Service

Audi TT 1999 ➤
Brake system
Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Audi TT 1999 ➤
Brake system

Repair Group
00 - Technical data
45 - Anti-locking brake system
46 - Brakes, Brake mechanics
47 - Brakes, Brake hydraulics

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

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 A0057005720

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Allocation of PR Nos./brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.1 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.3 Front-wheel drive vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.4 Four-wheel drive vehicles (Haldex coupling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3 Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.1 Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

45 - Anti-locking brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1 General notes on anti-locking brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.1 General notes on anti-locking brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.2 Notes for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2 ABS/ESP ITT Mark 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1 ABS/ESP ITT Mark 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3 Removing and installing ABS/ESP ITT Mark 20 system components . . . . . . . . . . . . . . . . . .13
3.1 Removing and installing ABS/ESP ITT Mark 20 system components . . . . . . . . . . . . . . . . . .13
3.2 Removing and installing brake light switch (square housing) . . . . . . . . . . . . . . . . . . . . . . . .13
3.3 Removing and installing brake light switch (round housing) . . . . . . . . . . . . . . . . . . . . . . . .14
3.4 Removing and installing lateral acceleration sender -G200 and yaw rate sender -G202 . . 14
3.5 Removing and installing longitudinal acceleration sender -G251 . . . . . . . . . . . . . . . . . . . . . .16
3.6 Removing and installing steering angle sender -G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.7 Removing and installing brake pressure senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4 Control unit and hydraulic unit; ABS/ESP ITT Mark 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.1 Control unit and hydraulic unit; ABS/ESP ITT Mark 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3 Removing and installing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5 Removing and installing ABS/ESP ITT Mark 20 system components on front axle . . . . . . . .29
5.1 Removing and installing ABS/ESP ITT Mark 20 system components on front axle . . . . . . . .29
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5.2 Explodedpermitted
view unless
. . . .authorised
. . . . . .by. AUDI
. . . AG.
. . .AUDI
. . .AG
. .does
. . .not. .guarantee
. . . . . or. .accept
. . . any
. . .liability
. . . . . . . . . . . . . . . . . . . .29
5.3 Removingwith and installing
respect wheelofspeed
to the correctness sensor
information . . . . . Copyright
in this document. . . . . . .by. AUDI
. . . AG.
. . . . . . . . . . . . . . . . . . . . .31
5.4 Checking rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
5.5 Replacing speed sensor wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6 Removing and installing ABS/ESP ITT Mark 20 system components on rear axle (vehicles
with front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
6.1 Removing and installing ABS/ESP ITT Mark 20 system components on rear axle (vehicles
with front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
6.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
6.3 Removing and installing speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6.4 Checking rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6.5 Replacing speed sensor wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
7 Removing and installing ABS/ESP ITT Mark 20 system components on rear axle (vehicles
with four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
7.1 Removing and installing ABS/ESP ITT Mark 20 system components on rear axle (vehicles
with four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
7.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
7.3 Removing and installing speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Contents i
 Audi TT 1999 ➤
Brake system - Edition 01.2002

7.4 Checking rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

7.5 Replacing speed sensor wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
8 ABS/ESP ITT Mark 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.1 ABS/ESP ITT Mark 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
9 Removing and installing ABS/ESP ITT Mark 60 system components . . . . . . . . . . . . . . . . . .55
9.1 Removing and installing ABS/ESP ITT Mark 60 system components . . . . . . . . . . . . . . . . . .55
9.2 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
9.3 Removing and installing lateral acceleration sender -G200 and yaw rate sender -G202
(vehicles up to approx. 08.01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
9.4 Removing and installing longitudinal acceleration sender -G251 (vehicles up to approx.
08.01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
9.5 Removing and installing ESP sensor unit -G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
9.6 Removing and installing steering angle sender -G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
9.7 Removing and installing brake pressure senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
10 Control unit and hydraulic unit; ABS/ESP ITT Mark 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.1 Control unit and hydraulic unit; ABS/ESP ITT Mark 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.3 Removing and installing control until and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
11 Removing and installing ABS/ESP ITT Mark 60 system components on front axle . . . . . . . .71
11.1 Removing and installing ABS/ESP ITT Mark 60 system components on front axle . . . . . . . .71
11.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
11.3 Removing and installing speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
11.4 Checking rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
11.5 Replacing speed sensor wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
12 Removing and installing ABS/ESP ITT Mark 60 system components on rear axle (vehicles
with front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
12.1 Removing and installing ABS/ESP ITT Mark 60 system components on rear axle (vehicles
with front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
12.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
12.3 Removing and installing speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
12.4 Checking rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
12.5 Replacing speed sensor wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
13 Removing and installing ABS/ESP ITT Mark 60 system components on rear axle (vehicles
with four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
13.1 Removing and installing ABS/ESP ITT Mark 60 system components on rear axle (vehicles
with four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
13.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
13.3 Removing and installing speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
13.4 Checking rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
13.5 Replacing speed sensor wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

46 - Brakes, Brake mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

1 Servicing front brake . . . Protected
. . . . . .by. copyright.
. . . . . Copying
. . . . .for. .private
. . . or. .commercial
. . . . . .purposes,
. . . . . in. part
. . .[Link]. whole,
. . . .[Link]
. . . . .91
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1.1 Servicing front brake . . . . . with
. . respect
. . . . to
. .the. .correctness
. . . . . .of. information
. . . . . . in. this
. . document.
. . . . . .Copyright
. . . . . by . .AUDI
. . .AG.
. . . . . . .91
1.2 Front brakes FN 3 - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
1.3 Removing and installing brake pads - Front brakes FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . .97
1.4 Removing and installing brake caliper - Front brakes FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . .101
2 Servicing rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
2.1 Servicing rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
2.2 Rear brake on vehicles with front-wheel drive - Exploded view . . . . . . . . . . . . . . . . . . . . . .102
2.3 Removing and installing brake pads - Vehicles with front-wheel drive . . . . . . . . . . . . . . . . . .106
2.4 Removing and installing brake caliper - Vehicles with front-wheel drive . . . . . . . . . . . . . . . .109
2.5 Rear brake on vehicles with four-wheel drive - Exploded view . . . . . . . . . . . . . . . . . . . . . .110
2.6 Removing and installing brake pads - Vehicles with four-wheel drive . . . . . . . . . . . . . . . . . .115
2.7 Removing and installing brake caliper - Vehicles with four-wheel drive . . . . . . . . . . . . . . . .118
3 Servicing front brake, brake caliper 2FN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

ii Contents
 Audi TT 1999 ➤
Brake system - Edition 01.2002

3.1 Servicing front brake, brake caliper 2FN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

3.2 Special tools and workshop equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
3.3 Removing and installing brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
4 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
4.1 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
4.2 Handbrake lever - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
4.3 Removing and installing handbrake cable - Vehicles with front-wheel drive . . . . . . . . . . . .134
4.4 Removing and installing handbrake cable - Vehicles with four-wheel drive . . . . . . . . . . . . . .136
4.5 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
5 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
5.1 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
5.2 Brake pedal on left-hand drive vehicles -Assembly overview . . . . . . . . . . . . . . . . . . . . . . . .141
5.3 Brake pedal on right-hand drive vehicles Protected by -copyright.
Assembly Copyingoverview
for private or .commercial
. . . . . .purposes,
. . . . .in. part
. . or. .in .whole,
. . . is.144
not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5.4 Removing and installing brake pedal [Link]
. . . .to. the
. . correctness
. . . . . . of. .information
. . . . . .in .this
. .document.
. . . . . Copyright
. . . . . .by. AUDI. . . AG.
. .147
5.5 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

47 - Brakes, Brake hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

1 High-pressure and low-pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
1.1 High-pressure and low-pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
2 Servicing front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
2.1 Servicing front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
2.2 Brake caliper FN 3 - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
2.3 Removing and installing front brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
3 Servicing brake caliper 2FN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
3.1 Servicing brake caliper 2FN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
3.2 Removing and installing front brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
4 Servicing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
4.1 Servicing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
4.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
4.3 Removing and installing rear brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
5 Bleeding brake system - ABS/ESP ITT Mark 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
5.1 Bleeding brake system - ABS/ESP ITT Mark 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
5.2 Bleeding brake system using brake filling and bleeding appliance VAS 5234 or V.A.G 1869
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
5.3 Bleeding brake system without brake filling and bleeding appliance . . . . . . . . . . . . . . . . . .169
5.4 Bleeding brake system when brake fluid reservoir was empty . . . . . . . . . . . . . . . . . . . . . . . .169
6 Bleeding brake system - ITT ABS/ESP Mark 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
6.1 Bleeding brake system - ITT ABS/ESP Mark 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
6.2 Bleeding brake system using brake filling and bleeding appliance VAS 5234 or V.A.G 1869
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
6.3 Bleeding brake system without brake filling and bleeding appliance . . . . . . . . . . . . . . . . . .176
6.4 Bleeding brake system when brake fluid reservoir was empty . . . . . . . . . . . . . . . . . . . . . . . .176
7 Vacuum servo pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
7.1 Vacuum servo pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
7.2 Checking vacuum pump for brakes -V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
7.3 Removing and installing vacuum pump for brakes -V192 . . . . . . . . . . . . . . . . . . . . . . . . . .181
8 Brake servo/brake master cylinder - Left-hand drive vehicles . . . . . . . . . . . . . . . . . . . . . . . .183
8.1 Brake servo/brake master cylinder - Left-hand drive vehicles . . . . . . . . . . . . . . . . . . . . . . . .183
8.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
8.3 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
8.4 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
9 Brake servo/brake master cylinder - Right hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
9.1 Brake servo/brake master cylinder - Right hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
9.2 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
9.3 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198

Contents iii
 Audi TT 1999 ➤
Brake system - Edition 01.2002

9.4 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

10 Brake pipes and hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
10.1 Brake pipes and hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
10.2 Removing and installing brake pipes and hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

iv Contents
 Audi TT 1999 ➤
Brake system - Edition 01.2002

00 - Technical data

1 - Technical data
1.1 - Technical data

1.2 - Allocation of PR Nos./brakes

-> The PR No. on the vehicle data sticker indicates the type of brakes fitted in the vehicle.
◆ Arrow 1 - Rear brake
◆ Arrow 2 - Front brake

The vehicle data sticker is located in the spare wheel recess and in service booklet.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
The PR No. can be used to identify
with respect the proper
to the correctness brakeincaliper/brake
of information disc/brake
this document. Copyright pad combination.
by AUDI AG.

=> Parts catalogue

Engine PR No. Front brake

1.8 l - 110 kW 1LT FN 3 (16")
1.8 l - 132 kW
1.8 l - 165 kW
1.8 l - 132 kW G1A, 1LV FN 3 (16")

Engine PR No. Front brake

3.2 l - 184 kW 1ZT 2 FN42 (17")

Engine PR No. Rear brake

Front-wheel drive
1.8 l - 110 kW 1KK C 38
1.8 l - 132 kW

1.1 - Technical data 1

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Engine PR No. Rear brake

1.8 l - 132 kW 2EK C 38

Engine PR No. Rear brake

Four-wheel drive
1.8 l - 132 kW 1KE, C 41
1.8 l - 165 kW 1KF, C 38

Four-wheel drive
3.2 l - 184kW 1KF C 38

1.3 - Brakes

Brake system
Dual-circuit diagonally split braking system, anti-locking brake system (ABS) with electronic brake pressure
distribution (EBPD), electronic differential lock (EDL), traction control system (ASR), electronic stability pro‐
gram (ESP)
Brake master cylin‐ dia., mm 23.81
der
Brake servo dia., inches LHD: 10
RHD: 7 / 8 tandem
Function pneumatic
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Boost factor i= 5 Copyright by AUDI AG.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document.

Front brakes
Brake caliper PR No. 1LT PR No. G1A, 1LV PR No. 1ZT
Front brake caliper FN 3 FN 3 2FN
Piston dia., mm 54 54 42
Brake disc
Front brake disc dia., mm 312 312 334
Brake disc thickness, ventilated mm 25 25 32
Wear limit mm 23 23 30
Brake pad
Pad thickness (new pad, without backplate) mm 14 14 14
Wear limit (without backplate) mm 2 2 2

Rear brakes
Brake caliper PR No. 1KK PR No. 1KE PR No. 2EK PR No. 1KF
Rear brake caliper C 38 C 41 HR C 38 C 38
Piston dia., mm 38 41 38 38
Brake disc
Rear brake disc dia., mm 232 239 232 256
Brake disc thickness, not ventilated mm 9 9 9 -

2 00 - Technical data
 Audi TT 1999 ➤
Brake system - Edition 01.2002

Rear brakes
Brake disc thickness, ventilated mm - - - 22
Wear limit mm 7 7 20 20
Brake pad
Pad thickness (new pad, without backplate) mm 12 12 12 12
Wear limit (without backplate) mm 2 2 2 2

2 - Brake test
2.1 - Brake test

2.2 - General

The wheels are driven by the dynamometer.

For test purposes, select neutral on vehicles with manual gearbox and position N on vehicles with automatic
gearbox.
Follow instructions of dynamometer manufacturer when performing test.

2.3 - Front-wheel drive vehicles

Brake test on single-axle dynamometer

We recommend use of a brake dynamometer with controlled roller speed and a max. test speed of 6 km/h.
Failure to comply with the above specifications can lead to brake application (EDL control).
In such cases switch off engine and ignition for test purposes. Run engine briefly if necessary to build up
sufficient vacuum for brake test.

2.4 - Four-wheel drive vehicles (Haldex coupling)

Brake test on single-axle dynamometer for four-wheel drive vehicles

The dynamometer drives the wheels of one axle in opposite directions to avoid the other axle being driven.
We recommend use of a brake dynamometer with controlled roller speed and a max. test speed of 6 km/h.
Failure to comply with the above specifications can lead to brake application (EDL control).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
In such cases switch offpermitted
engine andauthorised
unless ignition for test
by AUDI purposes.
AG. AUDI AG does not Run engine
guarantee briefly
or accept if necessary to build up
any liability
sufficient vacuum for brake
with test.
respect to the correctness of information in this document. Copyright by AUDI AG.

If no four-wheel drive dynamometer is available, testing can also be performed using a conventional dyna‐
mometer.
- Drive vehicle forward onto rollers.
- Switch off engine and wait 2 seconds.
- Perform brake test at front.
- Start engine and let it run for approx. 5 seconds to build up sufficient vacuum in brake servo.

1.3 - Brakes 3
 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Drive vehicle forwards until rear wheels are positioned on rollers.

- Switch off engine and wait 2 seconds.
- Perform brake test at rear.

Engine must not run and ignition not be switched on during test, as otherwise rear axle would be driven by
Haldex coupling.

3 - Brake fluid
3.1 - Brake fluid

3.2 - General information

Brake fluid is a hygroscopic liquid. As such it readily takes up moisture from the atmosphere and retains it.

-> An increase in the water content in the brake fluid causes its boiling point to drop. A reduced boiling point
can cause vapour bubbles to develop as the fluid heats up under intense braking. In this condition the brake is
likely to fail completely.
Brake fluid will take on a darker colour after some time. This discoloration is the result of chemical reactions,
and is NOT an indication of the fluid losing its properties. The effect appears
by AUDI after a relatively short time (few
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permitted unless authorised AG. AUDI AG does not guarantee or accept any liability
weeks), on vehicles fitted with ABS even faster. with respect to the correctness of information in this document. Copyright by AUDI AG.

Warning!
Avoid any contact of rubber components of the brake system (sleeves, sealing rings) with mineral oil, petrol
and cleaning solvents!

Even very small amounts of the above substances will transform structure and dimension of a sealing ring or
sleeve enough to adversely affect brake function. The effects of a polluted brake system will not be noticed for
several months until they have caused damage that requires extensive servicing, especially on vehicles fitted
with ABS.

4 00 - Technical data
 Audi TT 1999 ➤
Brake system - Edition 01.2002

-> A = Sleeve - original size

B = Sleeve - swollen as a result of contact with mineral oil

The above mentioned points require special rules for handling:

Always keep containers holding brake fluid tightly shut. Only this will safely keep oil, dirt or detergents as well
as moisture in the atmosphere from entering and polluting the brake fluid.

Take extra care to store containers holding brake fluid separate from containers holding oil (including hydraulic
fluid) or liquid detergents. This will prevent any chance of accidentally mixing these fluids or even filling the
brake system with the wrong fluid.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3.2 - General information 5

 Audi TT 1999 ➤
Brake system - Edition 01.2002

45 - Anti-locking brake system

1 - General notes on anti-locking brake system

1.1 - General notes on anti-locking brake system

1.2 - Notes for repair work on ABS

Caution!
The anti-locking brake system is basically maintenance-free.
Tests, installation and repair work must always be carried out by properly trained mechanics.
Failure tounless
observe thebypoints
AUDI [Link]
AUDI AGin thisnotWorkshop Manual may result in damage to the system and could
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted authorised does guarantee or accept any liability
makewiththe vehicle
respect [Link] information in this document. Copyright by AUDI AG.
to the correctness

◆ Before carrying out repair work on the anti-locking system, determine the cause of the fault using self diag‐
nosis.
◆ Do not unplug the connector on the hydraulic control unit unless the ignition is switched off.
◆ When installing a new hydraulic control unit, always perform coding

=> Running gear, Self-diagnosis; Repair group 01

◆ After work for which the brake system had to be opened, bleed the brake system: ABS/ESP Mark 20 =>Page
174 (e.g. using brake charge and bleed equipment V.A.G 1869 A or VAS 5234.
◆ When working with brake fluid, observe the relevant safety precautions and notes
◆ Absolute cleanliness is required when working on the anti-locking brake system, it is not permitted to use
any products which contain mineral oil, such as oils, greases etc.
◆ Ensure that no brake fluid enters plug connectors.
◆ Thoroughly clean all unions and the adjacent areas before loosening, do not use aggressive cleaning agents
such as brake cleaner, petrol, thinners or similar.
◆ Place removed parts on a clean surface and cover them over.

◆ Carefully cover or seal open components if repairs are not to be performed immediately.
Use sealing plugs from repair kit;
for Part No. refer to

=> Parts catalogue

◆ When the system is open do not work with compressed air and do not move the vehicle.
◆ Do not use fluffy cloths.
◆ Only use genuine packed parts.
◆ Only remove replacement parts from packaging immediately prior to installation.
◆ During the final road test, ensure that at least one ABS-controlled braking operation is performed (pulsations
must be felt at the brake pedal).
◆ During painting operations, the electronic control unit can be exposed to a max. temperature of 95 °Cfor
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.

=> General notes; Body repairs; Safety notes

6 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

2 - ABS/ESP ITT Mark 20

2.1 - ABS/ESP ITT Mark 20

2.2 - Exploded view

1 Rotor for rear right speed sensor
◆ Rotor is welded to wheel hub Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
◆ Checking => Page 46 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
◆ Removing and installing: with respect to the correctness of information in this document. Copyright by AUDI AG.

