Front Doors, Central Locking System (coupe) Audi TT 8J

DOOR, ADJUSTING

Special tools and workshop equipment required

1. Adjusting gauge 3371
2. Template T40038/7

Adjusting with Template T40038/7

The position of the door in relation to the sides, the height and the rear window can be checked using the template.

The distance to the side window can be checked using the grading for dimension -a-.

The recess of the door to the fender or the side panel to the door can be checked with gradings for dimensions -b- and -c-.

The template must be positioned at a distance of -a- = 100 mm from the rear edge of the door window or at the front as an extension from the windshield upper edge -arrow- to the roof trim molding.

Scheme 61

In the illustration show (min marking on window side), window is adjusted correctly when both contact surfaces -a- and -b- contact the door window and the contact surface on the roof trim molding shows a small gap.

Scheme 62

If the upper contact surface -a- does not make contact with the door window, the window is adjusted to far inward.

In the illustration shown (max marking on window side), the window is adjusted correctly when the contact surfaces makes contact with the roof trim molding and the upper contact surface -a- of the template shows a small gap.

Scheme 63

If the contact surface of the template does not make contact with the roof trim molding, the door window is too far out.

Height adjustment

Scheme 64

Apply a marking to an adhesive strip -2- at a distance of -a- = 17 mm, measured from the upper edge of the door window.

Position template as shown and slide upward as far as the stop on the roof trim strip -1-.

When adjusted correctly, the marking must be located in the area of the small grading as shown.

Adjustment to side window

Scheme 65

Slide template as show between guide rail -4- on side window -1- and door window -2- into door seal -3-.

The door window must be in the area of the small groove.

Gap dimensions

Scheme 66

The gap dimensions can be checked with the Adjustment Gauge 3371.

1. Dimension -A- = 3.5 mm +/- 0.5 mm
2. Dimension -B- = 3.5 mm +/- 0.5 mm
3. Dimension -C- = 0 mm to -1 mm.
4. Dimension -D- = 0 mm to +1 mm

Adjustment via striker

Scheme 67

Loosen bolts -2-.

Slide striker -1- until the door shell is flush with the contour of the chassis.

Tighten screws to 20 Nm.

Note. The striker should only be adjusted toward the vehicle center and not height-wise, otherwise the lock can be damaged.

Scheme 68

1. Door handle Before removing, remove lock cylinder with cover on driver's door or housing To remove, slide door handle back and disengage from operating lever on mounting bracket. Pull door handle out sideways at back end. Pull door handle back diagonally out of mounting bracket or door.
2. Bracket
3. Actuating link Door lock removed. Engage actuating link in door lock operating lever -arrow-. CAUTION: The release cable must not be kinked under any circumstances when installing, otherwise malfunctions may result. Perform a function test after installing. Slide actuating link sideways into door lock, then rotate 90° to lock.
4. Door lock Removing «DOOR LOCK ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe)
5. Hood catch
6. Hood release lever Engage actuating link in operating lever on door handle as shown.

Slide door handle into mounting bracket

Scheme 69

1. Rear backing Clip into door panel.
2. Door handle -- Before installing, backing plates -2- and -5- must be installed. -- Slide door handle into front door opening until it engages in brace on mounting bracket -arrow-. -- Press door handle on rear lock cylinder into mounting bracket. -- Insert lock cylinder with cover cap. -- Completely install bolt to secure lock cylinder «DOOR HANDLE AND DOOR LOCK»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe) .
3. Bracket
4. Front backing Slide onto door handle.
5. Door

When installing door handle -1-, rear end must slide into mounting bracket in -direction of arrow- as shown.

Scheme 70

1. Cover Pressed into door. When removing, unclip from lock cylinder and remove bolt below.
2. Bolt 20 Nm.
3. Door
4. Door lock Removing Door trim removed, refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-coupe) Rear cover on inner panel removed «WINDOW REGULATOR»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe) -- Raise window up. -- Lock cylinder removed. -- Remove bolts -2- and slide door lock down. -- Disengage internal mechanism cable -7- from door lock. Install in reverse sequence.
5. Lock cylinder shaft So-called >>paddle<< must be guided into groove -arrow- in door lock during installation
6. Lock cylinder
7. Inside door release mechanism cable

Scheme 71

To install, first insert release cable -2- vertically into release lever -3- as shown in the magnified area of illustration, then swivel 90° and clip into door lock -1- to secure.

