service AUDI TT ROADSTER 2008 Workshop Manual

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& WARNING
• Using a bumper jac k to raise the vehicle will damage the
bumper system . The jack may slip , causing injury .
• Never support your veh icle on cinder blocks , bri cks or other
obje cts. The se may not be able to support the load and could
c ause injury when they fail.
• Never start or run the engine while the vehicle is supported by
the jack .
• If you mu st work under the vehicle, always use safety stands
specifically des igned for this purpose .
• Never use the he xagonal socket in the handle of the screw­
driver to loo sen or tighten the wheel bolts . •
Tire repair
App lies to vehicles: with Tire Mob ility System
General and safety pointers
Tire repair is in tended only for te m porary, shor t- te rm use.
®
Fig . 16 7 Tire damage
for which the Tire Mobility Sy stem is not
suited
Your vehicle is equipped with a tire repai r kit, the Tire Mobil ity
System (TMS) *. I
n the event of a tire fai lure, the TMS is in the luggage compartment
u nde r th e floo r. It cons ists of the tir e sealan t and an el ectric a ir
pump .
U sing TMS, tire damage caused by foreign bodies up to about
0 .16 inch (4 mm ) in diam eter can be seale d relia bly.
T he foreign object can stay in the tire .
The tire sealant must not be used:
• for cuts or punctures in the tire which are large r than
0.16 inch (4 mm)~ fig . 167
G)
• for damage to the rim 0
• if you have been driving with very low tire pressures or tires w ith
n o air G)
Using the TMS is described in the section~ page
264, "Preliminary
steps" .
TMS can be used a t te m peratures down to -4 °F ( -20 °C).
& WARNING
Take the following precautions after repairing the tire :
• Do not drive faster than 50 mph (80 km /hi!
• Avoid full -throttle acceleration , heavy braking and fast
cornering .
• The vehicle's road behavior can be affe cted .
• Tires sealed with TMS are intended only for temporary , short­
term use .
• After using the tire sealant the tire pressure monitoring system
m ay no longer work properly . Drive carefully to the next profes­
s ional repair facility.
• TMS must NOT be used ,
- for cuts or punctures in the tire whi ch are larger than
0 .16 inch (4 mm )
- for damage to the rim
Vehicle care Do-it-yourself service irechnical data

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- Remove the "max. 50 mph" (80 km/h) sticker from the
sealant bottle and affix it to the instrument cluster in the
driver's view.
& WARNING
• Turn the hazard flashers on and set up the warning triangle if
you have a flat tire in moving traffic . In this way you protect your ­
self and other road users.
• Make sure that all passengers are in a safe place, out of the
danger zone (for example, behind a guard rail).
0 Note
Particular care is necessary if you are making a tire repair on a steep
incline.
[ i] Tips
Obey all laws. •
Applies to vehicles: with T ire Mobil ity System
Making a tire repair
Tire repair consists of the following sections.
Fig. 169 Parts of the
Tire Mobility System Fig
. 170 Connector for
the Tire Mobility System
Assembling Tire Mobility System
- Open the lid 0 of the electric air pump~ fig. 169.
- Pull the plug© and the pressure hose G)with the gauge
out of the housing.
- Screw the pressure hose© of the electric air pump onto
the flange © of the sealant bottle
G).
- Push the sealant bottle with the flange down into the
recess
G) on the lid of the electric air pump.
- Remove the dust cap from the valve of the defective tire.
- Screw the hose @) onto the valve
G) ~ fig. 170.
- Insert the plug©~ fig. 169 into the socket for the ciga-
rette lighter.
Inflating tire
- Move the switch®~ fig. 170 on the electric air pump 31
to position I. After 5 minutes, tire pressure must have
reached at least 1.8 bar.
~
3> The e lectric air pump should never run for longer than 8 minutes.
Vehicle care Do-it-yourself service irechnical data

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- If tire pressure is less than 1.3 bar, the tire is too severely
damaged. Do not continue to drive. Seek professional
assistance.
& WARNING
If tire pressure is less than 1.3 bar after driving for 10 minutes, the
tire is too severely damaged. Do not continue to drive. Seek profes­
sional assistance.
[ i] Tips
After a tire repair, have the sealant bottle replaced at a dealership.
This restores full functionality to the Tire Mobility System. •
What should I be aware of when
changing a tire?
General information
The following sections will provide you with important information
on how to change a tire using the vehicle tool kit .
However , we recommend that you have a qualified service center
change the tire and perform all work associated with changing it.•
Ap plies 10 vehicles: with decora tive wheel covers
Decorative wheel covers
The decorative wheel covers must be removed first to
access the wheel bolts.
Removing
Fig. 171 Wheel
change : removing the
wheel cover
- Insert the hook provided with the on board tool kit into
the hole on the center hub piece.
- Pull off the
decorative wheel cover=> fig. 171. •
Vehicle care Do-it-yourself service Technical data