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

2 Rear right speed sensor -G44

◆ Removing and installing
=> Page 45
3 Rear left speed sensor -G46
◆ Removing and installing

2.1 - ABS/ESP ITT Mark 20 7

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> Page 45

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4 Rotor for rear left speed sensor

◆ Rotor is welded to wheel hub
◆ Checking => Page 46
◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

5 Handbrake warning lamp - K14

◆ Fitting location: in dash panel insert
6 ABS warning lamp -K47
◆ Fitting location: in dash panel insert
7 Brake system warning lamp -K118
◆ Fitting location: in dash panel insert in driver information system (DIS)
8 Traction control system/ESP warning lamp -K86
◆ Fitting location: in dash panel insert

8 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

9 Brake light suppression relay -J508

◆ Fitting location: in 13-pin relay carrier behind driver's storage compartment
10 Brake light switch (F)
◆ Removing and installing
=> Page 14
11 Rotor for front left speed sensor
◆ Rotor is welded to wheel hub
◆ Testing => Page 31
◆ Removing and installing:

=> Running Gear, Front-wheel driveCopying

Protected by copyright. and four-wheel drive;purposes,
for private or commercial Repairingroup
part or in40; Exploded
whole, is not view of wheel bearing
Exploded view of wheel bearing
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

12 Front left speed sensor -G47

◆ Removing and installing
=> Page 31

2.2 - Exploded view 9

 Audi TT 1999 ➤
Brake system - Edition 01.2002

13 ABS hydraulic unit -N55 with ABS control unit -J104

◆ The hydraulic control unit comprises hydraulic pump -V64, hydraulic unit -N55 and control unit -J104
◆ Removing and installing
=> Page 23
14 Rotor for front right speed sensor
◆ Rotor is welded to wheel hub
◆ Testing => Page 31
◆ Removing and installing:

=> Running Gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view of wheel bearing
Exploded view of wheel bearing

15 Front right speed sensor -G45

◆ Removing and installing
=> Page 31

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

10 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

16 Longitudinal acceleration sender -G251

◆ Vehicles with four-wheel drive only
◆ Fitting location: A-pillar on passenger`s side
◆ Removing and installing
=> Page 16
17 Brake pressure sender -2- -G214
◆ Removing and installing
=> Page 19
18 Brake pressure sender -1- -G201
◆ Removing and installing
=> Page 19
19 Brake pressure solenoid trip switch -F84
◆Protected
Brakebyservo assembly must be replaced if solenoid is defective
copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.2 - Exploded view 11

 Audi TT 1999 ➤
Brake system - Edition 01.2002

20 Brake pressure solenoid valve, in brake servo -N247

◆ Brake servo assembly must be replaced if solenoid is defective
21 Brake fluid level warning contact -F34
22 Lateral acceleration sender -G200
◆ Removing and installing
=> Page 14
23 Yaw rate sender -G202
◆ Removing and installing
=> Page 14
24 Traction control system switch -E132
◆ Fitting location: on centre console
25 Steering angle sender -G85
◆ Removing and installing
=> Page 17
26 Handbrake warning switch -F9 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

◆ Fitting location: on handbrake lever unit with respect to the correctness of information in this document. Copyright by AUDI AG.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

12 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

3 - Removing and installing ABS/ESP ITT Mark 20 system components

3.1 - Removing and installing ABS/ESP ITT Mark 20 system components

3.2 - Removing and installing brake light switch (square housing)

Note:

To ensure a secure fitting, the switch may be installed only once.

Removing

- Remove storage compartment on driver's side.

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment

- Unplug electrical connector.

- -> Remove brake light switch -1- by turning anti-clockwise through 90°.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installing

Install in reverse sequence; note the following points:

- Pull brake light switch plunger fully out.

- Press brake pedal down as far as possible by hand.
- -> Guide switch through fitting hole and secure by turning 90°clockwise -arrows-.
- Release brake pedal.
- Ensure proper function of brake lights when brake pedal is pressed and released.

3.1 - Removing and installing ABS/ESP ITT Mark 20 system components 13

 Audi TT 1999 ➤
Brake system - Edition 01.2002

3.3 - Removing and installing brake light switch (round housing)

Note:
To ensure a secure fitting, the switch may be installed only once.
Removing
- Remove storage compartment on driver's side.

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment
- Unplug electrical connector.
- Remove brake light switch by turning anti-clockwise through 45°.

Installing
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Install in reverse sequence; note the following points:
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
- -> Pull brake light switch plunger fully out -arrow-.
- Fit retainer tabs -1- and -2- on switch into recesses of fitting hole and secure by turning clockwise through
45°.

Notes:
◆ When installing brake light switch, do not operate brake pedal.
◆ The plunger is adjusted automatically when the brake light switch is inserted.

- Ensure proper function of brake lights when brake pedal is pressed and released.

3.4 - Removing and installing lateral acceleration sender -G200 and yaw rate sender -G202

Work sequence
- Remove storage compartment on driver's side.

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment

14 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Unplug electrical connectors -arrows- on senders -G200/-G202.

- Unscrew bolt -1- and remove mounting bracket for senders -G200/-G202.

Removing and installing yaw rate sender -G202

- -> Unscrew nuts -a- and remove yaw rate sender -G202 -1-.
- To install: insert yaw rate sender -G202 into mounting bracket and align straight before tightening.

Notes:

◆ The yaw rate sender is sensitive to shocks or impact.

◆ Do not install a sender which has dropped to the ground otherwise proper operation is not ensured.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing and installing lateral acceleration sender -G200

- -> Use screwdriver to prise mount -1- off lateral acceleration sender -G200 -2- and remove sender.

- To install: insert lateral acceleration sender -G200 -1- in holder.

- -> Installation position: sloping side -arrow- of lateral acceleration sender -G200 must face mount -2-.

3.4 - Removing and installing lateral acceleration sender -G200 and yaw rate sender -

G202 15
 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Slip mount over lateral acceleration sender -G200 until it engages with a click.

Notes:

◆ The lateral acceleration sender is not resistant to shocks or impact.

◆ Do not install a sender which has dropped to the ground otherwise proper operation is not ensured.

Installing

The remaining installation steps are carried out in the reverse sequence - note the following points:

- Initiate basic setting for lateral acceleration sender -G200 and yaw rate sender -G202.

=> Running gear, Self-diagnosis; Repair group 01

Tightening torques
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Componentpermitted unless authorised by AUDI AG. AUDI AG does notNm guarantee or accept any liability

Yaw rate sender to holder 9

with respect to the correctness of information in this document. Copyright by AUDI AG.

Holder for sender to mounting bracket for steering 20

column

3.5 - Removing and installing longitudinal acceleration sender -G251

Removing

- Remove glove box:

=> General body repairs, Interior; Repair group 68; Trays, compartments and trim; Removing and installing
glove box Trays, compartments and trim Removing and installing glove box

- -> Unplug electrical connector -2-

- Use a screwdriver to prise mount off longitudinal acceleration sender -arrows- and remove sender -G251
-1-.

Notes:

◆ The longitudinal acceleration sender is not resistant to shocks or impact.

◆ Do not install a sender which has dropped to the ground otherwise proper operation is not ensured.

Installing

Install in reverse sequence; note the following points:

- Initiate basic setting for longitudinal acceleration sender -G251.

16 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> Running gear, Self-diagnosis; Repair group 01

3.6 - Removing and installing steering angle sender -G85

Note:

The coil connector with slip ring is enclosed in the housing of the steering angle sender -G85.

Removing

- Turn wheels to straight ahead position.

- Remove airbag unit and steering wheel.

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 48; Steering column and steering wheel
with airbag Steering column and steering wheel with airbag

- Remove storage compartment on driver's side.

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Unscrew bolts -1- and detach handle for steering column adjustment -5-.
- Unscrew bolts -2 ... 4-.
- Remove upper and lower sections of steering column trim.

- -> Unplug electrical connectors -1- and -2-.

3.5 - Removing and installing longitudinal acceleration sender -G251 17

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Carefully lift upper retainer tabs -arrows-.

- Carefully lift lower retainer tabs and pull off housing with coil connector, slip ring and steering angle sender
from steering column switch.

Installing

Install in reverse sequence; note the following points:

- Push on housing with coil connector, slip ring and steering angle sender onto steering column switch until
all retainer tabs engage with a click.
- Break off transportation protection.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Adjust steering angle sender to central position:

- Yellow dot must be visible in hole -arrow 1- and the two marks -arrows- must also be aligned.
- Install airbag unit and steering column.

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 48; Steering column and steering wheel
with airbag Steering column and steering wheel with airbag

- Initiate basic settings for steering angle sender -G85.

=> Running gear, Self-diagnosis; Repair group 01

18 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

3.7 - Removing and installing brake pressure senders

Special tools and workshop equipment required

◆ Brake charge and bleed equipment VAS 5234

or
◆ Brake charge and bleed equipment V.A.G 1869 A

Removing
- -> Remove forward left-hand cover panel -arrows-.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> If installed, disconnect secondary air intake hose -1- from air cleaner.
- Disconnect air hose -2- from air mass meter.
- Unplug connector -3- from air mass meter.
- Unscrew bolts -4- and -5-.
- Remove air cleaner housing.

3.7 - Removing and installing brake pressure senders 19

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Lay out sufficient lint-free cloths in area below brake master cylinder to catch escaping brake fluid.
- Draw off as much brake fluid as possible from brake fluid reservoir using brake charge and bleed equipment
VAS 5234 or extraction unit V.A.G 1869/4.

- -> Pull connector off relevant

Protected pressure
by copyright. sender
Copying for private (the one
or commercial to beinremoved)
purposes, -arrows-.
part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
a- Brake pressure sender 1 -G201 in primary piston circuit
b- Brake pressure sender 2 -G214 in secondary piston circuit

- Remove brake pressure sender.

Installing

Install in reverse sequence; note the following points:

- Bleed brake system => Page 167 .

- Bleed hydraulic system for clutch:

=> Manual gearbox; Repair group 30

- Initiate basic settings for brake pressure senders.

=> Running gear, Self-diagnosis; Repair group 01

Tightening torques

Component Nm
Brake pressure sender to brake master cylinder 14
Air cleaner housing 10

20 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

4 - Control unit and hydraulic unit; ABS/ESP ITT Mark 20

4.1 - Control unit and hydraulic unit; ABS/ESP ITT Mark 20

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4.2 - Exploded view

1 Nut - 20 Nm
◆ Self-locking
◆ Renew each time after removing
2 Retainer
3 Set bolt - 8 Nm
4 Cap nut - 20 Nm
5 ABS hydraulic unit -N55
◆ Fitting location: in engine compartment, left side
◆ Connecting brake pipes => Fig. 1
6 Brake pipe
◆ Master brake cylinder/secondary piston circuit to hydraulic unit

4.1 - Control unit and hydraulic unit; ABS/ESP ITT Mark 20 21

 Audi TT 1999 ➤
Brake system - Edition 01.2002

7 Brake pipe
◆ Brake master cylinder/primary piston circuit to hydraulic unit
8 ABS with EDL control unit -J104
◆ Fitting location: in engine compartment, left side
◆ The control unit is bolted to the hydraulic unit
9 Brake pipe
◆ Hydraulic unit to front left brake caliper
10 Brake pipe Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
◆ Hydraulic unit to rear rightunless
permitted brake caliper
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
11 Brake pipe with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ Hydraulic unit to rear left brake caliper

12 Brake pipe
◆ Hydraulic unit to front right brake caliper

22 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

-> Fig.1 Connecting brake pipes to hydraulic unit

A- Secondary piston circuit

B- Primary piston circuit
1- To front right brake caliper
2- To rear left brake caliper
3- To rear right brake caliper
4- To front left brake caliper

Warning:
Interchanging connections will result in ESP system malfunction.

- After connecting brake pipes to hydraulic unit, perform final control diagnosis.

=> Running gear, Self-diagnosis; Repair group 01

Note:

Final control diagnosis can be used to establish whether pipe connections have been interchanged.

4.3 - Removing and installing control unit and hydraulic unit

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

◆ Brake pedal depressor V.A.G 1869/2

4.2 - Exploded view 23

 Audi TT 1999 ➤
Brake system - Edition 01.2002

◆ Repair kit; Part No.

=> Parts catalogue

1- Valve dome transportation protection (plastic foam)

2- M10 sealing plugs for brake pipes and threaded holes
3- M12 sealing plugs for brake pipes and threaded holes

After separating the control unit from the hydraulic unit always fit the valve dome transportation protection on
the hydraulic unit.

Warranty claims for hydraulic units on which the valve dome transportation protection was not used, will not be
accepted. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing

- -> Remove forward left-hand cover panel -arrows-.

24 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> If installed, disconnect secondary air intake hose -1- from air cleaner.
- Disconnect air hose -2- from air mass meter.
- Unplug connector -3- from air mass meter.
- Unscrew bolts -4- Protected
and -5-.
by copyright. Copying for private or commercial purposes, in part or in whole, is not

- Remove air cleaner withhousing.

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Insert brake pedal depressor V.A.G 1869/2 between brake pedal and driver's seat. Depress the brake
pedal by at least 60 mm.
- Connect hose of bleeder bottle to bleeder screws on front left and rear left brake calipers and open bleeder
screws.

Note:

This dissipates pressure in hydraulic unit.

- Close front left and rear left bleeder screws.

- Do not remove brake pedal depressor V.A.G 1869/2.

- -> Release control unit connector -arrow 1- and unplug -arrow 2-.

4.3 - Removing and installing control unit and hydraulic unit 25

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Notes:

◆ Protect connector housing of control unit against escaping brake fluid. Otherwise corroding contacts can
cause a breakdown of the system.
◆ Carefully clean a moist or dirty connector housing with compressed air.

- Lay out sufficient lint-free cloths in area below control unit and hydraulic unit.
- Mark brake pipes.
- -> Disconnect brake pipes from hydraulic unit to brake master cylinder -arrows- and tie up.
- Disconnect remaining brake pipes on hydraulic unit.

Warning:
Take care not to bend brake pipes in the vicinity of the hydraulic unit.

- Seal brake pipes and threaded holes with plugs from repair set.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Remove bolts on hydraulic unit bracket -arrows- and take out hydraulic unit and control unit.

26 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Unscrewing control unit from hydraulic unit

- Unplug connector for hydraulic pump motor from control unit.
- -> Unscrew Torx head bolts -arrows- from control unit and detach control unit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> When detaching control unit, make sure valve domes of hydraulic unit do not catch on control unit sole‐
noids.
- Cover control unit solenoids with a lint free cloth.
- Protect components against moisture.
- Fit transportation protection for valve domes (enclosed in repair kit) after separating control unit and hydraulic
unit.

Installing
Install in reverse sequence; note the following points:
Notes:
◆ Only remove sealing plugs on new hydraulic unit when the corresponding brake pipe is going to be fitted.
◆ If the sealing plugs are removed too soon from the hydraulic unit, brake fluid may escape; it may no longer
be possible to fill and bleed the unit properly.

- When assembling control unit and hydraulic unit, make sure valve domes of hydraulic unit do not catch on
control unit solenoids.

4.3 - Removing and installing control unit and hydraulic unit 27

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Connect pipes as previously marked:

A- Secondary piston circuit

B- Primary piston circuit
1- To front right brake caliper
2- To rear left brake caliper
3- To rear right brake caliper
4- To front left brake caliper

- Fit connector on hydraulic pump.

- Bolt ABS unit to bracket.

Note:

Do not fully tighten bolts. This facilitates attachment of individual brake pipes to hydraulic unit.

- After tightening brake pipes, tighten hydraulic unit.

- Bleed brake system => Page 167
- If a new control unit has been fitted it must be coded.

=> Running gear, Self-diagnosis; Repair group 01

- After connecting brake pipes to hydraulic unit, perform final control diagnosis.

=> Running gear, Self-diagnosis; Repair group 01

Note:

Final control diagnosis can be used to establish whether pipe connections have been interchanged.

Tightening torques

Component Nm
Control unit to hydraulic unit 4 1)
Hydraulic unit to bracket 8
Brake pipes to hydraulic unit 14 2)
Air cleaner housing 10

1) Renew bolts

2) for M10-connections and M12-connections

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

28 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

5 - Removing and installing ABS/ESP ITT Mark 20 system components on front

axle
5.1 - Removing and installing ABS/ESP ITT Mark 20 system components on front axle

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5.2 - Exploded view

1 Speed sensor
◆ Removing and installing
=> Page 31
◆ Before inserting sensor, clean fitting hole inner surface and coat with lubricating paste G 000 650
◆ Replacing speed sensor wire
=> Page 32
2 Wheel bearing housing
3 Hexagon socket head bolt
- 8Nm
4 Splash plate
5 Bolt

5.1 - Removing and installing ABS/ESP ITT Mark 20 system components on front axle

29
 Audi TT 1999 ➤
Brake system - Edition 01.2002

◆ Tightening torque => Page 95

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

6 Wheel bearing
◆ Removing and installing:

=> Running Gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view of wheel bearing
Exploded view of wheel bearing

7 Cross-head screw
◆ Tightening torque => Page 92
8 Brake disc
◆ Allocation => from Page 1
9 Wheel hub with rotor
◆ Checking rotor => Page 31
◆ Only renew complete

=> Running Gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view of wheel bearing
Exploded view of wheel bearing

10 Circlip

30 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

5.3 - Removing and installing wheel speed sensor

Removing

- -> Release connector

authorised-1- on wheel
AG. AUDIspeed
AG does sensor and disconnect
any liabilitywiring.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless by AUDI not guarantee or accept
- Unscrew bolt -2-.
with respect to the correctness of information in this document. Copyright by AUDI AG.
- Pull speed sensor out of wheel bearing housing.

Installing

Install in reverse sequence; note the following points:

- Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with solid lubricant
paste G 000 650.
- Turn wheels fully onto left and right-hand lock and check clearance to speed sensor wiring.

Tightening torque

Component Nm
Wheel speed sensor to wheel bearing housing 8

5.4 - Checking rotor

- Remove wheel.
- Rotate brake disc and check rotor is not damaged or dirty.
- If rotor is damaged, remove and replace wheel hub with rotor.

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view: Wheel bearing
Exploded view: Wheel bearing

5.3 - Removing and installing wheel speed sensor 31

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Checking rotor lateral run-out

- -> Turn wheel hub and check that gap -a- between rotor and speed sensor is uniform.
- Distance a = 0.3 mm
- If lateral run-out is out of tolerance, remove and replace wheel hub with rotor.

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view: Wheel bearing
Exploded view: Wheel bearing

5.5 - Replacing speed sensor wire

Note:

Always use repair set VAS 1978 for repairs on wiring harnesses and connectors.

Special tools and workshop equipment required

◆ Wiring harness repair kit VAS 1978

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

32 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing

- -> Remove forward left-hand cover panel -arrows-.

- -> If installed, disconnect secondary air intake hose -1- from air cleaner.
- Disconnect air hose -2- from air mass meter.
- Unplug connector -3- from air mass meter.
- Unscrew bolts -4- and -5-.
- Remove air cleaner housing.

- -> Release control unit connector -arrow 1- and unplug -arrow 2-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5.5 - Replacing speed sensor wire 33

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Release cap on multi-pin connector with a screwdriver and remove.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Release secondary catch (violet) with a small screwdriver by pressing in direction indicated (arrow).

-> Contact assignment of 47-pin connector on control unit -J104

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

34 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Using a suitable ejector tool from wiring repair kit VAS 1978, push out the relevant contacts.

- -> Unplug brake wear indicator connector -1- on left brake.

- Unclip wiring from bracket -2-.
- Release connector on wheel speed sensor and disconnect wiring.
- Remove defective wiring for wheel speed sensor.

Installing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Install in reversewith
sequence; note theoffollowing
respect to the correctness information inpoints:
this document. Copyright by AUDI AG.

- Run in new wheel speed sensor wiring.

5.5 - Replacing speed sensor wire 35

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Clip in speed sensor wiring -arrows-.

Note:

Make sure sensor wire is not twisted in wheel housing.

- Guide contacts into connector housing.

- -> Push individual wiring seals in onto stop with an insertion tool from VAS 1978.
- Secure contacts with secondary locking device and fit multi-pin connector cover cap.