CENTRAL LOCKING COMPONENT OVERVIEW

Note. Central locking functions electronically. Actuators in doors are integrated in the door lock and have 2 motors. Actuators cannot be replaced separately. The first motor locks the door and the second motor locks the interior door mechanism (Safe function). Now, doors also can no longer be opened from the interior. After an accident in which the airbag deploys, the central locking system control module opens any doors which were locked. The central locking control module is located inside the right rear side panel.

Scheme 72

1. Front passenger door control module -J387
2. Anti-Theft Alarm System Sensor -G578- Removing and Installing, refer to «[For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#interior-lights-switches-coupe)
3. Comfort system central control module -J393- Removing and Installing, refer to «[For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#interior-lights-switches-coupe)
4. Fuel filler door unlock motor -V155- Removing and Installing, refer to «FUEL FILLER DOOR UNLOCK MOTOR V155»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe__fuel-filler-door-unlock-motor-v155)
5. Motor for rear lid release -V139
6. Driver door control module -J386
7. Engine hood contact switch -F266- Removing and Installing, refer to «HOOD SWITCH F266»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe__hood-switch-f266)

Special tools and workshop equipment required

1. Socket wrench T10011
2. Box spanner 3320/2
3. Socket 3410

Note. For various assembly work, the entire door can be completely raise from the door hinges after electrical connectors on lower >>A<< pillar have been disconnected. Adjustments must not be made after installation.

Scheme 73

1. Door plate -- Pull bellows down from >>A<< pillar. -- Disconnect electrical connectors on bottom of >>A<< pillar. -- Loosen screw -4- on top of door hinge. -- Remove bottom combination screw -9- on bottom of door hinge. -- Remove cover cap from hinge bolt. CAUTION: Protect painted surfaces on door and fender from damage. -- Carefully lift door up and out of hinges.
2. Upper door hinge, upper part No replacement part. Remains installed on door side.
3. Upper door hinge, lower part No replacement part. Remains installed on >>A<< pillar.
4. Securing nut 25 Nm
5. Cover Attach to nut.
6. Securing spring Only installed on replacement part. Remove after installing new hinge.
7. Bottom door hinge, upper part -- Remove any tension between upper and lower parts on bottom of door hinges if necessary with screwdriver, for example. No replacement part. Remains installed on door side.
8. Bottom door hinge, lower part No replacement part. Remains installed on >>A<< pillar.
9. Combination screw 32 Nm

DOOR SEALS

Special tools and workshop equipment required

1. Roller 3356
2. Adhesive strip remover VAS 6349

Roadster Inner Door Seal DOOR SEALS

Note. The inner door seal is glued on and must be replaced. Adhesion surfaces must be free of dust and grease. Both the vehicle and the seal must be room temperature.

Coupe Inner Door Seal

Scheme 74

1. Door seal Removing and installing with lower A-pillar trim, sill trim and B-pillar trim removed. Refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-coupe) . Removing -- Remove door seal all around from flange or from upper seal guides and side window. Installing: -- First press door seal into seal guide at upper B-pillar -arrow-. -- Then press door seal into seal guide at upper A-pillar -arrow-. -- First press door seal into seal guide at center of door frame, then along the entire length. -- Press bottom of door seal onto side window seal guide. -- Then, beginning at center and working out, press door seal completely into seal guide in the side window area. -- Press door seal onto door flange at lower B-pillar. -- Then press door seal on between side window and lower B-pillar, beginning at center and working out. -- Press door seal onto door flange at lower A-pillar. -- Then press door seal onto door flange between A-pillar and lower B-pillar, starting at the center and working out. -- Press door seal on completely between upper and lower A-pillar, beginning at center and working out.
2. Roof frame seal Pressed onto flange in roof frame
3. Roof trim molding

