit all bolts to sealing flange of exhauster pump and tighten: 9
Nm.
– Connect vacuum hose to exhauster pump.
– Fit air duct.
– Connect air duct at clamp -2-.

– Install cover on air cleaner housing.
– Connect breather hose -3-.
– Plug in electrical connector -1- on air mass meter.

pump (TT RS)

Audi TT 2007 ➤
Removing

The coolant pipe is routed in front of the exhauster pump.
– Remove coolant pipe ⇒ Rep. Gr. 19 .
Observe the following when working on the cooling system:
WARNING
Risk of scalding due to hot steam and hot coolant.

♦ When the engine is warm, the cooling system is pressur‐
ised.
♦ Release the pressure by covering the cap of the coolant
expansion tank with a cloth and opening it carefully.

Audi TT 2007 ➤
Carefully detach vacuum hose -2-. The vacuum hose must be

renewed if it is damaged.
– Remove bolts -1-.
– Detach exhauster pump; to do so, press coolant hoses slightly
to one side.
Installing
Note
Renew seal.
Ensure that seal is seated correctly.

shaft when exhauster pump is installed.
– Fit all bolts -1- to sealing flange of exhauster pump and tighten
to 9 Nm.
– Push vacuum hose -2- onto connection of exhauster pump.
Note
The vacuum hose must be pressed as far as possible onto con‐

nection of exhauster pump.
– Install coolant pipe ⇒ Rep. Gr. 19 .


Audi TT 2007 ➤
9 Brake lines and brake hoses
9.1 Removing and installing brake lines and

brake hoses
The various brake line fitting locations and torques are given in
the following.
Brake lines in area of brake master cylinder/hydraulic unit ITT
Mark 60/ ITT Mark 70
1 - Brake line at brake master cylinder, 14 Nm
Brake lines in area of brake master cylinder/hydraulic unit Mark

60
1 - Brake line at hydraulic unit, 14 Nm
Brake lines/hoses in area of front wheel - front-wheel drive vehi‐

cles
1 - Hexagon bolt, 8 Nm
2 - Brake line, 14 Nm
3 - Securing clip
9. Brake lines and brake hoses 137

Audi TT 2007 ➤

Tightening torques for brake line to front brake caliper:
♦ 16" FN-3 brakes: 35 Nm
♦ 17" FNR-G57 brakes: 14 Nm
♦ TT RS brakes: 35 Nm
Tightening torque for brake line to rear brake caliper:
♦ All models: 14 Nm
Brake line connections
Hexagon bolt -1-: 15 Nm
Brake line connection at underbody

Brake lines/hoses in area of rear wheel - front-wheel drive vehi‐

cles
2 - Securing clip
3 - Spacer -3- should face brake caliper when installing.

Audi TT 2007 ➤
Brake lines/hoses in area of rear axle

2 - Securing clip
4 - Spacer -4- should face brake caliper when installing.
Brake line connection

– When tightening banjo bolt -2-, counter-hold on banjo nut -1-.
♦ Tightening torque: 14 Nm
WARNING
brakes is OK.
9. Brake lines and brake hoses 139

Brake System

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Copyright © 2010 Audi AG, Ingolstadt A005TT00320

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.1 Servicing front brakes 16" FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7.5 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

1.1 Production code (PR No.) allocation:

1.3 Front brakes

1.4 Front brakes (TT RS)

1.5 Rear wheel brakes, front-wheel drive

1.6 Rear wheel brakes, four-wheel drive

1.7 Rear brakes (TT RS)

2 Rep. Gr.00 - Technical data

2.1 General notes

Electronic brake control systems are inoperative when the ignition

2.2 Vehicles with front-wheel drive

2.3 Four-wheel drive vehicles with Haldex

2.4 Testing four-wheel drive vehicles with

– Switch off engine and wait for 3 seconds.

4 Rep. Gr.00 - Technical data

3.1 General notes

Rubber parts of brake system (sleeves, seals) are not com‐

45 – Anti-lock brake system

1.1 Notes for repair work on ABS Mark 60

The anti-lock brake system is basically maintenance-free.

Malfunctions in the ABS system do not influence the brake system

Vehicles equipped with the ABS Mark 60 do not have a mechan‐

6 Rep. Gr.45 - Anti-lock brake system

♦ Only remove replacement parts from packaging immediately

1. General information on the anti-lock brake system 7

2 Connecting -VAS 505x- and select‐

♦ Test equipment must always be secured to the rear seat

– Attach the diagnosis cable connector to the diagnosis con‐

8 Rep. Gr.45 - Anti-lock brake system

– Switch on tester -arrow-.

2. Connecting VAS 505x and selecting functions 9

3 Components and fitting locations on brake system ABS/ESP Mark 60

1 - ESP and TCS warning lamp

10 Rep. Gr.45 - Anti-lock brake system

♦ lights up while the vehicle is in motion.

♦ On vehicles with TTS engine the

The brake vacuum sender -G 483 is

12 - Brake master cylinder

♦ On vehicles with TTS engine the

3. Components and fitting locations on brake system ABS/ESP Mark 60 11

13 - Brake light switch

15 - ABS hydraulic unit -N55-

The ABS sensor ring / rotor is incorporated in the corresponding

12 Rep. Gr.45 - Anti-lock brake system

4 Removing and installing parts of

4.1 Removing and installing brake light

♦ The brake light switch is located on the brake master cylinder.

– Unplug electrical connector -1-.

The brake light switch is not adjustable.

4.2 Removing and installing brake light

♦ The brake light switch is located on the brake master cylinder.

– Lift off engine cover panel -1-.