Tightening torque

Component Nm
Air cleaner housing 10

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

36 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

6 - Removing and installing ABS/ESP ITT Mark 20 system components on rear

axle (vehicles with front-wheel drive)
6.1 - Removing and installing ABS/ESP ITT Mark 20 system components on rear axle
(vehicles with front-wheel drive)

6.2 - Exploded view

1 Hexagon socket head bolt - 8 Nm
2 Speed sensor
◆ by Removing
Protected and
copyright. Copying installing
for private or commercial purposes, in part or in whole, is not
=> Page
permitted unless authorised39by AUDI AG. AUDI AG does not guarantee or accept any liability
◆ Before inserting sensor, clean fitting hole inner surface and coat with lubricating paste G 000 650
with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ Replace speed sensor wire

=>Page 40
3 Stub axle
4 Splash plate

6.1 - Removing and installing ABS/ESP ITT Mark 20 system components on rear axle

(vehicles with front-wheel drive) 37

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5 Wheel hub with wheel bearing and rotor

◆ Checking rotor => Page 39
◆ Only renew complete
◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42
6 12-point nut
◆ Tightening torque:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42
7 Grease cap
◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42
8 Brake disc
◆ Allocation => from Page 1
9 Cross-head screw
◆ Tightening torque => Page 103
10 Bolt - 60 Nm
11 Axle beam

38 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

6.3 - Removing and installing speed sensor

Removing

- -> Release connector -1- on wheel speed sensor and disconnect wiring.
- Unscrew bolt -2-.
- Pull speed sensor out of stub axle.

Installing

Install in reverse sequence; note the following points:

- Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with solid lubricant
paste G 000 650.

Tightening torque

Component Nm
Speed sensor to stub axle 8

6.4 - Checking rotor

- Remove wheel.
- -> Unscrew brake caliper housing -arrows- and hang to one side, securing it in position on vehicle with
welding wire.

Note:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Do not twist or kink brake hose/pipe.

6.2 - Exploded view 39

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Rotate brake disc and check whether rotor -1- is damaged or dirty.
- If rotor is damaged or in the event of excessive wheel bearing clearance, replace rotor together with wheel
hub.

=> Running gear, front-wheel drive and four-wheel drive; Repair group 42

- Install brake caliper housing => Page 106 .

6.5 Protected
- Replacing
by [Link]
Copying forsensor wire purposes, in part or in whole, is not
private or commercial
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Note:

Always use repair set VAS 1978 for repairs on wiring harnesses and connectors.

Special tools and workshop equipment required

◆ Wiring harness repair kit VAS 1978

40 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing

- Remove wheel housing liner.

=> General body repairs, Exterior; Repair group 66

- Release connector on wheel speed sensor and disconnect wiring.

- Remove interior side panel trim.

=> General body repairs, Interior; Repair group 70

- -> Pull insulating grommet -arrow- off wiring connection.

- -> Cut speed sensor wiring with wire strippers VAS 1978/3 and remove defective wiring.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

6.5 - Replacing speed sensor wire 41

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Installing

Install in reverse sequence; note the following points:

- -> Strip 15 mm of insulation off the end of the wire using wire strippers from VAS 1978/3 and bend back the
bare part of the wire over half its length.
- Run in new wheel speed sensor wiring.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Clip in speed sensor wiring -arrows-.

Note:

Make sure sensor wire is not twisted in wheel housing.

- Cut 2-pin connector off new speed sensor wiring with wire stripper pliers.
- Strip 15 mm of insulation from end of wire with wire strippers and bend back half.
- Connect speed sensor wiring with aid of suitable crimp connector from wiring harness repair set VAS 1978.

Note:

The instructions supplied with wiring repair kit VAS 1978 normally do not permit repairs to the wiring of the ABS
system. However, this only applies to the screened wiring in the system.

42 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

7 - Removing and installing ABS/ESP ITT Mark 20 system components on rear

axle (vehicles with four-wheel drive)
7.1 - Removing and installing ABS/ESP ITT Mark 20 system components on rear axle
(vehicles with four-wheel drive)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7.2 - Exploded view

1 Speed sensor
◆ Removing and installing
=> Page 45
◆ Before inserting sensor, clean fitting hole inner surface and coat with lubricating paste G 000 650
◆ Replacing speed sensor wire
=> Page 46
2 Hexagon socket head bolt - 8 Nm
3 Trailing arm
4 Splash plate

7.1 - Removing and installing ABS/ESP ITT Mark 20 system components on rear axle

(vehicles with four-wheel drive) 43

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5 Bolt - 10 Nm
6 Brake disc
◆ Allocation => from Page 1
7 Cross-head screw
◆ Tightening torque => Page 113
8 Wheel hub with rotor
◆ Checking rotor => Page 46
◆ Only renew complete
◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

9 Circlip
10 Wheel bearing
◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

44 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

7.3 - Removing and installing speed sensor

Removing

- -> Open cover -2- above connector for speed sensor.

- Unplug electrical connector -1-.

- -> Remove bolt -1-.

- Pull speed sensor out of trailing arm.

Installing

Install in reverse sequence; note the following points:

- Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with solid lubricant
paste G 000 650.

Tightening torque

Component Nm
Speed sensor to trailing arm 8

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7.3 - Removing and installing speed sensor 45

 Audi TT 1999 ➤
Brake system - Edition 01.2002

7.4 - Checking rotor

- -> Remove bolt -1-.

- Pull speed sensor out of trailing arm.
- Remove wheel.
- Rotate brake disc and check rotor is not damaged or dirty.
- If rotor is damaged, remove wheel hub with rotor and replace.

=> Running gear, front-wheel drive and four-wheel drive; Repair group 42
- Install speed sensor => Page 45 .

7.5 - ReplacingProtected
speed sensor
by copyright. wire
Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note:
Always use repair set VAS 1978 for repairs on wiring harnesses and connectors.

Special tools and workshop equipment required

◆ Wiring harness repair kit VAS 1978

46 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing

- -> Open cover -2- above connector for speed sensor.

- Unplug electrical connector -1-.

- Remove interior side panel trim.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
=> General body repairs, Interior; Repair
permitted unless group
authorised 70 AG. AUDI AG does not guarantee or accept any liability
by AUDI
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Pull insulating grommet -arrow- off wire connection.

- -> Cut speed sensor wiring with wire strippers VAS 1978/3 and remove defective wiring.

Installing

Install in reverse sequence; note the following points:

- -> Strip 15 mm of insulation off the end of the wire using wire strippers VAS 1978/3 and bend back the bare
part of the wire over half its length.

7.5 - Replacing speed sensor wire 47

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Run in new wheel speed sensor wiring.

- -> Clip in speed sensor wiring -arrows-.

Note:

Make sure sensor wire is not twisted in wheel housing.

- Plug in electrical connector -1- and close cover -2-.

- Cut 2-pin connector off new speed sensor wiring with wire stripper pliers.

- Strip 15 mm of insulation
permittedfrom
unless end of wire with
AG. wire strippers and bend back half.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised by AUDI AUDI AG does not guarantee or accept any liability
- Connect speed sensor withwiring with
respect to aid of suitable
the correctness crimp
of information in thisconnector frombywiring
document. Copyright AUDI [Link] repair set VAS 1978.

Note:

The instructions supplied with wiring repair kit VAS 1978 normally do not permit repairs to the wiring of the ABS
system. However, this only applies to the screened wiring in the system.

48 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

8 - ABS/ESP ITT Mark 60

8.1 - ABS/ESP ITT Mark 60

8.2 - Exploded view

1 Rear right speed sensor rotor
◆ Rotor is welded to wheel hub
◆ Protected
Checking =>Page
by copyright. 88for private or commercial purposes, in part or in whole, is not
Copying
◆ Removing
permitted unlessand installing:
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

2 Rear right speed sensor -G44

◆ Removing and installing
=> Page 87
3 Rear left speed sensor -G46
◆ Removing and installing

8.1 - ABS/ESP ITT Mark 60 49

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> Page 87

4 Rotor for rear left speed sensor

◆ Rotor is welded to wheel hub
◆ Checking => Page 88
◆ Removing and installing:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
=> Running with
gear, Front-wheel
respect drive
to the correctness and four-wheel
of information drive;
in this document. Repair
Copyright by AUDIgroup
AG. 42

5 Handbrake warning lamp - K14

◆ Fitting location: in dash panel insert
6 ABS warning lamp -K47
◆ Fitting location: in dash panel insert
7 Brake system warning lamp -K118
◆ Fitting location: in dash panel insert in driver information system (DIS)
8 Traction control system/ESP warning lamp -K86
◆ Fitting location: in dash panel insert

50 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

9 Brake light switch -F

◆ Removing and installing
=> Page 55
10 Rotor for front left speed sensor
◆ Rotor is welded to wheel hub
◆ Checking => Page 73
◆ Removing and installing:

=> Running Gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view of wheel bearing
Exploded view of wheel bearing

11 Front left speed sensor -G47

◆ Removing and installing
=> Page 73
12 ABS hydraulic unit -N55 with ABS control unit -J104
◆ The hydraulic control unit comprises hydraulic pump -V64, hydraulic unit -N55 and control unit -J104
◆ Removing and installing
=> Page 67

8.2 - Exploded view 51

 Audi TT 1999 ➤
Brake system - Edition 01.2002

13 Rotor for front right speed sensor

◆ Rotor is welded to wheel hub
◆ Checking => Page 73
◆ Removing and installing:

=> Running Gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view of wheel bearing
Exploded view of wheel bearing

14 Front right speed sensor -G45

◆ Removing and installing
=> Page 73 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
15 Longitudinal acceleration sender -G251
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
◆ Vehicles with four-wheel drive only
◆ Fitting location: A-pillar on passenger`s side
◆ Removing and installing
=> Page 58
◆ Integrated into ESP sensor unit -G419 from approx. 09.01=> Fig. 1

52 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

16 Brake pressure sender -2- -G214

◆ Removing and installing
=> Page 61
17 Brake pressure sender -1- -G201
◆ Removing and installing
=> Page 61
18 Brake fluid level warning contact -F34
19 Lateral acceleration sender -G200
◆ Removing and installing
=> Page 56
◆ Integrated into ESP sensor unit -G419 from approx. 09.01=> Fig. 1

8.2 - Exploded view 53

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

20 Yaw rate sender -G202

◆ Removing and installing
=> Page 56
◆ Integrated into ESP sensor unit -G419 from approx. 09.01=> Fig. 1
21 Traction control system switch -E132
◆ Fitting location: on centre console
22 ESP sensor unit -G419
◆ From approx. 09.01 =>Fig. 1
◆ Removing and installing
=> Page 58
23 Steering angle sender -G85
◆ Removing and installing
=> Page 59
24 Handbrake warning switch -F9
◆ Fitting location: on handbrake lever unit

54 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

-> Fig.1 ESP sensor unit -G419 from approx. 09.01

The ESP sensor unit -1- comprises the senders listed below:
◆ Lateral acceleration sender -G200
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
◆ Yaw rate sender -G202
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
◆ Longitudinal acceleration sender
with respect -G251 (four-wheel
to the correctness drive
of information in this vehicles
document. only)
Copyright by AUDI AG.

9 - Removing and installing ABS/ESP ITT Mark 60 system components

9.1 - Removing and installing ABS/ESP ITT Mark 60 system components

Note:
The ESP road test ascertains the plausibility of the signals transmitted from brake pressure sender -1- -G201,
brake pressure sender -2- -G214, lateral acceleration sender -G200, yaw rate sender -G202 and the longitudinal
acceleration sender -G251 (vehicles with four-wheel drive only). On vehicles from approx. 09.01 the three last-
mentioned senders are integrated into the ESP sensor unit.

9.2 - Removing and installing brake light switch

Note:
To ensure a secure fitting, the switch may be installed only once.
Removing
- Remove storage compartment on driver's side.

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment
- Unplug electrical connector.
- Remove brake light switch by turning anti-clockwise through 45°.

8.2 - Exploded view 55

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Installing

Install in reverse sequence; note the following points:

- -> Pull brake light switch plunger fully out -arrow-.

- Fit retainer tabs -1- and -2- on switch into recesses of fitting hole and secure by turning clockwise through
45°.

Notes:

◆ When installing brake light switch, do not operate brake pedal.

◆ The plunger is adjusted automatically when the brake light switch is inserted.

- Ensure proper function of brake lights when brake pedal is pressed and released.

9.3 - Removing and installing lateral acceleration sender -G200 and yaw rate sender -G202
(vehicles up to approx. 08.01)

Work sequence

- Remove storage compartment on driver's side.

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Unplug electrical connectors -arrows- on senders -G200/-G202.

- Unscrew bolt -1- and remove mounting bracket for senders -G200/-G202.

Removing and installing yaw rate sender -G202

- -> Unscrew nuts -a- and remove yaw rate sender -G202 -1-.

56 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- To install: insert yaw rate sender -G202 into mounting bracket and align straight before tightening.

Notes:
◆ The yaw rate sender is sensitive to shocks or impact.
◆ Do not install a sender which has dropped to the ground otherwise proper operation is not ensured.

Removing and installing lateral acceleration sender -G200

- -> Use screwdriver to prise mount -1- off lateral acceleration sender -G200 -2- and remove sender.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- To install insert lateral acceleration sender -G200 -1- in holder.

- -> Installation position: sloping side -arrow- of lateral acceleration sender -G200 must face mount -2-.
- Slip mount over lateral acceleration sender -G200 until it engages with a click.

Notes:
◆ The lateral acceleration sender is not resistant to shocks or impact.
◆ Do not install a sender which has dropped to the ground otherwise proper operation is not ensured.

Installing
The remaining installation steps are carried out in the reverse sequence - note the following points:
- Initiate basic setting for lateral acceleration sender -G200 and yaw rate sender -G202.

=> Running gear, Self-diagnosis; Repair group 01

- Perform ESP road test.

=> Running gear, Self-diagnosis; Repair group 01

Tightening torques

Component Nm

9.3 - Removing and installing lateral acceleration sender -G200 and yaw rate sender -G202

(vehicles up to approx. 08.01) 57

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Yaw rate sender to holder 9

Holder for sender to mounting bracket for steering 20
column

9.4 - Removing and installing longitudinal acceleration sender -G251 (vehicles up to approx.
08.01)

Removing

- Remove glove box:

=> General body repairs, Interior; Repair group 68; Trays, compartments and trim; Removing and installing
glove box Trays, compartments and trim Removing and installing glove box

- -> Unplug electrical connector -2-

- Use a screwdriver to prise mount off longitudinal acceleration sender -arrows- and remove sender -G251
-1-.

Notes:

◆ The longitudinal acceleration sender is not Protected

resistant to shocks
by copyright. Copyingorforimpact.
private or commercial purposes, in part or in whole, is not
◆ Do not install a sender which has dropped to the ground otherwise proper operation is not ensured.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installing

Install in reverse sequence; note the following points:

- Initiate basic setting for longitudinal acceleration sender -G251.

=> Running gear, Self-diagnosis; Repair group 01

- Perform ESP road test.

=> Running gear, Self-diagnosis; Repair group 01

9.5 - Removing and installing ESP sensor unit -G419

Removing

- Remove storage compartment on driver's side.

58 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment

- -> Remove bolts -arrows-.

- Pull ESP sensor unit -1- in direction of travel and out of holder.
- Unplug electrical connector -2-.

Notes:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
◆ The ESP sensor unit is not resistant to shocks orunless
permitted impact.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
◆ Do not install an ESP sender which has dropped to the
with respect to theground
correctnessotherwise
of information proper operation
in this document. isbynot
Copyright ensured.
AUDI AG.

Installing

Install in reverse sequence; note the following points:

- Initiate basic setting for the senders in the ESP sensor unit.

=> Running gear, Self-diagnosis; Repair group 01

- Perform ESP road test.

=> Running gear, Self-diagnosis; Repair group 01

Tightening torque

Component Nm
ESP sensor unit to holder 20

9.6 - Removing and installing steering angle sender -G85

Note:

The coil connector with slip ring is enclosed in the housing of the steering angle sender -G85.

Removing

- Turn wheels to straight ahead position.

- Removing airbag unit and steering wheel.

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 48; Steering column and steering wheel
with airbag Steering column and steering wheel with airbag

- Remove storage compartment on driver's side.

9.5 - Removing and installing ESP sensor unit -G419 59

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment

- -> Unscrew bolts -1- and detach handle for steering column adjustment -5-.
- Unscrew bolts -2 ... 4-.
- Remove upper and lower sections of steering column trim.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Unplug electrical connectors -1- and -2-.

- -> Carefully lift upper retainer tabs -arrows-.

- Carefully lift lower retainer tabs and pull off housing with coil connector, slip ring and steering angle sender
from steering column switch.

Installing

Install in reverse sequence; note the following points:

- Push on housing with coil connector, slip ring and steering angle sender onto steering column switch until
all retainer tabs engage with a click.
- Break off transportation protection.

60 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Adjust steering angle sender to central position:

- Yellow dot must be visible in hole -arrow 1- and the two marks -arrows- must also be aligned.
- Installing airbag unit and steering column.

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 48; Steering column and steering wheel
with airbag Steering column and steering wheel with airbag

- Initiate basic settings for steering angle sender -G85.

=> Running gear, Self-diagnosis;

Protected by [Link] group
Copying for private 01
or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
- Perform ESP roadwith
test.
respect to the correctness of information in this document. Copyright by AUDI AG.

=> Running gear, Self-diagnosis; Repair group 01

9.7 - Removing and installing brake pressure senders

Special tools and workshop equipment required

◆ Brake charge and bleed equipment VAS 5234

or

◆ Brake charge and bleed equipment V.A.G 1869 A

9.6 - Removing and installing steering angle sender -G85 61

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing
- -> Remove forward left-hand cover panel -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> If installed, disconnect secondary air intake hose -1- from air cleaner.
- Disconnect air hose -2- from air mass meter.
- Unplug connector -3- from air mass meter.
- Unscrew bolts -4- and -5-.
- Remove air cleaner housing.
- Lay out sufficient lint-free cloths in area below brake master cylinder to catch escaping brake fluid.
- Draw off as much brake fluid as possible from brake fluid reservoir using brake charge and bleed equipment
VAS 5234 or extraction unit V.A.G 1869/4.

- -> Pull connector off relevant pressure sender (the one to be removed) -arrows-.

a- Brake pressure sender 1 -G201 in primary piston circuit

b- Brake pressure sender 2 -G214 in secondary piston circuit

- Remove brake pressure sender.

62 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Installing

Install in reverse sequence; note the following points:

- Bleed brake system => Page 174

- Bleed hydraulic system for clutch:

=> Manual gearbox; Repair group 30

- Initiate basic settings for brake pressure senders.

=> Running gear, Self-diagnosis; Repair group 01

- Perform ESP road test.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with=> Running
respect gear, Self-diagnosis;
to the correctness RepairCopyright
of information in this document. groupby01 AUDI AG.

Tightening torques

Component Nm
Brake pressure sender to brake master cylinder 14
Air cleaner housing 10

9.7 - Removing and installing brake pressure senders 63

 Audi TT 1999 ➤
Brake system - Edition 01.2002

10 - Control unit and hydraulic unit; ABS/ESP ITT Mark 60

10.1 - Control unit and hydraulic unit; ABS/ESP ITT Mark 60

10.2 - Exploded view Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Warning:
Interchanging brake pipe connections will result in ESP system malfunction.

- After connecting brake pipes to hydraulic unit, perform final control diagnosis.

=> Running gear, Self-diagnosis; Repair group 01

Note:
Final control diagnosis can be performed to establish whether pipe connections have been interchanged.
1 Cap nut - 20 Nm

64 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2 Torx socket head bolt - 4 Nm

3 Brake pipe
◆ Hydraulic unit to rear left brake caliper
4 Torx socket head bolt - 4 Nm
5 Brake pipe
◆ Hydraulic unit to rear right brake caliper
6 ABS hydraulic unit -N55
◆ Fitting location: in engine compartment, left side
7 Brake pipe
◆ Brake master cylinder/primary piston circuit to hydraulic unit
8 Brake pipe
◆ Hydraulic unit to front left brake caliper
9 Brake pipe
◆ Hydraulic unit to front right brake caliper

10.2 - Exploded view 65

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

10 Brake pipe
◆ Master brake cylinder/secondary piston circuit to hydraulic unit
11 ABS with EDL control unit -J104
◆ Fitting location: in engine compartment, left side
◆ The control unit is bolted to the hydraulic unit
12 Cap nut - 20 Nm
13 Retainer
14 Bolt - 8 Nm

66 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

10.3 - Removing and installing control until and hydraulic unit

Special tools and workshop equipment required

◆ Brake pedal depressor V.A.G 1869/2

◆ Repair kit; Part No.