Scheme 75

1. Front seal NOTE: Pull out the protective films of the adhesive strips on the side only at the end of installation and firmly press the seal onto the roof frame. Upper A-pillar trim and roof frame trim removed. Refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-coupe) -- Unscrew the screws and remove the front seal starting at the >>A-pillar<<. -- Remove any adhesive residue from where the seal was secured with adhesive tape. -- Adhesion surfaces must be free of dust and grease, clean with cleaning solution D 009 401 04 -Reinigungslosung-. -- Attach the seal to the upper left and right corners of the roof flange. -- Slide the seal on the roof frame -- Attach the seal in a downward direction onto the flange of the >>A-pillar<<. -- Secure the upper seal with the left and right screws. -- Gradually pull the protective film to the side via the removal tabs out from between the roof frame and the seal and press the seal onto the roof frame with a roller 3356.
2. Inner door seal Lower A-pillar trim, sill panel, and rear panel trim removed. Refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-coupe) -- Remove the door seal around the body flange and under the front seal. -- Remove any adhesive residue from where the seal was secured with adhesive tape. -- Adhesion surfaces must be free of dust and grease, clean with cleaning solution D 009 401 04 -Reinigungslosung-. -- Place the door seal in the vehicle following the contour. -- Remove the protective films from the double-sided adhesive tape and press it onto the >>B-pillar<< on the left and right. -- Press the door seal on the >>B-pillar down onto the body flange<< -- Slide the door seal onto the >>A-pillar<< on the front seal. CAUTION: The door seal must be installed without a gap at the junction to the front seal. -- Press the door seal in the lower radii areas onto the flange while distributing any excess length in the sill area. -- Align the molded pieces of the door seal on the >>upper B-pillar<< with respect to the side piece and install. -- Press the door seal on both sides backward in the convertible top compartment onto the body flange.
3. Water tray Attach the door seal to the water tray as shown in the magnified area of the illustration -arrow-.

Replacing Outer Door Seal

Note. The door outer seal is completely bonded and can only be replaced. Adhesion surfaces must be free of dust and grease. Both the vehicle and the seal must be room temperature.

Scheme 76

1. Outer door seal NOTE: Before removing, mark the position on the door, for example with adhesive tape. Removing -- Bend the seal lengthwise and then pull it off little by little «DOOR SEALS»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe__door-seals) . Installation -- Clean the adhesive surface, if necessary, remove any remaining adhesive with adhesive strip remover VAS 6349. NOTE: Align the outer door seal to the corner of the lower B-pillar. Press the outer door seal beginning from the lower b-pillar according to the markings, working outward towards the top and front in steps. Position the distance marking for new doors -a- = 14 mm along the radius on the under side of the door. -- The outer door seal must make contact with -arrow- the door cover in the upper B-pillar area. -- Remove the protective film from the under side of the door to the B-pillar. -- Press on the outer door seal beginning from the lower B-pillar on the under side of the door and working forward and upward. -- Remove the protective film in stages upwardly and press on the outer door seal. CAUTION: Do not stretch or crush the seal when installing it. The seal will come off wherever it is stretched or crushed along the bottom or on the B-pillar. -- Only press the outer door seal onto the outer door seal end with a roller 3356, refer to «DOOR SEALS»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe__door-seals) . CAUTION: Do not close the door for at least 2 hours to prevent loosening or moving the door outer seal. The vehicle must be at room temperature.
2. Window shaft strip Press the window shaft strip tab -arrows- completely into the door cover on the upper B-pillar.

Scheme 77

Note. Pulling the seal laterally will loosen the adhesive and then it is possible to remove the door outer seal without any left over adhesive on it.

Bend and remove the door outer seal laterally as illustrated -arrow-.

Proceed the same way and remove the door outer seal completely.

Remove any left over adhesive with adhesive strip remover VAS 6349.

Scheme 78

Raise the outer door seal in direction of arrow -A- and press down firmly on the end of the outer door seal in direction of arrow -B- using the roller 3356.

Scheme 79

1. Door window Removing and installing, refer to «FRONT DOOR WINDOW»(/audi/tt/8j-2006-2010/remont/windows/#glass-window-regulators-coupe__front-door-window)
2. Window regulator Door trim removed. Refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-coupe) -- Window removed. -- Door inner panel cover removed «WINDOW REGULATOR»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe) -- Disconnect or unclip electrical wires. -- Window regulator motor removed. -- Remove nuts -4- and -7-. -- Lift the window regulator out of the door through the side door opening.
3. Door
4. Nut 8 Nm
5. Bolt 3.5 Nm
6. Window regulator motor NOTE: The power window motor can be removed or installed with the motor or side window in any position. To activate window regulator up/down function with motor installed and wires connected: Switch on ignition. Run window up as far as stop and release switch. Then hold switch for approximately 2 seconds in "window close" position. Up/down function is now activated.
7. Nut 8 Nm

Window regulator side adjustment

Scheme 80

1. Window regulator
2. Door
3. Nut 8 Nm
4. Nut 8 Nm
5. Adjusting screw For side adjustment, window regulator can be adjusted via the adjusting screws. -- Loosen nuts -3- and install or remove adjusting screws corresponding to door seal on roof or rear window.

Window regulator height adjustment

Note. The height of the window regulator can be adjusted without removing door trim.