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& WARNING
• Using force without control to speed the wheel change up can
cause the vehicle to slip off the jack and cause serious personal
injuries.
• Do not loosen the wheel bolts more than one turn before you
raise the vehicle with the jack . - Risk of injury!
[ i] Tips
• Never try and use the hexagonal socket in the handle of the
screwdriver to loosen or tighten the wheel bolts.
• If a wheel bolt sits very tight, you may find it easier to loosen by
carefully pushing down on the end of the wheel bolt wrench with
one foot only . As you do, hold on to the car to keep yourself stable
and take care not to slip. •
Rais ing the vehicle
The vehicle must be lifted with the jack first before the
wheel can be removed.
-
Fig. 174 Wheel
change: mounting
points for the lifting
jack Fig
. 175 Close-up:
proper positioning of
lifting jack
-Find the mounting point on the rocker panel which is
closest to the flat tire ~ fig. 174 -arrows-.
- Crank the jack up until it can be positioned under the lift
point on the vehicle.
- Align the jack so the claw~ fig. 175@ grips the
mounting point on the rocker panel and the flexible base
plate @ is flat on the ground.
- Continue to crank the jack until the wheel is lifted just
clear of the ground.
Recesses at the front and rear of the underbody rib mark the proper
mounting locations for the jack=> fig. 174 . There is
only one desig­
nated jack mounting point for each wheel.
Do not apply the jack
anywhere else=>&.
The jack should be positioned approximately 6 in. (15 cm) behind
the front wheel or 10 in. (25 cm) in front of the rear wheel.
An
unstable surface under the jack can cause the vehicle to slip off
the jack. Always provide a firm base for the jack on the ground. If
necessary place a sturdy board or similar support under the jack. On
hard, slippery surfaces (such as tiles) use a rubber mat or similar to
prevent the jack from slipping=> &. .,
Vehicle care Do-it-yourself service irechnical data

What do I do now? -
----------------
•
-Screw the threaded end of the alignment pin from the
tool kit hand-tight into the now vacant bolt hole
=:> page 270, fig. 177.
- Then completely unscrew the other wheel bolts as
described above.
- Take off the wheel leaving the alignment pin in the bolt
hole.
Putting on the wheel
- Lift the spare wheel and carefully slide it over the align­
ment pin to guide it in place.
- Use the hexagonal socket in the screwdriver handle to
screw in and tighten all wheel bolts slightly.
- Unscrew the alignment pin and insert and tighten the
remaining wheel bolt slightly like the rest.
- Turn the jack handle counter -clockwise to lower the
vehicle until the jack is fully released.
- Use the wheel bolt wrench to tighten all wheel bolts
firmly =:> page 268. Tighten them crosswise, from one
bolt to the (approximately) opposite one, to keep the
wheel centered.
[ i J Tips
Never use the hexagonal socket in the handle of the screwdriver to
loosen or tighten the wheel bolts.
• Pull the reversible blade from the screwdriver before you use the
hexagonal socket in the handle to turn the wheel bolts.
• When mounting tires with
unidirectional tread design make sure
the tread pattern is pointed the right way~
page 272.
• The wheel bolts should be clean and easy to turn. Check for dirt
and corrosion on the mating surfaces of both the wheel and the
hub . Remove all dirt from these surfaces before remounting the
wheel. •
Notes on wheel change
Please read the information~ page 249, "New tires and replacing
tires and wheels", if you are going to use a spare tire which is
different from the tires on your vehicle.
After you change a tire:
• Check the tire pressure on the spare immediately after
mounting.
• Have the wheel bolt tightening torque checked with a torque
wrench as soon as possible by your authorized Audi dealer or a qualified service station .
• With steel and alloy wheel rims, the wheel bolts are correctly
tightened at a torque of 90 ft lb (120 Nml.
• If you notice while changing a tire that the wheel bolts are
corroded and difficult to turn, then they should be replaced before
you check the tightening torque.
• Replace the flat tire with a new one and have it installed on your
vehicle as soon as possible. Remount the wheel cover.
Until then, drive with extra care and at reduced speeds.
& WARNING
• If you are going to equip your vehicle with tires or rims which
differ from those which were factory installed, then be sure to read
the information
~ page 249, "New tires and replacing tires and
wheels".
• Always store the tools securely in luggage compartment.
Otherwise, in an accident or sudden maneuver they could fly
forward, causing injury to passengers in the vehicle.
Do-it-yourself service