=> Parts catalogue

1- Valve dome transportation protection (plastic foam)

2- M10 sealing plugs for brake pipes and threaded holes
3- M12 sealing plugs for brake pipes and threaded holes
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
After separating the control unit from the hydraulic unit always
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
fit the valve dome transportation protection on
the hydraulic unit.

Warranty claims for hydraulic units on which the valve dome transportation protection was not used, will not be
accepted.

10.3 - Removing and installing control until and hydraulic unit 67

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing

- -> Remove forward left-hand cover panel -arrows-.

- -> If installed, disconnect secondary air intake hose -1- from air cleaner.
- Disconnect air hose -2- from air mass meter.
- Unplug connector -3- from air mass meter.
- Unscrew bolts -4- and -5-.
- Remove air cleaner housing.

- -> Insert brake pedal depressor V.A.G Protected

1869/2bybetween brake
copyright. Copying for pedal
private orand driver's
commercial seat.
purposes, Depress
in part or in whole,the brake
is not
pedal by at least 60 mm. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

- Connect hose of bleeder bottle to bleeder screws on front left and rear left brake calipers and open bleeder
with respect to the correctness of information in this document. Copyright by AUDI AG.

screws.

Note:

This dissipates pressure in hydraulic unit.

68 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Close front left and rear left bleeder screws.

- Do not remove brake pedal depressor V.A.G 18169/2.

- -> Release control unit connector -arrow 1- and unplug -arrow 2-.

Notes:
◆ Protect connector housing of control unit against escaping brake fluid. Otherwise corroding contacts can
cause a breakdown of the system.
◆ Carefully clean a moist or dirty connector housing with compressed air.

- Lay out sufficient lint-free cloths

Protected by in area Copying
copyright. belowforcontrol
private or unit andpurposes,
commercial hydraulic unit.
in part or in whole, is not
- Mark brake pipes. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
- -> Disconnect brake pipeswith -1-respect
fromtohydraulic unit
the correctness to brake
of information master
in this cylinder
document. Copyright and
by [Link].
- Disconnect remaining brake pipes on hydraulic unit.

Warning:
Take care not to bend brake pipes in the vicinity of the hydraulic unit.

- Seal brake pipes and threaded holes with plugs from repair set.
- Unscrew bolts at hydraulic unit -arrows- and take out hydraulic unit and control unit.

10.3 - Removing and installing control until and hydraulic unit 69

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing control unit from hydraulic unit

- Place hydraulic unit with control unit down on a clean flat surface.
- -> Remove Torx socket head bolts -arrows-.

Warning:
The hydraulic pump must not be separated from the hydraulic unit.

- Separate hydraulic unit with hydraulic pump from control unit by lifting carefully off joint -1-.

- -> When detaching control unit, make sure valve domes of hydraulic unit do not catch on control unit sole‐
noids.
- Cover control unit solenoids with a lint free cloth.
- Protect components against moisture.
- Fit transportation protection for valve domes (enclosed in repair kit) after separating control unit and hydraulic
unit.

Note:

The valve dome -2- supplied as spare part with the control unit can only be clipped in once. It is not possible
to separate the connection afterwards.

Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Install in reverse sequence; note the followingwith
points:
respect to the correctness of information in this document. Copyright by AUDI AG.

Notes:

◆ Only remove sealing plugs on new hydraulic unit when the corresponding brake pipe is going to be fitted.
◆ If the sealing plugs are removed too soon from the hydraulic unit, brake fluid may escape, it may no longer
be possible to fill and bleed the unit properly.

- When assembling control unit and hydraulic unit, make sure valve domes of hydraulic unit do not catch on
control unit solenoids.
- Connect pipes as previously marked => Page 64 .
- Bolt ABS unit to bracket.

Note:

Do not fully tighten bolts. This facilitates attachment of individual brake pipes to hydraulic unit.

- After tightening brake pipes, tighten hydraulic unit.

- Bleed brake system => Page 174 .

- If a new control unit has been fitted it must be coded.

=> Running gear, Self-diagnosis; Repair group 01

- After connecting brake pipes to hydraulic unit, perform final control diagnosis.

70 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> Running gear, Self-diagnosis; Repair group 01

Note:
Final control diagnosis can be used to establish whether pipe connections have been interchanged.
Tightening torques
Component Nm
Control unit to hydraulic unit 4 1)
Hydraulic unit to bracket 8
Brake pipes to hydraulic unit 14 2)
Air cleaner housing 10
1) Renew bolts
2) for M10-connections and M12-connections

11 - Removing and installing ABS/ESP ITT Mark 60 system components on

front axle
11.1 - Removing and installing ABS/ESP ITT Mark 60 system components on front axle

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

10.3 - Removing and installing control until and hydraulic unit 71

 Audi TT 1999 ➤
Brake system - Edition 01.2002

11.2 - Exploded view

1 Speed sensor
◆ Removing and installing
=> Page 73
◆ Before inserting sensor, clean fitting hole inner surface and coat with lubricating paste G 000 650
◆ Replacing speed sensor wire
=> Page 74
2 Wheel bearing housing
3 Hexagon socket head bolt - 8 Nm
4 Splash plate
5 Bolt
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
◆ Tightening torque => Page 95 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

6 Wheel bearing
◆ Removing and installing:

=> Running Gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view of wheel bearing
Exploded view of wheel bearing
7 Cross-head screw
◆ Tightening torque => Page 92
8 Brake disc

72 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

◆ Allocation => From page 1

9 Wheel hub with rotor
◆ Checking rotor => Page 73
◆ Only renew complete

=> Running Gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view of wheel bearing
Exploded view of wheel bearing

10 Circlip

11.3 - Removing and installing speed sensor

Removing

- -> Release connector -1- on wheel speed sensor and disconnect wiring.
- Unscrew bolt -2-.
- Pull speed sensor out of wheel bearing housing.

Installing

Install in reverse sequence; note the following points:

- Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with solid lubricant
paste G 000 650. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
- Turn wheels fully onto permitted
left andunless
right-hand lock
authorised by AUDIand check
AG. AUDI clearance
AG does to orspeed
not guarantee sensor
accept any liability wiring.
with respect to the correctness of information in this document. Copyright by AUDI AG.
Tightening torque

Component Nm
Wheel speed sensor to wheel bearing housing 8

11.4 - Checking rotor

- Remove wheel.
- Rotate brake disc and check rotor is not damaged or dirty.
- If rotor is damaged, remove and replace wheel hub with rotor.

11.2 - Exploded view 73

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view: Wheel bearing
Exploded view: Wheel bearing

Checking rotor lateral run-out

- -> Turn wheel hub and check that gap -a- between rotor and speed sensor is uniform.
- Distance a = 0.3 mm
- If lateral run-out is out of tolerance, remove and replace wheel hub with rotor.

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view: Wheel bearing
Exploded view: Wheel bearing

11.5 - Replacing speed sensor wire

Note:

Always use repair set VAS 1978 for repairs on wiring harnesses and connectors.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

◆ Wiring harness repair kit VAS 1978

74 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing

- -> Remove forward left-hand cover panel -arrows-.

- -> If installed, disconnect secondary air intake hose -1- from air cleaner.
- Disconnect air hose -2- from air mass meter.
- Unplug connector -3- from air mass meter.
- Unscrew bolts -4- and -5-.
- Remove air cleaner housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Release control unit connector -arrow 1- and unplug -arrow 2-.

11.5 - Replacing speed sensor wire 75

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Release cap on multi-pin connector with a screwdriver and remove.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Release secondary catch (violet) with a small screwdriver by pressing in direction indicated (arrow).

-> Contact assignment of 47-pin connector on control unit -J104

=> Current flow diagrams, Electrical fault finding and Fitting locations binder

76 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Using a suitable ejector tool from wiring repair kit VAS 1978, push out the relevant contacts.

- -> Unplug brake wear indicator connector -1- on left brake.

- Unclip wiring from bracket -2-.
- Release connector on wheel speed sensor and disconnect wiring.
- Remove defective wiring for wheel speed sensor.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installing

Install in reverse sequence; note the following points:

- Run in new wheel speed sensor wiring.

11.5 - Replacing speed sensor wire 77

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Clip in speed sensor wiring -arrows-.

Note:

Make sure sensor wire is not twisted in wheel housing.

- Guide contacts into connector housing.

- -> Push individual wiring seals in onto stop with an insertion tool from VAS 1978.
- Secure contacts with secondary locking device and fit multi-pin connector cover cap.

Tightening torque

Component Nm
Air cleaner housing 10

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

78 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

12 - Removing and installing ABS/ESP ITT Mark 60 system components on

rear axle (vehicles with front-wheel drive)
12.1 - Removing and installing ABS/ESP ITT Mark 60 system components on rear axle
(vehicles with front-wheel drive)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

12.2 - Exploded view

1 Hexagon socket head bolt - 8 Nm
2 Speed sensor
◆ Removing and installing
=> Page 81
◆ Before inserting sensor, clean fitting hole inner surface and coat with lubricating paste G 000 650
◆ Replacing speed sensor wire
=> Page 82
3 Stub axle
4 Splash plate

12.1 - Removing and installing ABS/ESP ITT Mark 60 system components on rear axle

(vehicles with front-wheel drive) 79

 Audi TT 1999 ➤
Brake system - Edition 01.2002

5 Wheel hub with wheel bearing and rotor

◆ Checking rotor => Page 81
◆ Only renew complete
◆ Removing and installing:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42
6 12-point nut
◆ Tightening torque:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42
7 Grease cap
◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42
8 Brake disc
◆ Allocation => from Page 1
9 Cross-head screw
◆ Tightening torque => Page 103
10 Bolt - 60 Nm
11 Axle beam

80 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

12.3 - Removing and installing speed sensor

Removing

- -> Release connector -1- on wheel speed sensor and disconnect wiring.
- Unscrew bolt -2-.
- Pull speed sensor out of stub axle.

Installing

Install in reverse sequence; note the following points:

- Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with solid lubricant
paste G 000 650.

Tightening torque

Component Nm
Speed sensor to stub axle 8

12.4 - Checking rotor

- Remove wheel.
- -> Unscrew brake caliper housing -arrows- and hang to one side securing it in position on vehicle with welding
wire. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Note:

Do not twist or kink brake hose/pipe.

12.2 - Exploded view 81

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Rotate brake disc and check whether rotor -1- is damaged or dirty.
- If rotor is damaged or in the event of excessive wheel bearing clearance, replace rotor together with wheel
hub.

=> Running gear, front-wheel drive and four-wheel drive; Repair group 42

- Install brake caliper housing => Page 106 .

12.5 - Replacing speed sensor wire

Note:

Always use repair set VAS 1978 for repairs on wiring harnesses and connectors.

Special tools and workshop equipment required

◆ Wiring harness repair kit VAS 1978

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

82 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing

- Remove wheel housing liner.

=> General body repairs, Exterior; Repair group 66

- Release connector on wheel speed sensor and disconnect wiring.

- Remove interior side panel trim.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
=> General body repairs,
permitted Interior;
unless authorised Repair
by AUDI group
AG. AUDI 70not guarantee or accept any liability
AG does
with respect to the correctness of information in this document. Copyright by AUDI AG.
- -> Pull insulating grommet -arrow- off wiring connection.

- -> Cut speed sensor wiring with wire strippers VAS 1978/3 and remove defective wiring.

12.5 - Replacing speed sensor wire 83

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Installing

Install in reverse sequence; note the following points:

- -> Strip 15 mm of insulation off the end of the wire using wire strippers from VAS 1978/3 and bend back the
bare part of the wire over half its length.
- Run in new wheel speed sensor wiring.

- -> Clip in speed sensor wiring -arrows-.

Note:

Make sure sensor wire is not twisted in wheel housing.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
- Cut 2-pin connector off new speed sensor wiring with wire stripper pliers.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
- Strip 15 mm of insulation from end of wire with wire strippers and bend back half.
- Connect speed sensor wiring with aid of suitable crimp connector from wiring harness repair set VAS 1978.

Note:

The instructions supplied with wiring repair kit VAS 1978 normally do not permit repairs to the wiring of the ABS
system. However, this only applies to the screened wiring in the system.

84 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

13 - Removing and installing ABS/ESP ITT Mark 60 system components on

rear axle (vehicles with four-wheel drive)
13.1 - Removing and installing ABS/ESP ITT Mark 60 system components on rear axle
(vehicles with four-wheel drive)

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

13.2 - Exploded view

1 Speed sensor
◆ Removing and installing
=> Page 87
◆ Before inserting sensor, clean fitting hole inner surface and coat with lubricating paste G 000 650
◆ Replacing speed sensor wire
=> Page 88
2 Hexagon socket head bolt - 8 Nm
3 Trailing arm
4 Splash plate

13.1 - Removing and installing ABS/ESP ITT Mark 60 system components on rear axle

(vehicles with four-wheel drive) 85

 Audi TT 1999 ➤
Brake system - Edition 01.2002

5 Bolt - 10 Nm
6 Brake disc
◆ Allocation => from Page 1
7 Cross-head screw
◆ Tightening torque => Page 113
8 Wheel hub with rotor
◆ Checking rotor => Page 88
◆ Only renew complete
◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

9 Circlip Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10 Wheel bearing with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

86 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

13.3 - Removing and installing speed sensor

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing

- -> Open cover -2- above connector for speed sensor.

- Unplug electrical connector -1-.

- -> Remove bolt -1-.

- Pull speed sensor out of trailing arm.

Installing

Install in reverse sequence; note the following points:

- Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with solid lubricant
paste G 000 650.

Tightening torque

Component Nm
Speed sensor to trailing arm 8

13.3 - Removing and installing speed sensor 87

 Audi TT 1999 ➤
Brake system - Edition 01.2002

13.4 - Checking rotor

- -> Remove bolt -1-.

- Pull speed sensor out of trailing arm.
- Remove wheel.
- Rotate brake disc and check rotor is not damaged or dirty.
- If rotor is damaged, remove wheel hub with rotor and replace.

=> Running gear, front-wheel drive and four-wheel drive; Repair group 42
- Installing speed sensor => Page 87 .

13.5 - Replacing speed sensor wire

Note:
Always use repair set VAS 1978 for repairs on wiring harnesses and connectors.

Special tools and workshop equipment required

◆ Wiring harness repair kit VAS 1978
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

88 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing

- -> Open cover -2- above connector for speed sensor.

- Unplug electrical connector -1-.

- Remove interior side panel trim.

=> General body repairs, Interior; Repair group 70

- -> Pull insulating grommet -arrow- off wire connection.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Cut speed sensor wiring with wire strippers VAS 1978/3 and remove defective wiring.

Installing

Install in reverse sequence; note the following points:

- -> Strip 15 mm of insulation off the end of the wire using wire strippers VAS 1978/3 and bend back the bare
part of the wire over half its length.

13.5 - Replacing speed sensor wire 89

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Run in new wheel speed sensor wiring.

- -> Clip in speed sensor wiring -arrows-.

Note:

Make sure sensor wire is not twisted in wheel housing.

- Plug in electrical connector -1- and close cover -2-.

- Cut 2-pin connector off new speed sensor wiring with wire stripper pliers.

- Strip 15 mm of insulation from end of wire with wire strippers and bend back half.
- Connect speed sensor wiring with aid of suitable crimp connector from wiring harness repair set VAS 1978.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

The instructions supplied with wiring repair kit VAS 1978 normally do not permit repairs to the wiring of the ABS
system. However, this only applies to the screened wiring in the system.

90 45 - Anti-locking brake system

 Audi TT 1999 ➤
Brake system - Edition 01.2002

46 - Brakes, Brake mechanics

1 - Servicing front brake

1.1 - Servicing front brake

General notes

◆ For extracting brake fluid from reservoir, always use brake charge and bleed equipment VAS 5234 or ex‐
traction unit V.A.G 1869/4.
◆ Prior to removing a brake caliper or disconnecting a brake hose from the brake caliper, use brake pedal
depressor V.A.G 1869/2 to prevent the brake fluid reservoir running dry.

Warning:
After fitting brake pads, press brake pedal firmly several times with vehicle stationary to ensure that pads
become properly seated.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1.1 - Servicing front brake 91

 Audi TT 1999 ➤
Brake system - Edition 01.2002

1.2 - Front brakes FN 3 - Exploded view

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

General notes => Page 91

1 Cross-head screw - 4 Nm
2 Brake disc
◆ Allocation, dimensions, wear limit => from Page 1
◆ Unscrew brake caliper housing prior to removing
◆ Never remove brake discs from hub by force. If necessary use penetrating fluid, otherwise brake discs
can be damaged.
◆ When worn always renew both sides

92 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

3 Brake pads
◆ Pad thickness, wear limit
=> Page 00-5
◆ Different versions possible

=> Parts List

◆ Checking pad thickness:

=> Maintenance

◆ Removing and installing

=>Page 97
◆ Note installation position => Fig. 1
◆ When worn always renew both sides

4 Retaining spring
◆ Insert in both brake caliper housing drillings
5 Brake carrier
◆ Replacement brake
Protected carriers
by copyright. are supplied
Copying assembled
for private or commercial andinwith
purposes, part orsufficient
in whole, is notgrease at guide pins
◆ Fit repair setpermitted
in the event of damage to protective caps; use pad provided to grease guide pins.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1.2 - Front brakes FN 3 - Exploded view 93

 Audi TT 1999 ➤
Brake system - Edition 01.2002

6 Brake caliper housing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
◆ Piston diameter => Technical data,
permitted unless Page
authorised 00-5AG. AUDI AG does not guarantee or accept any liability
by AUDI
◆ Unscrew from brake carrier to replace brake pads
with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ Removing and installing

=> Page 101
◆ Servicing => Page 152
7 Guide pin - 28 Nm
8 Protective cap
9 Brake hose with banjo union and banjo bolt - 35 Nm
◆ Anti-twist element => Fig. 2
10 Ribbed bolt - 125 Nm
◆ Clean ribs if using again
11 Wheel bearing housing
◆ Different versions possible

=> Parts List

94 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

12 Socket head bolt

◆ Tightening torque => Page 29
13 Speed sensor
◆ Removing and installing
=> Page 31
14 Splash plate
15 Bolt - 10 Nm
16 Wheel bearing
◆ Removing and installing:

=> Running Gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view of wheel bearing
Exploded view of wheel bearing

17 Circlip
18 Wheel hub with rotor
◆ Removing and installing:

=> Running Gear, Front-wheel drive and four-wheel drive; Repair group 40; Exploded view of wheel bearing
Exploded view of wheel bearing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1.2 - Front brakes FN 3 - Exploded view 95

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

19 Brake pads
◆ With wear indicator (left side only)
- Warning lamp in dash panel insert lights up when wear limit is reached
◆ Pad thickness, wear limit
=> Page 00-5
◆ Different versions possible

=> Parts List

◆ Checking pad thickness:

=> Maintenance

◆ Removing and installing

=>Page 97
◆ Note installation position => Fig. 1
◆ When worn always renew both sides

20 Electrical connector
◆ Remove from bracket -item 21 - when changing pads
21 Bracket
22 Self-tapping screw

96 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

-> Fig.1 Installation position of brake pads

1 - Right piston-side brake pad

2 - Left piston-side brake pad
- When installed, arrow on backplate of brake pad must face downwards.

-> Fig.2 Brake hose connection with anti-twist element

- Make sure that the groove in the ring connection of the brake hose is fitted in the locating lug -arrow-.

1.3 - Removing and installing brake pads - Front brakes FN 3

Special tools and workshop equipment required

◆ Piston resetting tool

1.2 - Front brakes FN 3 - Exploded view 97

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing
- Remove both front wheels.
- -> Unplug brake wear indicator connector -1- on left brake.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
- -> Lever off brake pad retaining spring from brakewithcaliper
respect tohousing using
the correctness a screwdriver
of information -arrow-
in this document. andbydetach.
Copyright AUDI AG.