Scheme 81

1. Window regulator To adjust, run window regulator all the way down. Guide 5 mm hex socket head wrench through door panel from below into adjusting screws and -arrows- and adjust.
2. Rear driver Rear adjusting screw -arrow
3. Front driver Front adjusting screw -arrow

Window regulator motor, removing

Door trim removed. Refer to Removal and Installation

Bolt -2- 3.5 Nm

Scheme 82

Note. The power window motor can be removed or installed with the motor or side window in any position. Before removing motor, disconnect electrical harness connectors.

Remove bolts -2- and remove nut -1- from threaded pins.

Installation

When installing, ensure threaded pins -3- engage with retainers in inner door panel.

Slide window regulator motor -1- onto threaded pin -3- and secure with screws -2-.

Note. Only switch ignition on after installing motor and connecting wires. Then move door window upward to stop and keep pressing switch for window regulator for approximately. 2 seconds longer. This position is the base position and the high- and low-running function is activated.

Inner door panel rear cover, removing and installing

Scheme 83

1. Inside door release mechanism cable
2. Grommet Must be pressed into cover -4- completely.
3. Door inner panel
4. Cover To removal, release cover retaining tabs in stages using a thin object. Retaining tab location

Scheme 84

Release retainers -arrows- on cover -1- from inner door panel -2- in stages using a thin object.

Replace seal -3- if necessary

Inner door panel front covers, removing and installing

Scheme 85

Insert centering pin -arrow- on cover -1- into inner door panel -4- and press on.

Replace seal -2- on cover -3- if necessary.

>>A-pillar<< trim, removing

Scheme 86

1. Trim Attach trim from above as shown -arrow- and secure with bolt -4-.
2. Door
3. Outer window shaft strip Trim -1- removed for disassembly.
4. Bolt 2.5 Nm

Coupe side impact member

It is removed and installed through the oblong hole for the bellows.

Scheme 87

To install impact member -1-, slide in through oblong hole in door -2- and tighten bolts -3- to 12 Nm.

Roadster side impact member

It is removed and installed through the oblong hole for the bellows.

Scheme 88

For installation, insert the impact member through the oblong hole into the door.

First insert the impact member into the hole on the A-pillar and then secure slightly with screw -1-.

Then secure impact member -2- with bolt -1-.

Tighten the screws from back to front starting on the B-column with 12 Nm.

Scheme 89

Bolt -1- 3.5 Nm

Insert side protective cushion in door and secure with bolts.

Scheme 90

To remove, drill out rivet heads and drive out rivet shafts.

Outer Window Shaft Strip, Removing and Installing

Scheme 91

1. Door
2. Spring nut Pressed into door flange.
3. Window shaft strip Door trim and door window removed. Refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-coupe) -- Remove A-pillar trim. Remove bolts and remove window shaft strip. When installing, align shaft strip on B-pillar and secure with bolts -4-.
4. Bolt 1.5 Nm

Inner window shaft strip, removing and installing

Scheme 92

1. Door
2. Inner window shaft strip The door trim panel is removed. Door window removed. -- To installed, slide into guide rail on >>A-pillar<<. -- Attach shaft strip to >>A-pillar<< -arrow-. -- Then clip into door at >>B-pillar<<. -- Press shaft strip onto door flange from above.
3. Door window
4. >>A-pillar<< trim

Scheme 93

1. Door lock Door trim removed. Refer to «Removal and Installation»(/audi/tt/8j-2006-2010/remont/exteriorinterior-trim/#interior-trim-coupe) . The door lock can be removed without removing window regulator. Removing, refer to «DOOR LOCK ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe)
2. Bolt 20 Nm
3. Anti-theft cover Slid onto door panel «DOOR HANDLE AND DOOR LOCK»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe)
4. Bracket Removing and installing with door handle and lock cylinder handle removed. Cable, disengaging at door lock To remove, remove the bolt -11-, slide mounting bracket slightly to rear and remove from door.
5. Actuating link Engage in door lock DOOR HANDLE ASSEMBLY OVERVIEW
6. Rear backing Insert in door panel
7. Lock cylinder housing Removing -- Unclip cover cap on front side of door. -- Remove door handle. -- Remove bolt as far as stop using socket wrench (AF T20). -- With light pressure on bold, release lock cylinder and remove sideways from door. Installing: -- Cover cap -8- must be attached before installing.
8. Cover Attached to lock cylinder.
9. Door handle
10. Front backing Attach to door handle.
11. Bolt 2.5 Nm.

Anti-theft cover, removing

Scheme 94

The anti-theft cover -1- is slid between the door lock -2- and mounting bracket -3- onto the door panel -4- as shown.