Fuses and bul bs -
------------------
Fuses and bulbs
Fuses
Replacing a fuse
A problem in the electrical system may be caused by a
blown fuse.
Fig . 178 End face o f
i n str ume nt pan el:
re m ov ing cover pla te
t o access f uses
Fig . 179 Left si de o f
engine co mpartm ent:
fu se cover
Fus e cove r on the left end face of the instrum ent
panel
- Switch off the ignition and the e lectr ica l component
affected . - Carefully pry the fuse cover off the instrument panel
using the ignition key or a screwdriver=> fig. 178.
- C heck the fuse listing on the next pages to find out w hich
fuse belongs to the component which has failed => page 274, "F use Location, Instrument Pane l le ft".
- Remove the blown fuse with the plastic clip provided .
The clip is located on the holder in the fuse box .
Replace a blown fuse (recognizable by the melted metal
str ip inside) with a fuse of the same amperage.
- Firmly snap the cover back onto the instrument panel
face.
Fuse cov er in engin e compartment
- Switch the ignition a nd the affec ted co nsumer off .
- Unlatch the fuse cover, push the two s lides forward
=> fig . 179.
- Find out which fuse belongs to the equipment which
stopped working=> page 276, "Fuse location, left side of
engine compartment".
- Remove the plastic from its retainer in the fuse box cover (left face end of the instrument pane l), place it on the
fuse in question and pull it out.
- If the fuse is burned out (recognizable by melted strips of metal), replace it with a new fuse of the same rating.
- Replace the fuse cover.
- Push the two slides to the rear=> fig. 179 . Install the fuse
cover carefully to prevent water from entering. .,
Vehicle care Do-it-yourself service irechnical data

Fuses and bulbs -
----------------
Equipment No. Equipment
Amps
Engine relay, fuel tank control unit, Airbag Off
16 A/C system (control unit) 10
1
light, light switch (switch illumination), diagnos-10
tic connector
17 Tire pressure monitoring system (control unit) 5
18
Not used
ABS, ASR, ESP, brake light switch
5 19
Not used
3 AFS headlight (left) 5
Not used
Oil level sensor (extended maintenance interval)
(WIV), tire pressure monitoring system, switch
21 Fuel injectors (gasoline engine) 10
4 for Electronic Stability Program (ESP), AFS head-5 Wind deflector (Roadster) 30
lights (control unit), A/C system (pressure sen -23 Horn 20 sorl, backup light switch
Automatic headlight range control, AFS head-
24 Transmission (control unit) 15
5
light (right)/ manual headlight range control, 5/10
25 Heater rear window Coupe/heated rear window 30/20
halogen headlights Roadster
Control unit for CAN data transfer (gateway),
26 Driver's side power window 30
6 electromechanical steering, automatic transmis-5
27 Passenger's side power window 30
sion shift gate
28 Not used
Acoustic Park Assist, automatic dipping interior
rear view mirror, garage door opener, heatable
29 Washer pump 15
7
windshield washer nozzles, washer pump, wind 5
30 Cigarette lighter 20
deflector relay (Roadster)
31 Starter 40
8
Haldex clutch 5 32 Steering column module 5
9
Control unit Audi magnetic ride 5 33
Instrument cluster 5
Airbag control unit 5 34 Radio navigation system, radio 15
1 1 Mass airflow sensor, crankcase heating 5/10
35
Audio amplifier 30
12 Door control unit (central locking driver/passen-10
36 Engine (control unit) 10 ger)
13 Diagnostic connector 10 37 CAN (Gateway) 5
Rain sensor, automatic transmission shift gate 5 38 Not used
15 Roof
light (interior lighting) 5 39 Not used
• Do-it
-yourself service