- -> Remove protective caps -arrows-.

98 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Unscrew guide pins -arrows-.

- Detach brake caliper housing and secure on vehicle with wire.

Note:
Do not twist or kink brake hose/pipe.
- Take brake pads out of brake caliper housing or from brake carrier.

Note:
If reusing brake pads mark location and fit in same position when installing otherwise uneven braking will be
caused!

Installing
Install in reverse sequence; note the following points:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

- Clean brake caliper housing, in particular the bonding surfaceto thefor the brake pad. Itin this
must be free of adhesive
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect correctness of information document. Copyright by AUDI AG.
and grease residues.

Use methylated spirit only for cleaning the brake caliper housing.
- -> Press piston back.

Note:
Before inserting new brake pads, press piston back into the cylinder with resetting tool. Before pressing the
piston back, draw off brake fluid from the reservoir with a bleeder bottle. Otherwise particularly if reservoir has
been topped up, fluid will overflow and cause damage.
Warning
Brake fluid is poisonous and must never be sucked off by mouth using a hose.

1.3 - Removing and installing brake pads - Front brakes FN 3 99

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Insert brake pads, noting installation position.

1 - -> Right piston-side brake pad

2 - Left piston-side brake pad
- When installed, arrow on backplate of brake pad must face downwards.

- Fit outer brake pad to brake carrier.

- -> Pull protective foil off outer brake pad backplate.

- -> Insert retaining spring -arrow- into brake caliper housing.

Warning:
◆ Press retaining spring under brake carrier after inserting spring into the both holes. Improper installation
prevents outer brake pad from being adjusted when worn causing excessive pedal travel.
◆ After installing brake pads, press brake pedal firmly several times with vehicle stationary to ensure that pads
become properly seated.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- Check brake fluid level and top up if necessary.

Tightening torque

Component Nm
Brake caliper housing to brake carrier 28

100 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

1.4 - Removing and installing brake caliper - Front brakes FN 3

Special tools and workshop equipment required

◆ Brake pedal depressor V.A.G 1869/2

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing

- Remove brake pads => Page 97 .

- -> Insert brake pedal depressor V.A.G 1869/2 between brake pedal and driver's seat. Depress the brake
pedal by at least 60 mm.

Note:
Pressing down the brake pedal closes the valves in the brake master cylinder to prevent the brake fluid reservoir
running dry.
- Connect bleeder bottle hose to bleeder screw of removed brake caliper.
- Open bleeder screw.
- Do not remove brake pedal depressor V.A.G 18169/2.
- Unscrew brake hose from brake caliper.

Installing

Install in reverse sequence; note the following points:

- Install brake pads => Page 99 .

- Bleed brake system: ABS/ESP Mark 20 =>Page 174 .

Tightening torque

Component Nm
Brake hose to brake caliper 35

1.4 - Removing and installing brake caliper - Front brakes FN 3 101

 Audi TT 1999 ➤
Brake system - Edition 01.2002

2 - Servicing rear brake

2.1 - Servicing rear brake

General notes

◆ For extracting brake fluid from reservoir always use brake charge and bleed equipment VAS 5234 or ex‐
traction unit V.A.G 1869/4.
◆ Prior to removing a brake caliper or disconnecting a brake hose from the brake caliper apply brake pedal
depressor V.A.G 1869/2 to prevent the brake fluid reservoir running dry.

Warning:
After fitting brake pads, press brake pedal firmly several times with vehicle stationary to ensure that pads
become properly seated.

2.2 - Rear brake on vehicles with front-wheel drive - Exploded view

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

102 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

General notes => Page 102

1 Cross-head screw - 4 Nm
2 Brake disc
◆ Allocation, dimensions, wear limit
=> from page 1
◆ Never remove brake discs from hub by force. If necessary use penetrating fluid, otherwise brake discs
can be damaged.
◆ When worn always renew both sides
3 Grease cap
◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

4 12-point nut
◆ Tightening torque:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5 Wheel hub with wheel bearing and rotor

◆ Only renew complete

2.2 - Rear brake on vehicles with front-wheel drive - Exploded view 103
 Audi TT 1999 ➤
Brake system - Edition 01.2002

◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42
6 Bolt - 60 Nm
7 Splash plate
8 Stub axle
9 Handbrake cable
◆ Removing and installing
=> Page 134
◆ Adjusting handbrake
=> Page 139 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 Axle beam permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
11 Speed sensor
◆ Removing and installing
=> Page 81
12 Socket head bolt
◆ Tightening torque => Page 81

13 Hexagon socket head bolt - 65Nm

14 Brake carrier
◆ With guide pins and protective cap
◆ Supplied as replacement part assembled with sufficient grease on guide pins

104 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

◆ Fit repair set in the event of damage to protective caps; use pad provided to grease guide pins.
15 Brake hose/pipe
◆ With banjo bolt and seals
◆ Replace if banjo bolt is loosened
◆ Tighten banjo bolt to 38 Nm
16 Bolt - 35 Nm
◆ Self-locking
◆ When loosening and tightening counter hold on guide pin
◆ Renew each time after removing

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

17 Brake caliper housing

◆ Piston diameter => Page 2
◆ Different versions possible

=> Parts List

◆ Removing and installing
=> Page 109
◆ Servicing => Page 162
◆ Adjust handbrake cable first after maintenance or replacement => Page 139

18 Brake pads
◆ Pad thickness, wear limit
=> Page 2

2.2 - Rear brake on vehicles with front-wheel drive - Exploded view 105
 Audi TT 1999 ➤
Brake system - Edition 01.2002

◆ Checking pad thickness:

=> Maintenance
◆ Removing and installing
=> Page 106
◆ When worn always renew both sides

19 Pad retaining springs

◆ Always renew when changing pads

2.3 - Removing and installing brake pads - Vehicles with front-wheel drive

Special tools and workshop equipment required

◆ 3272 Piston compressing and extractingProtected
tool by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing
- Remove wheels.
- -> Prise off clip -1- for handbrake cable.
- Press brake lever -2- in direction of arrow and unhook brake cable -3-.

106 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Detach brake caliper housing; to do this counterhold guide pin.

- Secure brake caliper housing on vehicle with wire.

Note:

Do not twist or kink brake hose/pipe.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Remove brake pads and pad retaining springs -arrows-.

Note:

If reusing brake pads mark location and fit in same position when installing otherwise uneven braking will be
caused!

Installing

Install in reverse sequence; note the following points:

- Clean brake caliper housing, in particular the bonding surface for the brake pad. It must be free of adhesive
and grease residues.

Use methylated spirit only for cleaning the brake caliper housing.

Note:

Prior to pressing the piston back, draw off brake fluid from the reservoir. Use a bleeder bottle or a plastic bottle
which is only used for brake fluid.

Attention!
Brake fluid is poisonous and must under no circumstances be sucked via a hose with the mouth.

- -> Apply special tool 3272 together with 3272/1 to piston of brake caliper housing.

2.3 - Removing and installing brake pads - Vehicles with front-wheel drive 107
 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Screw in piston by turning knurled wheel of special tool 3272 clockwise, do not damage protective cap when
doing this.

Note:

If piston is stiff, 13 mm open-ended wrench can be applied at appropriate flats -arrow-.

- -> Insert brake pads and brake pad retaining springs -arrows- into brake carrier.
- Pull protective foil off outer brake pad backplate.
- Secure brake caliper housing with new self-locking bolts.

Note:

The repair set contains four self-locking hexagon bolts, which must always be fitted.

- -> Press brake lever -2- in direction of arrow and attach handbrake cable.
- Open clip -1- securing handbrake cable.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Attention!
with respect to the correctness of information in this document. Copyright by AUDI AG.

After installing brake pads, press brake pedal firmly several times with vehicle stationary to ensure that brake
pads become properly seated.

- Check brake fluid level and top up if necessary.

Tightening torques

Component Nm
Brake caliper housing to brake carrier 35 1)

1) Renew bolts

108 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

2.4 - Removing and installing brake caliper - Vehicles with front-wheel drive

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Special tools and workshop equipment required

with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ Brake pedal depressor V.A.G 1869/2

Removing
- Remove brake pads => Page 106 .
- -> Insert brake pedal depressor V.A.G 1869/2 between brake pedal and driver's seat. Depress the brake
pedal by at least 60 mm.

Note:
Pressing down the brake pedal closes the valves in the brake master cylinder to prevent the brake fluid reservoir
running dry.
- Connect bleeder bottle hose to bleeder screw of removed brake caliper.
- Open bleeder screw.
- Do not remove brake pedal depressor V.A.G 18169/2.
- Unscrew brake hose from brake caliper.

Installing
Install in reverse sequence; note the following points:
- Install brake pads => Page 107 .
- Adjust handbrake after installing a serviced or new brake caliper => Page 139 . Do not press foot brake
until handbrake has been adjusted.
- Bleed brake system: ABS/ESP Mark 20 =>Page 174 .

Tightening torque

Component Nm

2.4 - Removing and installing brake caliper - Vehicles with front-wheel drive 109
 Audi TT 1999 ➤
Brake system - Edition 01.2002

Brake hose to brake caliper 38 1)

1) Always replace brake hose/brake pipe with banjo bolt after unscrewing banjo bolt.

2.5 - Rear brake on vehicles with four-wheel drive - Exploded view

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1 Hexagon socket head bolt - 65 Nm

2 Brake carrier
◆ With guide pins and protective cap
◆ Supplied as replacement part assembled with sufficient grease on guide pins
◆ Fit repair set in the event of damage to protective caps; use pad provided to grease guide pins.
3 Bolt - 35 Nm
◆ Self-locking
◆ Renew each time after removing
◆ When loosening and tightening counter hold on guide pin

110 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

4 Brake hose/pipe
◆ With banjo bolt and seals
◆ Replace banjo bolt with angled sealing element after unscrewing banjo bolt
◆ Tighten banjo bolt to 38 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 Brake caliper housing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
◆ Piston diameter => Page 2
◆ Different versions possible

=> Parts List

◆ Removing and installing

=>Page 118
◆ Servicing => Page 162
◆ Adjust handbrake cable first after maintenance or replacement => Page 139

2.5 - Rear brake on vehicles with four-wheel drive - Exploded view 111
 Audi TT 1999 ➤
Brake system - Edition 01.2002

6 Brake pads
◆ Pad thickness, wear limit => Page 2
◆ Different versions possible

=> Parts List

◆ Checking pad thickness:

=> Maintenance

◆ Removing and installing

=>Page 115
◆ When worn always renew both sides

7 Pad retaining springs

◆ Always renew when changing pads
8 Splash plate Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

9 Bolt - 10 Nm
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

112 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

10 Brake disc
◆ Allocation, dimensions, wear limit => from page 1
◆ Different versions possible

=> Parts List

◆ Never remove brake discs from hub by force. If necessary use penetrating fluid, otherwise brake discs
can be damaged.
◆ When worn always renew both sides

11 Cross-head screw - 4 Nm
12 Wheel hub with rotor
◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

13 Circlip

2.5 - Rear brake on vehicles with four-wheel drive - Exploded view 113
 Audi TT 1999 ➤
Brake system - Edition 01.2002

14 Wheel bearing
◆ Removing and installing:

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 42

15 Trailing arm
16 Speed sensor
◆ Removing and installing
=> Page 45
17 Socket head bolt
◆ Tightening torque => Page 45-58 and 87
18 Handbrake cable
◆ Removing and installing
=> Page 136
◆ Adjusting handbrake
=> Page 139

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

114 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

2.6 - Removing and installing brake pads - Vehicles with four-wheel drive

Special tools and workshop equipment required

◆ 3272 Piston compressing and extracting tool

Removing

- Remove wheels.
- -> Prise off clip -1- for handbrake cable.
- Press brake lever -2- in direction of arrow and unhook brake cable -3-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Detach brake caliper housing; to do this counterhold guide pin.

- Secure brake caliper housing on vehicle with wire.

Note:

Do not twist or kink brake hose/pipe.

2.6 - Removing and installing brake pads - Vehicles with four-wheel drive 115
 Audi TT 1999 ➤
Brake system - Edition 01.2002

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
- -> Remove brake pads and pad retaining springs -arrows-.

Note:

If reusing brake pads mark location and fit in same position when installing otherwise uneven braking will be
caused!

Installing

Install in reverse sequence; note the following points:

- Clean brake caliper housing, in particular the bonding surface for the brake pad. It must be free of adhesive
and grease residues.

Use methylated spirit only for cleaning the brake caliper housing.

Note:

Prior to pressing the piston back, draw off brake fluid from the reservoir. Use a bleeder bottle or a plastic bottle
which is only used for brake fluid.

Attention!
Brake fluid is poisonous and must under no circumstances be sucked via a hose with the mouth.

- -> Apply special tool 3272 together with 3272/1 to piston of brake caliper housing.
- Screw in piston by turning knurled wheel of special tool 3272 clockwise, do not damage protective cap when
doing this.

Note:

If piston is stiff, 13 mm open-ended wrench can be applied at appropriate flats -arrow-.

116 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Insert brake pads and brake pad retaining springs -arrows- into brake carrier.
- Pull protective foil off outer brake pad backplate.
- Secure brake caliper housing with new self-locking bolts.

Note:

The repair set contains four self-locking hexagon bolts, which must always be fitted.

- -> Press brake lever -2- in direction of arrow and attach handbrake cable.
- Open clip -1- securing handbrake cable.

Attention!
After installing brake pads, press brake pedal firmly several times with vehicle stationary to ensure that brake
pads become properly seated.

- Check brake fluid level and top up if necessary.

Tightening torque

Component Nm
Brake caliper housing to brake carrier 35 1)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1) Renew bolts with respect to the correctness of information in this document. Copyright by AUDI AG.

2.6 - Removing and installing brake pads - Vehicles with four-wheel drive 117
 Audi TT 1999 ➤
Brake system - Edition 01.2002

2.7 - Removing and installing brake caliper - Vehicles with four-wheel drive

Special tools and workshop equipment required

◆ Brake pedal depressor V.A.G 1869/2

Removing
- Remove brake pads => Page 115 .
- -> Insert brake pedal depressor V.A.G 1869/2 between brake pedal and driver's seat. Depress the brake
pedal by at least 60 mm.

Note:
Pressing down the brake pedal closes the valves in the brake master cylinder to prevent the brake fluid reservoir
running [Link] by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
- Connect bleeder bottle
with respect hose toofbleeder
to the correctness informationscrew of removed
in this document. Copyrightbrake
by AUDI caliper.
AG.
- Open bleeder screw.
- Do not remove brake pedal depressor V.A.G 18169/2.
- Unscrew brake hose from brake caliper.

Installing
Install in reverse sequence; note the following points:
- Install brake pads => Page 116 .
- Adjust handbrake after installing a serviced or new brake caliper => Page 139 . Do not press foot brake
until handbrake has been adjusted.
- Bleed brake system: ABS/ESP Mark 20 =>Page 174 .

Tightening torque

Component Nm

118 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Brake hose to brake caliper 38 1)

1) Always replace brake hose/pipe with banjo bolt after unscrewing banjo bolt.

3 - Servicing front brake, brake caliper 2FN

3.1 - Servicing front brake, brake caliper 2FN

3.2 - Special tools and workshop equipment required

◆ V.A.G 1331 Torque wrench
◆ V.A.G 1410 Torque wrench
◆ V.A.G 1869/2 Brake pedal depressor
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.7 - Removing and installing brake caliper - Vehicles with four-wheel drive 119
 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ After changing brake pads, press brake pedal firmly several times with vehicle stationary to ensure that pads
become properly seated.
◆ For extracting brake fluid from reservoir, always use brake charge and bleed equipment VAS 5234 or ex‐
traction unit V.A.G 1869/4.
◆ Before removing a brake caliper or disconnecting a brake hose from the caliper, apply brake pedal depressor
V.A.G 1869/2.
◆ Tightening torques for wheel bolts
◆ Fitting wheels

=> Wheels/tyres

1 Cross-head screw, 4 Nm

120 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

2 Brake disc
◆ When worn always renew both sides
◆ Left and right discs are different; arrow shows direction of rotation
◆ Unbolt brake caliper before removing

=> Brake system; Repair group 00; Technical data Technical data

3 Brake pads
◆ With wear indicator
- Warning lamp lights up in instrument cluster when wear limit is reached (approx. 4 mm)
◆ Checking thickness

=> Maintenance manual

◆ Always renew both sides together

◆ Removing and installing
=> from Page 127 onwards

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3.2 - Special tools and workshop equipment required 121

 Audi TT 1999 ➤
Brake system - Edition 01.2002

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4 Retaining spring
◆ Press under brake carrier and insert in two bores in brake caliper housing

If the retaining spring is installed incorrectly, the wear of the outer pad cannot be compensated, so brake pedal
travel will increase accordingly.

5 Brake carrier
◆ Bolted onto wheel bearing housing

122 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

6 Brake caliper housing

◆ Do not disconnect brake hose when changing pads
◆ Removing:
- Remove brake pads=>Page 127
- Apply brake pedal depressor V.A.G 1869/2
- Unscrew brake hose -Item 12 - from caliper
◆ Installing:
- Install brake pads =>Page 127
- Screw brake hose -Item 12 - onto caliper
- Take out brake pedal depressor V.A.G 1869/2
- Bleed brake system (Mark 60) =>Page 174
◆ Servicing => Page 156
◆ Hose must not be twisted when installed

=> Brake system; Repair group 00; Technical data Technical data

3.2 - Special tools and workshop equipment required 123

 Audi TT 1999 ➤
Brake system - Edition 01.2002

7 Bush
8 Guide pin, 25 Nm
9 Cap
◆ Detach
◆ Upper cap combined with wiring retainer for pad wear indicator
10 Bracket
◆ Bolted to brake caliper housing
11 Hexagon bolt, 8 Nm
12 Brake hose/pipe, 15 Nm
◆ Screw into brake caliper housing
◆ Do not disconnect brake hose when changing pads
◆ Hose must not be twisted when installed

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

124 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

13 Ribbed bolt, 125 Nm

◆ Clean if re-installed
14 Wheel bearing housing
15 Socket head bolt
8 Nm
16 ABS wheel speed sensor
◆ Before fitting sensor, clean inside of bore and lubricate with grease G 000 650
17 Splash plate

3.2 - Special tools and workshop equipment required 125

 Audi TT 1999 ➤
Brake system - Edition 01.2002

18 Hexagon bolt, 10 Nm
19 Wheel hub with rotor
◆ Removing and installing

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 40; Servicing front suspension Servicing
front suspension

20 Connector
21 Bracket
22 Bolt

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

126 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

3.3 - Removing and installing brake pads

Special tools and workshop equipment required

◆ V.A.G 1331 Torque wrench

◆ Piston resetting tool

Removing

Note:

If old pads are to be re-installed, mark on removal and re-fit in the same position, otherwise braking effect will
be uneven.

- Remove wheels

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Secure brake disc with one wheel bolt.

- -> Push retaining spring in -A- until you can pry it out of bore in brake caliper.

3.3 - Removing and installing brake pads 127

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Then pull bottom of retaining spring in direction -A- and hold in this position. Now push top of retaining
spring in direction -B-. At the same time, turn spring slightly anti-clockwise and pull it out of bore in caliper
(arrow -D-).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Unplug connector -1- for pad wear indicator.

- Detach wire for pad wear indicator from retainer -2- on upper cap and from retainer -3- on dust cap.

- -> Take off caps -1-.

Upper cap is combined with wiring retainer for pad wear indicator.

128 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Unscrew and remove both guide pins from brake caliper.
- Detach brake caliper housing and put it aside so that the weight of the caliper does not strain or damage
the brake hose.
- Take brake pads out of caliper housing and brake carrier.

Use only methylated spirits to clean brake caliper housing.

Installing

Before inserting new brake pads, push pistons back into cylinder with resetting tool. Before pushing the pistons
back, draw off brake fluid from the reservoir using a bleeder bottle. Otherwise (particularly if reservoir has been
topped up) fluid will overflow and cause damage.