Lock cylinder, removing and installing

Scheme 95

Pry off cover -1-.

Pull door handle and hold firmly.

Remove bolt -2- as far as stop using socket wrench (AF T20).

The lock cylinder housing is only completely released with light pressure on the socket wrench or bolt.

Remove lock cylinder housing -2- sideways from door or mounting bracket.

Installation

Reverse order of removal.

HOOD SWITCH F266

Note. Central locking functions electronically. Actuators in doors are integrated in the door lock and have 2 motors. Actuators cannot be replaced separately. The first motor locks the door and the second motor locks the interior door mechanism (Safe function). Now, doors also can no longer be opened from the interior. After an accident in which the airbag deploys, the central locking system control module opens any doors which were locked. The central locking control module is located inside the right rear side panel.

Removing

Scheme 96

Note. When installing, position cable ties in same place.

Remove bumper FRONT BUMPER .

Remove the bolts -arrows-.

Remove air guide -1-.

Remove the nuts -1- and bolts -3- and -4-.

Scheme 97

Remove brace -6-.

Detach bottom theft protection -2- from lock carrier -5- -arrows- and remove.

Remove the electrical harness connector from the bracket by releasing the retaining bracket -5-.

Scheme 98

Disconnect the connector -4-.

Cut through cable tie -1-.

Thread the wiring harness out of the lock carrier.

Unlock retaining bracket -3- and detach and remove the hood contact switch -F266- in the -direction of the arrow- from lid lock -2-.

Installation

1. For the correct tightening specifications, refer to «HOOD LOCKS ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/exterior-body-panels/#hood-lids-coupe) .

Install in reverse order of removal. Note the following

Install the bumper FRONT BUMPER .

FUEL FILLER DOOR UNLOCK MOTOR V155

Note. Central locking functions electronically. Actuators in doors are integrated in the door lock and have 2 motors. Actuators cannot be replaced separately. The first motor locks the door and the second motor locks the interior door mechanism (Safe function). Now, doors also can no longer be opened from the interior. After an accident in which the airbag deploys, the central locking system control module opens any doors which were locked. The central locking control module is located inside the right rear side panel.

Special tools and workshop equipment required

Scheme 99

1. Socket wrench T10010.

Assembly Overview

Scheme 100

1. Emergency release
2. Bracket
3. Fuel filler door unlock motor -V 155- Installing «FUEL FILLER DOOR UNLOCK MOTOR V155»(/audi/tt/8j-2006-2010/remont/door-locks-anti-theft-systems/#front-doors-central-locking-system-coupe__fuel-filler-door-unlock-motor-v155)
4. Fuel Filler Door Release Cable
5. Fuel filler door Removing «FUEL FILLER DOOR»(/audi/tt/8j-2006-2010/remont/exterior-body-panels/#hood-lids-coupe)
6. Bolt With bracket -2- installed, loosen bolts clockwise using Socket Wrench T10010. 2 Nm
7. Nut 9 Nm

Fuel filler door emergency release cable routing

Scheme 101

1. Emergency release motor
2. Emergency release clip Press into emergency release bracket.
3. Emergency release bracket

Fuel Filler Door Unlock Motor, Installing

Scheme 102

Insert emergency release clip -2- in motor -1-.

Insert motor in bracket -2- and tighten with bolts -1-.

Scheme 103

Guide emergency release -2- through clip -3- on motor -1-.

Scheme 104

Connect emergency release -2- to cable -3-.

Scheme 105

Insert cable -1- in operating rod -2- and turn until it engages audibly.

Scheme 106

Slide emergency release cap -3- onto operating rod and press cable bracket -2- into bracket mount -arrow-.

Scheme 107

Secure assembly -2- in upper wheel housing with nuts -1-.

Scheme 108

SPECIAL TOOLS

Special tools and workshop equipment required

Scheme 109

Scheme 110

Scheme 111

1. Template T40038/7
2. Roller 3356
3. Adjusting gauge 3371
4. Socket wrench T10011
5. Box spanner 3320/2
6. Socket 3410

Scheme 112

See also:
• Removal and Installation
• [For transmission(s) 02E] [For engine(s) CBRA, BPY, CETA, CCTA, CEPB, CDMA] Removal and Installation
• FRONT DOOR WINDOW
• FRONT BUMPER
• HOOD LOCKS ASSEMBLY OVERVIEW
• DOOR LOCK ASSEMBLY OVERVIEW
• FUEL FILLER DOOR UNLOCK MOTOR V155
• HOOD SWITCH F266
• DOOR SEALS