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•
No. II Equipment Amps
8
Ignition coils (4 -cylinder)/ignition coils (6 -cylin -20/30 der)
-
9 Engine (control unit) 25
Water pump delayed-off 10
11 Feed (clutch pedal, brake pedal) 5
12
Activated charcoal filter/charge pressure con-10 trol valve (4-cylinder)
--
Bulbs
Replacing light bulbs
For your safety, we recommend that you have your autho­
rized Audi dealer replace burned out bulbs for you.
It is becoming increasingly more and more difficult to replace
vehicle light bulbs since in many cases, other parts of the car must
first be removed before you are able to get to the bulb. This applies
especially to the light bulbs in the front of your car which you can
only reach through the engin e compartment .
Sheet metal and bulb holders can have sharp edges that can cause
serious cuts, and parts must be correctly taken apart and then prop­
erly put back together to help prevent breakage of parts and long
term damage from wa ter that can enter housings that have not
been properly resealed.
For your safety , we recommend that you have your authorized Audi
dealer replace any bulbs for you, since your dealer has the proper
tools, the correct bulbs and the expertise.
Gas discharge lamps (Xenon lights)*:
•
Due to the high electrical voltage, have the bulbs replaced by a qual­
ified technician. Headlights with Xenon light can be identified by the
high voltage sticker.
& WARNING
Contact with high-voltage components of the electrical system
and improper replacement of gas discharge (Xenon) headlight
bulbs can cause serious personal injury and death.
• Xenon bulbs are pressurized and can explode when being
changed.
• Changing Xenon lamps requires the special training, instruc­
tions and equipment .
• Only an authorized Audi dealer or other qualified workshop
should change the bulbs in gas discharge lamps.
& WARNING
There are parts with sharp edges on the openings and on the bulb holders that can cause serious cuts.
• If you are uncertain about what to do, have the work performed
by an authorized Audi dealer or other qualified workshop. Serious
personal injury may result from improperly performed work.
[ i] Tips
• If you must replace the light bulbs yourself, always remember
that the engine compar tment of any vehicle is a hazardous area to
work in. Always read and heed all WARNINGS =>
page 212, "Engine
compartment"=> &.
• It is best to ask your authorized Audi dealer whenever you need
to change a bulb. •
Do-it-yourself service

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& WARNING !continued)
• Before you check anything in the engine compartment, always
read and heed all WARNINGS~ page 212, "Engine compartment".
0 Note
• Applying a higher voltage booster battery will cause expensive
damage to sensitive electronic components, such as control units,
relays, radio, etc .
• There must be no electrical contact between the vehicles as
otherwise current could already start to flow as soon as the positive
(+) terminals are connected.
[ i) Tips
The discharged battery must be properly connected to the vehicle's
electrical system. •
Use of jumper cables
Make sure to connect the jumper cable clamps in exactly
the order described below!
Fig. 182 For jump
starting or charging
the battery, there is a
jump start connection
on the left side of the
engine compartment . Fig. 183 Jump
start
using the battery in
another vehicle: A -
Discharge, B-Female
socket
On vehicles with the 6-cylinder engine, instead of the
battery, on the left side of the engine compartment there is
a
Jump start connection=:> fig. 182. For jump starting, open
the cover on the positive terminal.
Preparatory measures
1. Do not jump start a frozen battery! Replace such a
battery!
2. Otherwise apply the hand brake and shift into idle gear if
your vehicle has manual transmission, and put the
selector lever into P position if your vehicle has auto ­
matic transmission.
3. For both vehicles switch off all consumers and the igni­
tion.
Connecting/disconnecting the jumper cable.
4. Connect one end of the red jumper cable to the positive
terminal
G) =:> fig. 183 in the external starting point@ of
your vehicle .
5. Connect the other end of the red jumper cable to the
positive terminal
® of the booster battery®·
Vehicle care Do-it-yourself service irechnical data

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Emergency towing with commercial
tow truck
General hints
Your Audi requires special handling for towing.
The following information is to be used by commercial tow truck
operators who know how to operate their equipment safely.
• Never tow your Audi, towing will cause damage to the engine
and transmission.
• Never wrap the safety chains or winch cables around the brake
lines.
• To prevent unnecessary damage, your Audi must be transported
with a car carrier (flatbed truck).
• To load the vehicle on to the flat bed, use the towing loop found
in the vehicle tools and attach to the front or rear anchorage
=> page 281 and=> page 282.
& WARNING
A vehicle being towed is not safe for passengers. Never allow
anyone to ride in a vehicle being towed, for any reason. •
Front towing loop
Do not install the front towing loop until it is needed.
Fig. 184 Front
bumper: removing the
grill
Fig . 185 Front
bumper: screwing
in
the towing loop
The towline eye fits into the threaded hole located on the
right side of the front bumper behind the grill.
- Remove the screwdriver and towing loop from the
vehicle toolkit=>
page 262.
-Insert the screwdriver into the slot as shown and press
toward the center of the vehicle => fig. 184. At the same
time, pull the grill forward and out.
- Screw the towing loop tightly into the threaded hole as
far as it will go => fig. 185.
~
Vehicle care Do-it-yourself service irechnical data