- -> Push back pistons.

- -> Fit brake pad with retaining springProtected

in caliper housing (pistons).
by copyright. Copying for private or commercial purposes, in part or in whole, is not
- Fit outer brake pad on brake carrier. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3.3 - Removing and installing brake pads 129

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Secure brake caliper housing to brake carrier with two guide pins.
- Fit both caps.

Upper cap is combined with wiring retainer for pad wear indicator.

- -> Fit wire for pad wear indicator under dust cap -3- on bleeder valve and in retainer -2- on upper cap.
- Attach connector -1- for pad wear indicator.

- -> Locate retaining spring at top of brake carrier. Then press top of retaining spring in direction -B-, and at
the same time hold bottom of spring by exerting pressure in the opposite direction -A-. Now push retaining
spring into bore in brake caliper.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

130 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Locate retaining spring at bottom of brake carrier. Then press retaining spring in direction -A- first, hold
in this position and at the same time press into bore in brake caliper.
- Fit wheels.

=> Wheels/tyres

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 44; Wheels and tyres

◆ After changing brake pads, press brake pedal firmly several times with vehicle stationary to ensure that pads
become properly seated.
◆ Check brake fluid level after changing brake pads.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3.3 - Removing and installing brake pads 131

 Audi TT 1999 ➤
Brake system - Edition 01.2002

4 - Handbrake
4.1 - Handbrake

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

4.2 - Handbrake lever - Exploded view

1 Handbrake lever
◆ The handbrake lever is supplied as spare part assembled with pull rod, locking pawl, pushrod, push
button, compression spring and ratchet
◆ Before removing take out rear section of centre console

=> General body repairs, Interior; Repair group 68

2 Lock washer
3 Handbrake lever trim
◆ Pull off forwards
4 Nut - 18 Nm
5 Pull rod

132 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

6 Compensator
7 Nut - 8 Nm
◆ Self-locking
◆ To adjust handbrake
◆ Adjusting handbrake
=> Page 139
8 Pivot pin
◆ For handbrake lever
◆ Insert pull rod -Item 5 - into hole of pivot pin.
9 Handbrake cable
◆ Removing and installing on vehicles with front-wheel drive
=> Page 134
◆ Removing and installing on vehicles with four-wheel drive
=> Page 136
Protected◆ Adjusting
by copyright. Copyinghandbrake
for private or commercial purposes, in part or in whole, is not
=> Page 139
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
10 Switch
◆ For handbrake warning lamp

4.2 - Handbrake lever - Exploded view 133

 Audi TT 1999 ➤
Brake system - Edition 01.2002

4.3 - Removing and installing handbrake cable - Vehicles with front-wheel drive

Removing

- -> Remove switch mount with storage compartment and cover for rear centre console.

=> General body repairs, Interior; Repair group 68

- Release handbrake.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
- -> Loosenpermitted
adjustment nut -arrow- until the handbrake cable can be unhooked from the compensator.
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Prise off clip -1- for handbrake cable.

- Press brake lever -2- in direction of arrow and unhook brake cable -3-.

134 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Unclip handbrake cable from retainer on rear axle -arrow A- and unhook from retainers -arrows-.

- -> Pull handbrake cable out from guide tube -1- in direction of arrow.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installing
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Install in reverse sequence; note the following points:

- Slide handbrake cable into guide tube.

- -> Press brake lever -2- in direction of arrow and attach handbrake cable.
- Open clip -1- securing handbrake cable.

4.3 - Removing and installing handbrake cable - Vehicles with front-wheel drive 135
 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Clip handbrake cable into retainer on rear axle -arrow A-.

Note:

Clamping ring at handbrake cable must be positioned in centre of clip.

- Hook handbrake cable into retainers -arrows-.

- Hook handbrake cable into compensator.

- -> Pretension handbrake cable with adjustment nut -arrow-.
- Adjust handbrake => Page 139 .
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

4.4 - Removing and installing handbrake cable - Vehicles with four-wheel drive
with respect to the correctness of information in this document. Copyright by AUDI AG.

Removing

- -> Remove switch mount with storage compartment -1- and cover for rear centre console -2-.

136 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> General body repairs, Interior; Repair group 68

- Release handbrake.

- -> Loosen adjustment nut -arrow- until the handbrake cable can be unhooked from the compensator.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Prise off clip -1- for handbrake cable.

- Press brake lever -2- in direction of arrow and unhook brake cable -3-.

- -> Remove rubber grommet -arrow A- in trailing arm.

- Unhook handbrake cable -arrow- from retainer and pull out of trailing arm in direction of arrow.

4.4 - Removing and installing handbrake cable - Vehicles with four-wheel drive 137
 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Pull handbrake cable out from guide tube -1- in direction of arrow.

Installing

Install in reverse sequence; note the following points:

- Slide handbrake cable into guide tube.

- -> Press brake lever -2- in direction of arrow and attach handbrake cable.
- Open clip -1- securing handbrake cable.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Install rubber grommet -arrow A- in trailing arm.

- Hook handbrake cable in retainer -arrow-.

138 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Hook handbrake cable into compensator.

- -> Pretension handbrake cable with adjustment nut -arrow-.
- Adjust handbrake => Page 139 .

4.5 - Adjusting handbrake

Note:

A new adjustment is only necessary after renewing, handbrake cables, brake calipers and brake discs.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Remove switch mount with storage compartment -1- and cover for rear centre console -2-.

=> General body repairs, Interior; Repair group 68

- -> Handbrake lever in "rest/off" position. Tighten adjusting nut -arrow- .....

4.4 - Removing and installing handbrake cable - Vehicles with four-wheel drive 139
 Audi TT 1999 ➤
Brake system - Edition 01.2002

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- -> .... until lever -arrow- lifts off the brake caliper stop.
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
- The maximum permissible distance from thewithstop is to3the
respect mm on either
correctness side. in this document. Copyright by AUDI AG.
of information
- Pull handbrake on firmly three times and then release again.
- Check that both wheels turn freely while handbrake lever is released.

Note:

Due to the automatic rear wheel brake adjustment there is no requirement to adjust the handbrake after making
new/initial adjustment.

140 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

5 - Brake pedal
5.1 - Brake pedal

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5.2 - Brake pedal on left-hand drive vehicles -Assembly overview

Warning!
The brake pedal travel must not be restricted by additional floor coverings.

1 Mounting bracket
◆ From approx. 06.99 with collapsing support -Item 2 -.
◆ When installing a new mounting bracket with collapsing support on a vehicle with year of make prior to
approx 06.99, the support must be cut off at the point indicated with an -arrow- if there is no means of
attachment
2 Collapsing support

5.1 - Brake pedal 141

 Audi TT 1999 ➤
Brake system - Edition 01.2002

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

3 Nut - 28 Nm
◆ Self-locking
◆ Renew each time after removing
4 Brake light switch
◆ Removing and installing; adjusting (square housing)
=> Page 13
◆ Removing and installing; adjusting (round housing)
=> Page 55
5 Accelerator pedal
6 Bolt
7 Brake pedal
◆ Removing and installing
=> Page 147
◆ Separating from brake servo
=>Page 148
◆ Before installing, grease all bearings with polycarbamide grease,
G 052 142 A2
8 Pad

142 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
9 Nut - 20 Nm
◆ Self-locking
◆ Renew each time after removing
10 Mounting bush
◆ Before installing, grease all bearings with polycarbamide grease,
G 052 142 A2
11 Pivot pin
◆ Before installing, grease all bearings with polycarbamide grease,
G 052 142 A2

5.2 - Brake pedal on left-hand drive vehicles -Assembly overview 143

 Audi TT 1999 ➤
Brake system - Edition 01.2002

5.3 - Brake pedal on right-hand drive vehicles - Assembly overview

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Warning!
The brake pedal travel must not be restricted by additional floor coverings.

1 Mounting bracket
2 Nut - 28 Nm
◆ Self-locking
◆ Renew each time after removing
3 Brake light switch
◆ Removing and installing; adjusting (square housing)
=> Page 13
◆ Removing and installing; adjusting (round housing)
=> Page 55
4 Accelerator pedal

144 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

5 Nut - 25 Nm
◆ Self-locking
◆ Renew each time after removing
6 Mounting bush
◆ Before installing, grease all bearings with polycarbamide grease,
G 052 142 A2
7 Brake pedal
◆ Removing and installing
=> Page 147
◆ Separating from brake servo
=>Page 148
◆ Before installing, grease all bearings with polycarbamide grease,
G 052 142 A2
8 Pad
9 Pivot pin
◆ Before installing, grease all bearings with polycarbamide grease,
G 052 142 A2 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
10 Bolt with respect to the correctness of information in this document. Copyright by AUDI AG.

5.3 - Brake pedal on right-hand drive vehicles - Assembly overview 145

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

11 Nut - 10 Nm
◆ Self-locking
◆ Renew each time after removing
12 Mounting bracket support
13 Brake servo
14 Gasket
◆ For brake servo

146 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

5.4 - Removing and installing brake pedal

Removing

- Remove storage compartment on driver's side.

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment

- -> Unscrew bolts -1-.

- Remove cover -A-.

- Remove brake light switch (square housing) => Page 13 .

- Remove brake light switch (round housing) => Page 55 .
- -> Remove connecting plate between clutch pedal and brake pedal -arrows- on vehicles with manual gear‐
box.

- Unplug 6-pin connector on accelerator pedal module.

- Separate brake pedal from brake servo =>Protected
Page by148 .
copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Vehicles with left-hand drive:

- Remove hexagon nut -Item 143 and detach brake pedal.

Vehicles with right-hand drive:

- Remove nuts -Item 144 .

- Remove mounting bracket with pedal cluster.
- Remove brake pedal.

5.4 - Removing and installing brake pedal 147

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Installing

Install in reverse sequence; note the following points:

Note:

Before installing, grease all bearings with polycarbamide grease, G 052 142 A2.

- -> Hold ball head of push rod in front of mounting and push brake pedal in direction of brake servo, so that
the ball head locates audibly.
- Install brake light switch (square housing) => Page 13 .
- Install brake light switch (round housing) => Page 56 .

Tightening torque

Component Nm
Brake servo/mounting bracket to bulkhead 28 1)

1) Renew nuts

5.5 - Separating brake pedal from brake servo

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

◆ T 10006 Release tool

Separating

- Remove storage compartment on driver's side.

148 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment

- Remove brake light switch (square housing) => Page 13 .

- Remove brake light switch (round housing) => Page 55 .
- Unplug electrical connectors from clutch pedal switch and from interlock switch.

- -> Remove connecting plate between clutch pedal and brake pedal -arrows- on vehicles with manual gear‐
[Link] by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Right-hand drive vehicles

- -> Remove foot rest -arrows-.

- -> Remove mounting bracket support -arrow-, if installed.

5.5 - Separating brake pedal from brake servo 149

 Audi TT 1999 ➤
Brake system - Edition 01.2002

All models

- -> Press brake pedal -1- in direction of brake servo and hold.
- Insert release tool T 10006 as shown and pull towards driver's seat whilst providing support at brake pedal
-1- (pedal must not be allowed to move to rear at this point). This presses retainer tabs -3- off ball head.
- Pull both release tool T 10006 and brake pedal towards driver's seat (this pulls brake pedal off push rod ball
head.

Note:

For ease of illustration, Fig. shows separation of brake pedal from brake servo with pedal cluster removed.

Installing

Install in reverse sequence; note the following points:

- -> Hold push rod ball head in front of mounting and push brake pedal in direction of brake servo, so that the
ball head audibly locates.
- Install brake light switch (square housing) => Page 13 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
- Install brake
permittedlight
unlessswitch (round
authorised by AUDI housing)
AG. AUDI AG =>
doesPage 56 .or accept any liability
not guarantee
with respect to the correctness of information in this document. Copyright by AUDI AG.

150 46 - Brakes, Brake mechanics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

47 - Brakes, Brake hydraulics

1 - High-pressure and low-pressure test

1.1 - High-pressure and low-pressure test

Special tools and workshop equipment required

◆ V.A.G 1310 A

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ V.A.G 1869/2

Test requirement:

• Brake system (brake master cylinder, brake hoses, brake pipes and brake calipers) tested for operation and
tightness.

High-pressure test:

- Remove bleed screw at one of the front brake calipers. Connect pressure gauge V.A.G 1310 A and bleed.
- Insert brake pedal depressor V.A.G 1869/2 between brake pedal and driver's seat. Apply pressure to brake
pedal until the gauge indicates a pressure of 50 bar. The test lasts for 45 seconds, during which time the
pressure must not drop by more than 4 bar.

If the drop in pressure is greater, renew the hydraulic control unit.

Low-pressure test:

- Move the brake pedal depressor back until the pressure gauge indicates a pressure of 6 bar.

1.1 - High-pressure and low-pressure test 151

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- The test lasts for 3 minutes, during which time the pressure must not drop by more than 1 bar.

If the drop in pressure is greater, renew the hydraulic control unit.

2 - Servicing front brake caliper

2.1 - Servicing front brake caliper
Notes:
◆ Fit complete repair set when performing service work.
◆ New brake calipers are filled with brake fluid and pre-bled.
◆ Apply thin coat of assembly paste G 052 150 A2 to brake cylinder, piston and sealing ring.

2.2 - Brake caliper FN 3 - Assembly overview

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1 Protective seal
2 Bleed screw - 10 Nm
◆ Apply thin coat of assembly paste
G 052 150 A2 to threads before screwing in

152 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

3 Cap
◆ Insert in mounting bush
4 Guide pin - 28 Nm
5 Mounting bush
◆ Insert into brake caliper housing
6 Brake caliper housing
7 Brake carrier

8 Retaining spring
◆ Insert both ends in the holes in brake caliper housing
9 Seal
◆ Do not damage when inserting piston
◆ Removing and installing
=> Page Protected
154 by copyright. Copying for private or commercial purposes, in part or in whole, is not
10 Piston permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
◆ Removing and installing
with respect to the correctness of information in this document. Copyright by AUDI AG.

=> Page 154

◆ Apply thin coat of assembly paste G 052 150 A2 to piston
11 Protective seal
◆ Pull outer sealing lip onto piston
◆ Removing and installing

2.2 - Brake caliper FN 3 - Assembly overview 153

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> Page 154

2.3 - Removing and installing front brake caliper piston

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools and workshop equipment required
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
◆ 3409 Removal wedge
◆ Piston resetting tool

Removing

- -> Force piston out of brake caliper housing using compressed air.

Note:
Place a piece of wood in the recess to prevent damaging the piston.

- -> Remove seal using wedge 3409.

154 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Note:

When removing ensure that the surface of the cylinder is not damaged.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Installing

- The surface of the piston and seal must only be cleaned with methylated spirits and then dried.
- Thinly coat piston and seal with fitting paste G 052 150 A2 before inserting.
- Insert seal in brake caliper housing.
- -> Position outer sealing lip of protective seal on piston.

- -> Using wedge 3409, insert the inner sealing lip into the grove in the cylinder.

Note:

When doing this hold piston in front of caliper housing.

- -> Press piston into the brake caliper housing using piston resetting tool.

2.3 - Removing and installing front brake caliper piston 155

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Note:

The protective seal outer sealing lip will then locate in the piston groove.

3 - Servicing brake caliper 2FN

3.1 - Servicing brake caliper 2FN

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ Fit complete repair set when performing service work.

◆ New brake calipers are filled with brake fluid and pre-bled.
◆ Apply thin coat of assembly paste G 052 150 A2 to brake cylinder, piston and seal.

1 Dust cap
◆ Fit on bleeder valve
2 Bleeder valve, 10 Nm
◆ Before screwing in, grease lightly with assembly paste G 052 150 A2
3 Caps
◆ Insert in mounting bush

156 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

4 Guide pin, 25 Nm
5 Mounting bush
◆ Insert into brake caliper housing
6 Brake caliper housing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7 Brake carrier
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
◆ Bolt onto brake caliper housing
8 Retaining spring

3.1 - Servicing brake caliper 2FN 157

 Audi TT 1999 ➤
Brake system - Edition 01.2002

9 Seal
◆ Removing and installing
=> Page 159
10 Piston
◆ Removing and installing
=> Page 159
◆ Apply thin coat of assembly paste G 052 150 A2 to piston before installing
11 Protective seal Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

◆ Removing and installing

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
=> Page 159
◆ Do not damage when inserting piston

158 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

3.2 - Removing and installing front brake caliper piston

Special tools and workshop equipment required

◆ 3409 Removal wedge

◆ Piston resetting tool

Removing

- -> Force piston out of brake caliper housing using compressed air.

Place a piece of wood in the recess to prevent damaging the piston.

You can only remove one piston at a time; hold the other piston in the caliper housing using the piston resetting
tool.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
- -> Remove
permitted protective
unless authorised by AUDIseal from
AG. AUDI AGpiston
does not groove using
guarantee or accept wedge
any liability3409.
- Take outtopiston.
with respect the correctness of information in this document. Copyright by AUDI AG.

3.2 - Removing and installing front brake caliper piston 159

 Audi TT 1999 ➤
Brake system - Edition 01.2002

When removing, ensure that the surface of the cylinder is not damaged.

- -> Take out protective seal using wedge 3409.

- -> Remove seal using wedge 3409.

When removing, ensure that the surface of the cylinder is not damaged.

Installing

- The surface of the piston and seal must be cleaned with methylated spirits only, and then dried.

- Thinly coat piston and seal with assembly paste G 052 150 A2 before inserting.
- Insert seal in brake caliper housing.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

160 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Position outer sealing lip of protective seal on piston.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with-respect
-> to
Using wedgeof 3409,
the correctness insert
information the inner
in this document. sealing
Copyright lip AG.
by AUDI into the grove in the cylinder.

When doing this hold piston in front of caliper housing.

- -> Press piston into brake caliper housing as far as possible by hand.

3.2 - Removing and installing front brake caliper piston 161

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Press piston into brake caliper housing using piston resetting tool.

The outer sealing lip of the protective seal will then locate in the piston groove.

4 - Servicing rear brake caliper

4.1 - Servicing rear brake caliper
Notes:
◆ Fit complete repair set when performing service work.
◆ New brake calipers are filled with brake fluid and pre-bled.
◆ Apply thin coat of assembly paste G 052 150 A2 to brake cylinder, piston and sealing ring.
◆ When performing repair work, always pre-bleed brake calipers accordingly prior to installation in vehicle
(without brake pads) => Page 167 .

4.2 - Exploded view

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

1 Bolt - 35 Nm
◆ Self-locking

162 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

◆ Renew each time after removing

◆ When loosening and tightening counter-hold on guide pin
2 Bleed screw - 10 Nm
◆ Apply thin coat of assembly paste
G 052 150 A2 to threads before screwing in
3 Protective seal
4 Guide pins
◆ Grease before pulling on protective cap
5 Protective cap
◆ Pull onto brake carrier and guide pin

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

6 Brake carrier with guide pin and protective cap

◆ Supplied as replacement part, assembled with sufficient grease on guide pins
◆ If protective caps or guide pins are damaged, install repair kit. Use grease sachet supplied to lubricate
the guide pins.
7 Protective cap
◆ Pull outer sealing lip onto piston
8 Piston with automatic adjustment
◆ Removing and installing
=> Page 165

4.2 - Exploded view 163

 Audi TT 1999 ➤
Brake system - Edition 01.2002

◆ Apply thin coat of assembly paste G 052 150 A2 to piston

9 Seal
◆ Do not damage when inserting piston
◆ Removing and installing
=> Page 165
10 Brake caliper housing with handbrake cable lever
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
◆ If a leak exists atpermitted
the handbrake cable
unless authorised lever
by AUDI renew
AG. AUDI brake
AG does caliperorhousing
not guarantee accept any liability
◆ After repairing, pre-bleed
with respectcaliper housing
to the correctness => Page
of information in this167
document. Copyright by AUDI AG.

164 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

4.3 - Removing and installing rear brake caliper piston

Special tools and workshop equipment required

◆ 3272 Piston compressing and extracting tool

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ 3409 Removal wedge

◆ Bleeder container

Removing

- -> Apply special tool 3272 together with 3272/1 to piston of brake caliper housing.
- Screw piston out of brake caliper housing by turning the knurled wheel anti-clockwise.

Note:

If piston is stiff, 13 mm open-ended wrench can be applied at appropriate flats -arrow-.

4.3 - Removing and installing rear brake caliper piston 165

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Remove seal using wedge 3409.

Installing

- The surface of the piston and seal must only be cleaned with methylated spirits and then dried.
- Thinly coat piston and seal with fitting paste G 052 150 A2 before inserting.
- Insert oil seal in brake caliper housing.
- -> Place protective seal with the outer sealing lip on the piston.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Using wedge 3409, insert the inner sealing lip into the grove in the cylinder.

Note:

When doing this hold piston in front of caliper housing.

166 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Apply special tool 3272 together with 3272/1 to piston of brake caliper housing.
- Screw piston into housing by turning knurled wheel clockwise.

Note:
Adjusting piston with a normal resetting tool destroys automatic adjuster in brake caliper.
- Fit brake pads.

Pre-bleeding brake caliper

- -> Open bleed screw -arrow A- and use a standard bleeder bottle to fill with brake fluid until bubble-free
brake fluid flows from the threaded hole -arrow B- (brake hose connection). Close bleed screw.

Note:
Position brake caliper as illustrated to pre-bleed.

5 - Bleeding brake system - ABS/ESP ITT Mark 20

5.1 - Bleeding brake system - ABS/ESP ITT Mark 20

Warning!
◆ Do not under any circumstances allow brake fluid to come into contact with liquids which 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 under any circumstances be sucked through a tube using the mouth.
Because of its caustic properties it must also not come into contact with paintwork.
◆ 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.

4.3 - Removing and installing rear brake caliper piston 167

 Audi TT 1999 ➤
Brake system - Edition 01.2002

System must first be pre-bled when one chamber in the brake fluid reservoir is completely empty (e.g. brake
system leaking) => Page 170 .
Afterwards the hydraulic unit must be bled with vehicle diagnostic, testing and information system VAS 5051
in function "04 - Basic setting" =>Page 169 .
When using a brake filling and bleeding appliance (such as VAS 5234 or V.A.G 1869 A) to replenish the brake
fluid, make sure that filling pressure does not exceed 1 bar.
If the filling pressure exceeds 1 bar, a hydraulically controlled change-over valve (which is required for the EDL
function) prevents unrestricted flushing of the EDL-related parts of the hydraulic unit. If this is the case, it may
not be possible to bleed the system properly.
For this reason the brake fluid pressure must be reduced to 1 bar on the brake filling and bleeding appliance.
=> Operating instructions for VAS 5234 and V.A.G 1869 A
Notes:
◆ Use only new brake fluid with part No. B 000 700 A . (Container contents available from 0.25 to 30 litres).
◆ Rinse off any brake fluid spillages using plenty of water.

5.2 - Bleeding brake system using brake filling and bleeding appliance VAS 5234 or V.A.G
1869 A

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

Special tools and workshop equipment required

◆ Brake filling and bleeding appliance VAS 5234

or
◆ Brake filling and bleeding appliance V.A.G 1869 A

Work sequence
- Connect brake filling and bleeding appliance VAS 5234 or V.A.G 1869 A.
- Remove protective cap from bleed screw on brake caliper and attach bleeder bottle hose to bleed screw.

Bleeding sequence
1- Front left brake caliper
2- Front right brake caliper
3- Rear left brake caliper
4- Rear right brake caliper

- Leave bleed screw open, with bleeder bottle hose connected, until brake fluid emerges out of the bleed
screw clear and free from air bubbles.
- Build up pressure in brake system to aid bleeding by pumping pedal five times.
- Tighten bleed screw to 10 Nm. Detach hose and fit protective cap on bleed screw.

168 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Repeat procedure on remaining brake calipers in the specified bleeding sequence.

- Top up fluid level in reservoir to "MAX" mark (according to degree of pad wear) and close reservoir cap.
- Start engine and test pedal travel and pedal pressure.
- If the pedal travel is excessive, check brake system for leaks or repeat bleeding procedure.

A test drive must be carried out after bleeding brakes. When doing this an ABS-controlled brake application on
all four wheels must be performed at least once.
Changing brake fluid
=> Maintenance booklet

5.3 - Bleeding brake system without brake filling and bleeding appliance
Note:
Make sure there is always sufficient brake fluid in the reservoir.
- Remove protective cap from bleed screw on brake caliper and attach bleeder bottle hose to bleed screw.

Bleeding sequence => Page 168

- Build-up brake pressure in brake system by pumping the brake pedal.

Note:
Pump the pedal slowly to ensure bubble-free flow.
- Hold brake pedal down after building up pressure.
- Open bleed screw with bleeder bottle hose attached until pressure drops (pedal sags).
- With brake pedal held down, close bleed screw.

- Release brake pedal and wait for approx. 2 seconds to enable brake fluid to run from brake fluid reservoir.
- Repeat operation until brake fluid emerges clear and free from air bubbles.
- Tighten bleed screw to 10 Nm, detach bleed hose and fit protective cap on bleed screw.
- Repeat procedure at the remaining brake calipers in the specified bleeding sequence.

Notes:
◆ If one chamber of permitted
brake unless
fluid authorised
reservoir hasAG. runAUDI
completely empty or (e.g. due to leak in brake system), brake
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
by AUDI AG does not guarantee accept any liability
system must be pre-bled =>toPage
with respect 170 .of information in this document. Copyright by AUDI AG.
the correctness
◆ In addition on vehicles with right-hand drive the brake master cylinder must be bled. Bleeding sequence =>
Page 174 .

- Top up fluid level in reservoir to "Max" mark (according to degree of pad wear) and close reservoir cap.

- Start engine and check pedal travel and brake pedal pressure.
- If the pedal travel is excessive, check brake system for leaks or repeat bleeding procedure.

Changing brake fluid

=> Maintenance booklet

5.4 - Bleeding brake system when brake fluid reservoir was empty

5.2 - Bleeding brake system using brake filling and bleeding appliance VAS 5234 or V.A.G

1869 A 169
 Audi TT 1999 ➤
Brake system - Edition 01.2002

Special tools and workshop equipment required

◆ Brake charge and bleed equipment VAS 5234

or
◆ Brake charge and bleed equipment V.A.G 1869 A

◆ Vehicle diagnostic, testing and information system VAS 5051 and VAS 5051/1

When using a brake system filling and bleeding appliance (such as VAS 5234 or V.A.G 1869 A) to replenish
the brake fluid, make sure that filling pressure does not exceed 1 bar.
If the filling pressure exceeds 1 bar, a hydraulically controlled change-over valve (which is required for the EDL
function) prevents unrestricted flushing of the EDL-related parts of the hydraulic unit. If this is the case, it may
not be possible to bleed the system properly.
For this reason the brake fluid pressure must be reduced to 1 bar on the brake filling and bleeding appliance.
=> Operating instructions for VAS 5234 and V.A.G 1869 A
Filler and bleeder unit V.A.G 1238/B is not suitable for bleeding the brake system by using the "Basic setting"
function.
If only filler and bleeder unit V.A.G 1238/B is available, then switch unit on/off to ensure that sufficient brake
fluid is always present in reservoir.
Requirement for test:
• Connect vehicle diagnostic, testing and information system VAS 5051, select "Vehicle self-diagnosis" and
vehicle system "03 - Brake electronics".

=> Running gear, Self-diagnosis; Repair group 01

Pre-bleeding of brake system
- Connect brake system filling and bleeding appliance VAS 5234 or V.A.G 1869 A.
- Open bleeder screws in the specified sequence and pre-bleed brake calipers.

1- Bleed front left and front right brake calipers simultaneously.

2- Bleed rear left and rear right brake calipers simultaneously.

- Leave the bleed screw open, with brake fluid hose connected, until brake fluid free from air bubbles comes
out of the bleed screw.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

170 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Bleeding

-> Display on VAS 5051:

- Select the diagnosis function "04 - Basic settings" from the menu -1-.

Note:

During the next steps the ABS warning lamp flashes.

-> Display on VAS 5051:

1- Enter display group

- Using the keypad -2-, enter "001" to select Display group 001 and confirm entry with Q key.

-> Display on VAS 5051:

1- System in basic setting

2- Display group 1
3- Press pedal and hold in position ...

- Operate pedal with substantial foot pressure and hold.

- Pedal sags, hydraulic pump starts up, pedal returns

Display on VAS 5051:

Protected by3 - Release
copyright. Copying forpedal;
private or FR/FL
commercial bleed screws
purposes, in part orOPEN
in whole, <>
is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
- Release pedal, open front bleed screws.

5.4 - Bleeding brake system when brake fluid reservoir was empty 171
 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Press the s button to advance to Display group 002.

-> Display on VAS 5051:

1- System in basic setting

2- Display group 2
3- Please wait .. (10 sec.)

- Wait for 10 seconds.

- Hydraulic pump starts up briefly

Display on VAS 5051:

3- Press pedal 10X; bleed screws CLOSED <>

- Press pedal 10 times, close front bleed screws.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- Press the s button to advance to display group 003.

-> Display on VAS 5051:

1- System in basic setting

2- Display group 3
3- Press pedal and hold in position ...

- Repeat bleeding procedure as described above

- Press the s button several times to advance to the next display groups until display group 17 is indicated.

172 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

-> Display on VAS 5051:

1- System in basic setting

2- Display group 17
3- Partial bleeding over ...

- Press the ◂ button to exit from diagnosis function "04 - Basic settings".

-> Display on VAS 5051:

- Select diagnosis function "06 - End output" from the menu -1-.

-> Display on VAS 5051:

- When this display appears, switch off ignition and unplug diagnostic connector.
- Now perform bleeding of brake system => Page 167
Protected by .copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

5.4 - Bleeding brake system when brake fluid reservoir was empty 173
 Audi TT 1999 ➤
Brake system - Edition 01.2002

Special point with right-hand drive vehicles:

-> Brake master cylinder must be bled via bleed screws -arrows- after completion of basic settings if one
chamber in the brake fluid reservoir has run completely dry.

6 - Bleeding brake system - ITT ABS/ESP Mark 60

6.1 - Bleeding brake system - ITT ABS/ESP Mark 60

Warning!
◆ Do not under any circumstances allow brake fluid to come into contact with liquids which 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 under any circumstances be sucked through a tube using the mouth.
Because of its caustic properties it must also not come into contact with paintwork.
◆ 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.

System must first be pre-bled when one chamber in the brake fluid reservoir is completely empty (e.g. brake
system leaking) => Page 177 .

Then the hydraulic unit must be bled with vehicle diagnostic, testing and information system VAS 5051 in
function "04 - Basic setting" =>Page 176 .

When using a brake filling and bleeding appliance (such as VAS 5234 or V.A.G 1869 A) to replenish the brake
fluid, make sure that filling pressure does not exceed 1 bar.

If the filling pressure exceeds 1 bar, a hydraulically controlled change-over valve (which is required for the EDL
function) prevents unrestricted flushing of the EDL-related parts of the hydraulic unit. If this is the case, it may
not bepermitted
possible toauthorised
bleed the system properly.
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unless by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
For this reason the brake fluid pressure must be reduced to 1 bar on the brake filling and bleeding appliance.

=> Operating instructions for VAS 5234 and V.A.G 1869 A

Notes:

◆ Use only new brake fluid with part No. B 000 700 A . (Container contents available from 0.25 to 30 litres).
◆ Rinse off brake fluid spillages, by using plenty of water.

174 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

6.2 - Bleeding brake system using brake filling and bleeding appliance VAS 5234 or V.A.G
1869 A

Special tools and workshop equipment required

◆ Brake charge and bleed equipment VAS 5234

or

◆ Brake charge and bleed equipment V.A.G 1869 A

Work sequence

- Connect brake filling and bleeding appliance VAS 5234 or V.A.G 1869 A.
- Remove protective cap from bleed screw on brake caliper and attach bleeder bottle hose to bleed screw.

Bleed sequence

1- Front left brake caliper

2- Front right brake caliper Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3- Rear left brake caliper permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4- Rear right brake caliper with respect to the correctness of information in this document. Copyright by AUDI AG.

- Leave bleed screw open, with bleeder bottle hose connected, until brake fluid emerges out of the bleed
screw clear and free from air bubbles.
- Build up pressure in brake system to aid bleeding by pumping pedal five times.
- Tighten bleed screw to 10 Nm. Detach hose and fit protective cap on bleed screw.
- Repeat procedure on remaining brake calipers in the specified bleeding sequence.
- Top up fluid level in reservoir to "MAX" mark (according to degree of pad wear) and close reservoir cap.
- Start engine and check brake pedal travel and pressure.
- If the pedal travel is excessive, check brake system for leaks or repeat bleeding procedure.

A zero compensation of brake pressure senders must be performed after bleeding brake system.

=> Running gear, Self-diagnosis; Repair group 01

A test drive must be carried out after bleeding brakes. When doing this an ABS-controlled brake application on
all four wheels must be performed at least once.

Changing brake fluid

=> Maintenance booklet

6.2 - Bleeding brake system using brake filling and bleeding appliance VAS 5234 or V.A.G

1869 A 175
 Audi TT 1999 ➤
Brake system - Edition 01.2002

6.3 - Bleeding brake system without brake filling and bleeding appliance

Note:
Make sure there is always sufficient brake fluid in the reservoir.
- Remove protective cap from bleed screw on brake caliper and attach bleeder bottle hose to bleed screw.

Bleeding sequence => Page 175

- Build-up brake pressure in brake system by pumping the brake pedal.

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Note:
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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Pump the pedal slowly to ensure bubble-free flow.

- Hold brake pedal down after building up pressure.
- Open bleed screw with bleeder bottle hose attached until pressure drops (pedal sags).
- With brake pedal held down, close bleed screw.

- Release brake pedal and wait for approx. 2 seconds to enable brake fluid to run from brake fluid reservoir.
- Repeat operation until brake fluid emerges clear and free from air bubbles.
- Tighten bleed screw to 10 Nm, detach bleed hose and fit protective cap on bleed screw.
- Repeat procedure at the remaining brake calipers in the specified bleeding sequence.

Notes:
◆ If one chamber of brake fluid reservoir has run completely empty (e.g. due to leak in brake system), brake
system must be pre-bled => Page 177 .
◆ In addition brake master cylinder must be bled on vehicles with right-hand drive. Bleeding sequence =>
Page 181 .

- Top up fluid level in reservoir to "Max" mark (according to degree of pad wear) and close reservoir cap.

- Start engine and check brake pedal travel and pressure.

- If the pedal travel is excessive, check brake system for leaks or repeat bleeding procedure.

Changing brake fluid

=> Maintenance booklet

6.4 - Bleeding brake system when brake fluid reservoir was empty

Special tools and workshop equipment required

◆ Brake charge and bleed equipment VAS 5234

176 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

or
◆ Brake charge and bleed equipment V.A.G 1869 A

◆ Vehicle diagnostic, testing and information system VAS 5051 and VAS 5051/1

When using a brake system filling and bleeding appliance (such as VAS 5234 or V.A.G 1869 A) to replenish
the brake fluid, make sure that filling pressure does not exceed 1 bar.
If the filling pressure exceeds 1 bar, a hydraulically controlled change-over valve (which is required for the EDL
function) prevents unrestricted flushing of the EDL-related parts of the hydraulic unit. If this is the case, it may
not be possible to bleed the system properly.
For this reason the brake fluid pressure must be reduced to 1 bar on the brake filling and bleeding appliance.
=> Operating instructions for VAS 5234 and V.A.G 1869 A
Filler and bleeder unit V.A.G 1238/B is not suitable for bleeding the brake system by using the "Basic setting"
function.
If only filler and bleeder unit V.A.G 1238/B is available, then switch unit on/off to ensure that sufficient brake
fluid is always present in reservoir.
Requirement for test:
• Connect vehicle diagnostic, testing and information system VAS 5051, select "Vehicle self-diagnosis" and
vehicle system "03 - Brake electronics".

=> Running gear, Self-diagnosis; Repair group 01

Pre-bleeding
- Connect brake system filling and bleeding appliance VAS 5234 or V.A.G 1869 A.
- Open bleeder screws in the specified sequence and pre-bleed brake calipers.

1- Bleed front left and front right brake calipers simultaneously.

2- Bleed rear left and rear right brake calipers simultaneously.

- Leave the bleed screw open, with brake fluid hose connected, until brake fluid free from air bubbles comes
out of the bleed screw.
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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6.4 - Bleeding brake system when brake fluid reservoir was empty 177
 Audi TT 1999 ➤
Brake system - Edition 01.2002

Bleeding

-> Display on VAS 5051:

- Select the diagnosis function "04 - Basic settings" from the menu -1-.

Note:

During the next steps the ABS warning lamp flashes.

-> Display on VAS 5051:

1- Enter display group

- Using the keypad -2-, enter "001" to select Display group 001 and confirm entry with Q key.

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-> Display on VAS 5051:

1- System in basic setting

2- Display group 1
3- Press pedal and hold in position ...

- Operate pedal with substantial foot pressure and hold.

- Pedal sags, hydraulic pump starts up, pedal returns

Display on VAS 5051:

3- Release pedal; FR/FL bleed screws OPEN <>

- Release pedal, open front bleed screws.

178 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Press the s button to advance to Display group 002.

-> Display on VAS 5051:

1- System in basic setting

2- Display group 2
3- Please wait .. (10 sec.)

- Wait for 10 seconds.

- Hydraulic pump starts up briefly

Display on VAS 5051:

3- Press pedal 10X; bleed screws CLOSED <>

- Press pedal 10 times, close front bleed screws.

- Press the s button to advance to display group 003.

-> Display on VAS 5051:

1- System in basic setting

2 - Display
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3 - Press
permitted pedal and
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AG. AUDI AG does not ...guarantee or accept any liability
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- Repeat bleeding procedure as specified earlier.

- Press the s button several times to advance to the next display groups until display group 17 is indicated.

6.4 - Bleeding brake system when brake fluid reservoir was empty 179
 Audi TT 1999 ➤
Brake system - Edition 01.2002

-> Display on VAS 5051:

1- System in basic setting

2- Display group 17
3- Partial bleeding over ...

- Press the ◂ button to exit from diagnosis function "04 - Basic settings".

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-> Display on VAS 5051:

- Select diagnosis function "06 - End output" from the menu -1-.

-> Display on VAS 5051:

- When this display appears, switch off ignition and unplug diagnostic connector.
- Now perform bleeding of brake system => Page 175 .

180 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Special point with right-hand drive vehicles:

-> Brake master cylinder must be bled via bleed screws -arrows- after completion of basic settings if one
chamber in the brake fluid reservoir has run completely dry.

7 - Vacuum servo pump

7.1 - Vacuum servo pump

From 2001 models onwards, certain petrol engine versions in conjunction with automatic gearbox are equipped
with an electric vacuum pump to boost the vacuum supplied to the brake servo.

7.2 - Checking vacuum pump for brakes -V192

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Test procedure permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
- Drive vehicle onto lifting platform, switch off engine.
- Start engine.
- While the engine is being started the vacuum pump for brakes -V192 (located on subframe in front of
steering box, left side) should run briefly.
- A second person has to touch the pump by hand to check whether it is running.

If vacuum pump for brakes -V192 does not run:

- Interrogate fault memory of engine control unit

=> Injection and ignition system; Repair group 01

7.3 - Removing and installing vacuum pump for brakes -V192

There is no provision for repairing the vacuum pump for brakes -V192. The pump must be renewed if defective.

6.4 - Bleeding brake system when brake fluid reservoir was empty 181
 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing

- Unscrew hexagon bolt securing guard plate.

- -> Unscrew bolts -1- on bracket for vacuum pump on left side of subframe.
- Disconnect vacuum hose -arrow- from vacuum pump.
- Unplug electrical connector.
- Take out vacuum pump for brakes -V192.

- -> To remove bracket -arrow-, unscrew nut -2- from bolt -1- .
- Remove bolt -4- and detach bracket.
- To dismantle bracket further, remove bolts -3-.

Installing

Installation is performed in reverse sequence.

Tightening torques

Component Nm
Bracket for vacuum pump to subframe 20
Vacuum pump to bracket 8
Air cleaner housing 10
Guard plate to bracket 10

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

182 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

8 - Brake servo/brake master cylinder - Left-hand drive vehicles

8.1 - Brake servo/brake master cylinder - Left-hand drive vehicles

8.2 - Exploded view

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Notes:
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ Brake master cylinder and brake servo can be replaced as individual components.
◆ The Fig. shows the brake servo of the ABS/ESP Mk 20 system.
◆ With the ABS/ESP Mk 60 system the components -Item 2, 14 and 15- as well as the electrical connector for
the brake pressure solenoid valve -N247 on the brake servo and the brake pressure solenoid trip switch -
F84 are missing.

8.1 - Brake servo/brake master cylinder - Left-hand drive vehicles 183

 Audi TT 1999 ➤
Brake system - Edition 01.2002

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

1 Brake servo
with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ Functional check
- With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
- Now depress brake pedal with average foot pressure, hold and start engine. If the servo unit is working
properly, the pedal will be felt to give slightly under foot (servo assistance becomes effective).
◆ The vacuum required is taken from the intake manifold.
◆ If loud suction noise is heard on braking, check proper positioning of inner bellows => -Item 20 -
◆ Detaching from brake pedal
=> Page 148
◆ Removing and installing
=> Page 191

184 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

2 Bracket
◆ Used to mount the electrical connector -Item 14 -
3 Cap
◆ With integrated float and brake fluid warning indicator
4 Brake fluid reservoir
◆ Moisten with brake fluid and press into sealing plugs in brake master cylinder
◆ Locate with retaining pin -Item 6 -
◆ With warning contact for brake fluid level (phased introduction)
◆ Remove brake
Protected fluid reservoir
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private warning
or commercial contact
purposes, in part or in whole, is not
5 Sealing plug
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
◆ Moisten with brake fluid and press into brake master cylinder
◆ Press brake fluid reservoir into sealing plugs.

8.2 - Exploded view 185

 Audi TT 1999 ➤
Brake system - Edition 01.2002

6 Retaining pin
◆ For brake fluid reservoir
7 Brake master cylinder
◆ Removing and installing
=> Page 188
8 Mounting plate
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
◆ Different versions
with respectavailable
to the correctness of information in this document. Copyright by AUDI AG.
◆ Allocation

=> Parts List

9 Nut - 4 Nm
◆ Self-locking
◆ Renew each time after removing
10 Heat shield
◆ Allocation

=> Parts List

11 Brake pressure sender -2- -G214
◆ Removing and installing
=> Page 19
12 Brake pressure sender -1- -G201

186 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

◆ Removing and installing

=> Page 19

13 Seal
◆ Renew
14 Electrical connector
15 Electrical wire
16 Vacuum pipe
◆ With non-return valve
◆ Check non-return valve => Fig. 2
17 Sealing plug
18 Gasket
◆ For brake servo
19 Nut - 28 Nm
◆ Self-locking
◆ Renew permitted
each time unless after removing
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20 Bellows with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ If unusually loud suction noise is heard on braking, check proper positioning of inner bellows => Fig. 1

8.2 - Exploded view 187

 Audi TT 1999 ➤
Brake system - Edition 01.2002

-> Fig.1 Checking inner bellows of brake servo

- Remove storage compartment on driver's side.

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment
- Check whether bellows have slipped out of annular groove as shown in this figure.
- Remove brake-pedal mounting bracket to insert bellows
=> Page 144

-> Fig.2 Checking non-return valve

◆ Non-return valve -A- should be open and allow passage of air in direction of arrow (blow into valve).
◆ Valve should remain closed in opposite direction and not allow passage of air.

Note:
Pay attention to correct installation position.

8.3 - Removing and installing brake master cylinder

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188 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Special tools and workshop equipment required

◆ Hose clamps 3094

◆ Brake charge and bleed equipment VAS 5234

or
◆ Brake charge and bleed equipment V.A.G 1869 A

◆ Repair kit; Part No. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
=> Parts catalogue with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - Valve dome transportation protection (plastic foam)
2 - M10 sealing plugs for brake pipes and threaded holes
3 - M12 sealing plugs for brake pipes and threaded holes

8.3 - Removing and installing brake master cylinder 189

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing

- Remove engine cover panel where necessary for access to components.

- -> Remove forward left-hand cover panel -arrows-.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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- -> If installed, disconnect secondary air intake hose -1- from air cleaner.
- Disconnect air hose -2- from air mass meter.
- Unplug connector -3- from air mass meter.
- Unscrew bolts -4- and -5-.
- Remove air cleaner housing.
- Lay out sufficient lint-free cloths in area below brake master cylinder to catch escaping brake fluid.
- Draw off as much brake fluid as possible from brake fluid reservoir using brake charge and bleed equipment
VAS 5234 or extraction unit V.A.G 1869/4.
- Clamp off clutch master cylinder supply hose with hose clamp 3094.
- Pull off clutch master cylinder supply hose.
- Pull connector off float warning indicator sender if part of original equipment.

- -> Pull connectors -arrows- off brake pressure senders -a- and -b-.
- Disconnect brake pipes on brake master cylinder and seal brake pipes with plugs from repair kit.
- Unscrew securing nuts from brake master cylinder.
- Remove heat shield with retainer plate, if part of original equipment.
- Remove brake master cylinder from brake servo.

Installing

Install in reverse sequence; note the following points:

- Renew sealing ring between brake master cylinder and brake servo.
- When inserting brake master cylinder, make sure that push rod in brake servo is correctly positioned.
- Apply slight pressure to the brake pedal; this makes it easier to guide brake master cylinder onto pushrod.

- Bleed brake system: ABS/ESP Mark 20 =>Page 174 .

- Bleed hydraulic system for clutch:

190 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

=> Manual gearbox; Repair group 30

- Initiate basic settings for brake pressure senders.

=> Running gear, Self-diagnosis; Repair group 01

- Perform ESP road test on vehicles with ABS/ESP Mark 60 system.

=> Running gear, Self-diagnosis; Repair group 01

Tightening torques
Component Nm
Brake master cylinder to brake servo 20 1)
Brake pressure sender to brake master cylinder 14
Air cleaner housing 10
1) Renew nuts

8.4 - Removing and installing brake servo

Removing
- Release brake servo vacuum by operating the brake pedal several times.
- Remove brake master cylinder => Page 188 .
- Pull vacuum hose off brake servo unit.
- Unplug electrical connector from brake servo if part of original equipment.
- Remove storage compartment on driver's side.

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment

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with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Unscrew bolts -1-.

- Remove cover -A-.
- Separate brake pedal from brake servo => Page 148 .

8.3 - Removing and installing brake master cylinder 191

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- -> Unscrew nuts -arrows-.

- Remove brake servo.

Installing

Install in reverse sequence; note the following points:

- Mount brake pedal on brake servo =>Page 150 .

- Install brake master cylinder => Page 190 .
- Bleed brake system: ABS/ESP Mark 20 =>Page 174 .
- Bleed hydraulic system for clutch:

=> Manual gearbox; Repair group 30

- Initiate basic settings for brake pressure senders.

=> Running gear, Self-diagnosis; Repair group 01

- Perform ESP road test on vehicles with ABS/ESP Mark 60 system.

=> Running gear, Self-diagnosis; Repair group 01

Tightening torque

Component Nm
Brake servo/mounting bracket to bulkhead 28 1)

1) Renew nuts

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with respect to the correctness of information in this document. Copyright by AUDI AG.

192 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

9 - Brake servo/brake master cylinder - Right hand drive

9.1 - Brake servo/brake master cylinder - Right hand drive

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

9.2 - Exploded view

Notes:

◆ Brake master cylinder and brake servo can be replaced as independent components.
◆ The Fig. shows the brake servo of the ABS/ESP Mk 20 system.
◆ With the ABS/ESP Mk 60 system the electrical connector -Item 17- for the brake pressure solenoid valve -
N247 on the brake servo and the brake pressure solenoid trip switch -F84 are missing.

9.1 - Brake servo/brake master cylinder - Right hand drive 193

 Audi TT 1999 ➤
Brake system - Edition 01.2002

1 Brake servo
◆ Functional check
- With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit).
- Now depress brake pedal with average foot pressure, hold and start engine. If the servo unit is working
properly, the pedal will be felt to give slightly under foot (servo assistance becomes effective).
◆ The vacuum required is taken from the intake manifold.
◆ If loud suction noise is heard on breaking, check proper positioning of inner bellows => Fig. 1
◆ Detaching from brake pedal
=> Page 148
◆ Removing and installing
=> Page 201

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

194 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

2 Gasket
◆ For brake servo
3 Nut - 28 Nm
◆ Self-locking
◆ Renew each time after removing
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4 Sealing plug permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5 Vacuum pipe with respect to the correctness of information in this document. Copyright by AUDI AG.

◆ With non-return valve

◆ Checking non-return valve => Fig. 2
6 Securing bolt - 2 Nm
◆ For brake fluid reservoir
◆ Can only be unscrewed after removing brake master cylinder
=> Page 200

9.2 - Exploded view 195

 Audi TT 1999 ➤
Brake system - Edition 01.2002

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

7 Brake fluid reservoir

◆ Reservoir can only be detached after removing brake master cylinder
=> Page 198
◆ Moisten with brake fluid and press into sealing plugs in brake master cylinder
◆ With warning contact for brake fluid level (phased introduction)
◆ Remove brake fluid reservoir to replace warning contact
8 Cap
◆ With integrated float and brake fluid warning indicator
9 Sealing plug
◆ Moisten with brake fluid and press into brake master cylinder
◆ Press brake fluid reservoir into sealing plugs.
10 Dust cap

196 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

11 Bleed valve - 7 Nm
12 Brake master cylinder
◆ Removing and installing
=> Page 198
13 Brake pressure sender -2- -G214
◆ Removing and installing
=> Page 19
14 Brake pressure sender -1- -G201
◆ Removing and installing
=> Page 19
15 Nut - 4 Nm
◆ Self-locking
◆ Renew each time after removing
16 Seal
◆ Renew
17 Electrical wire
◆ For brake pressure solenoid valve -N247 and brake pressure solenoid trip switch -F84

9.2 - Exploded view 197

 Audi TT 1999 ➤
Brake system - Edition 01.2002

-> Fig.1 Checking inner bellows of brake servo

- Remove storage compartment on driver's side.

=> General body repairs, Interior; Repair group 68; Storage compartments, covers; Removing driver's storage
compartment Storage compartments, covers Removing driver's storage compartment
- Check whether bellows have slipped out of annular groove as shown in this figure.
- Remove brake-pedal mounting bracket to insert bellows
=> Page 144

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
-> Fig.2 Checking non-return valve
◆ Non-return valve -A- should be open and allow passage of air in direction of arrow (blow into valve).
◆ Valve should remain closed in opposite direction and not allow passage of air.

Note:
Pay attention to correct installation position.

9.3 - Removing and installing brake master cylinder

198 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Special tools and workshop equipment required

◆ Hose clamps 3094

◆ Brake charge and bleed equipment VAS 5234

or
◆ Brake charge and bleed equipment V.A.G 1869 A

◆ Repair kit; Part No.

=> Parts catalogue

1 - Valve dome transportation protection (plastic foam)
2 - M10 sealing plugs for brake pipes and threaded holes
3 - M12 sealing plugs for brake pipes and threaded holes

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

9.3 - Removing and installing brake master cylinder 199

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Removing

Note:

-> Reservoir can only be detached after removing brake master cylinder, as securing bolt -arrow- is otherwise
not accessible.

- Lay out sufficient lint-free cloths in area below brake master cylinder to catch escaping brake fluid.
- Draw off as much brake fluid as possible from brake fluid reservoir using brake charge and bleed equipment
VAS 5234 or extraction unit V.A.G 1869/4.
- Clamp off clutch master cylinder supply hose with hose clamp 3094.
- Pull off clutch master cylinder supply hose.
- Pull connector off float warning indicator sender if part of original equipment.
- Pull connectors off brake pressure senders.
- Disconnect brake pipes on brake master cylinder and seal brake pipes with plugs from repair kit.
- Unscrew securing nuts from brake master cylinder.
- Remove brake master cylinder from brake servo.

Installing

Install in reverse sequence; note the following points:

- -> Mount reservoir with securing bolt -arrow- on brake master cylinder.
- Renew sealing ring between brake master cylinder and brake servo.
- When inserting brake master cylinder, make sure that push rod in brake servo is correctly positioned.
- Apply slight pressure to the brake pedal; this makes it easier to guide brake master cylinder onto pushrod.
- Bleed brake system: ABS/ESP Mark 20 =>Page 174 .
- Bleed hydraulic system for clutch:

=> Manual gearbox; Repair group 30

- Initiate basic settings for brake pressure senders.

=> Running gear, Self-diagnosis; Repair group 01

- Perform ESP road test on vehicles with ABS/ESP Mark 60 system.

=> Running gear, Self-diagnosis; Repair group 01

Tightening torques

Component Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Securing bolt for brake fluid reservoir
permitted unless authorised by AUDI AG. AUDI AG 2does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Brake pressure sender to brake master cylinder 14

200 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

9.4 - Removing and installing brake servo

Special tools and workshop equipment required

◆ 10-222 A engine support

◆ Retainer 3180

Removing

- Release brake servo vacuum by operating the brake pedal several times.
- Remove brake master cylinder => Page 198 .
- Pull vacuum hose off brake servo unit.
- Unplug electrical connector on brake servo if part of original equipment.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Remove noise insulation -arrows- if components are otherwise not accessible.

9.4 - Removing and installing brake servo 201

 Audi TT 1999 ➤
Brake system - Edition 01.2002

- Disconnect right drive shaft from gearbox drive flange.

- -> Unbolt swing mounting -arrows-.
- Remove front exhaust pipe.

=> Engine Mechanics; Repair group 26

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- -> Unscrew coolant expansion tank -arrows- if engine support mounts are otherwise not accessible; leave
hoses connected.

- -> Set up engine support bracket 10-222 A in front of gas strut on bolted flanges of wing panels with spindles
at front.
- Bolt retainer 3180 to the right-hand lifting eye and engage on lifting hook on right-hand spindle.
- Engage lifting hook on left-hand spindle in left-hand lifting eye.
- Raise the engine slightly, taking up the weight evenly on both spindles.

202 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Note:

Mark installation position of engine/gearbox supports.

- -> Unbolt engine support from engine console -arrows-.

- -> Unbolt gearbox support from gearbox console -arrows-.

- Lower engine/gearbox by adjusting spindles on support bar 10-222 A.
-Engine side: approx. 60 mm
-Gearbox side: approx. 90 mm

Note:

When lowering, always make sure that the coolant hoses to the heating system exchanger are not stretched.

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

- Separate brake pedal from brake servo => Page 148 .

- -> Unscrew nuts -arrows-.
- Remove brake servo.
- Removal of brake servo involves second mechanic pulling engine in direction of travel.

9.4 - Removing and installing brake servo 203

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Installing

Install in reverse sequence; note the following points:

- Adjust engine mounts.

=> Engine mechanics; Repair group 10

- Connect right drive shaft to gearbox drive flange.

=> Running gear, Front-wheel drive and four-wheel drive; Repair group 40

- Screw on pendulum support.

=> Engine mechanics; Repair group 10

- Install front exhaust pipe.

=> Engine Mechanics; Repair group 26

- Fit brake pedal to brake servo =>Page 150 .

- Install brake master cylinder => Page 200 .
- Bleed brake system: ABS/ESP Mark 20 =>Page 174 .
- Bleed hydraulic system for clutch:

=> Manual gearbox; Repair group 30

- Initiate basic settings for brake pressure senders.

=> Running gear, Self-diagnosis; Repair group 01

- Perform ESP road test on vehicles with ABS/ESP Mark 60 system.

=> Running gear, Self-diagnosis; Repair group 01

Tightening torque

Component Nm
Brake servo/mounting bracket to bulkhead 28 1)

1) Renew nuts
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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

10 - Brake pipes and hoses

with respect to the correctness of information in this document. Copyright by AUDI AG.

10.1 - Brake pipes and hoses

10.2 - Removing and installing brake pipes and hoses

The next pages show different installation positions and lists tightening torques for brake pipes and hoses.

204 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

-> Brake pipes at brake master cylinder/hydraulic unit; ITT Mark 20

1- Brake pipe to brake master cylinder - 14 Nm

2- Brake pipe to hydraulic unit - 14 Nm

-> Brake pipes at brake master cylinder/hydraulic unit; ITT Mark 60

1- Tightening torque14 Nm
2- Tighteningtorque 24 Nm
3- Tightening torque 8 Nm
4- Tighteningtorque 20 Nm

10.2 - Removing and installing brake pipes and hoses 205

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

-> Brake pipes/hoses at front wheels - Vehicles with front-wheel drive

1- Banjo bolt - 35 Nm
2- Brake pipe - 14 Nm
3- Retaining clip
4- Brake hose

-> Brake pipes/hoses at front wheels - Vehicles with four-wheel drive

1 - Banjo bolt - 35 Nm
2 - Brake pipe - 14 Nm
3 - Retaining clip
4 - Heat shield
- Mounting to suspension strut => Next fig.

206 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

-> Brake hose mounting on suspension strut - Vehicles with front-wheel drive

1- Clamp
2- Bolt - 9 Nm
3- Heat shield
4- Brake hose
5- Retaining clip

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

-> Brake pipes/hoses at front wheels - Vehicles with2FN brake system

1- Hexagon bolt- 8 Nm
2- Bracket
3- Brake pipe
4- Brake caliper

-> Brake pipes/hoses at brake caliper - Vehicles with2FN brake system

1- Brake hose

10.2 - Removing and installing brake pipes and hoses 207

 Audi TT 1999 ➤
Brake system - Edition 01.2002

Connections going to caliper must point inwards after installing brake hose in wheel housing -arrow-.

2- Brake caliper

Union nut on brake hose is applied by hand.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

-> Brake pipe/hoses at rear wheels - Vehicles with front-wheel drive

1- Brake hose
2- Brake pipe - 14 Nm
3- Bracket
4- Retaining clip

-> Brake hose mounting on brake caliper - Vehicles with front-wheel drive

1 - Banjo bolt - 38 Nm
Always replace brake pipe/hose with banjo bolt after unbolting banjo bolt.
2 - Brake hose

208 47 - Brakes, Brake hydraulics

 Audi TT 1999 ➤
Brake system - Edition 01.2002

-> Brake pipe/hoses at rear wheels - Vehicles with four-wheel drive

1- Bracket
2- Brake hose
3- Brake pipe - 14 Nm
4- Retaining clip

-> Brake pipe/angled sealing element mounting on brake caliper - Vehicles with four-wheel drive

1 - Brake pipe - 14 Nm
2 - Angled sealing element
3 - Banjo bolt - 38 Nm
Always replace sealing element and banjo bolt after unbolting banjo bolt.

-> Brake pipe connection

- Counterhold union nut -1- when

permittedtightening banjo boltAG.-2-.
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unless authorised by AUDI AUDI AG does not guarantee or accept any liability
- Tightening torque: 14 Nmwith respect to the correctness of information in this document. Copyright by AUDI AG.

10.2 - Removing and installing brake pipes and hoses 209

 Audi TT 1999 ➤
Brake system - Edition 01.2002

-> Brake hose connection with locating element

- Make sure that the groove in the ring connection of the brake hose is fitted in the locating lug -arrow-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

210 47 - Brakes, Brake hydraulics