Hướng dẫn sửa chữa thân vỏ xe Audi TT Type 8J KK MK2. Hỗ trợ kỹ thuật viên các hướng dẫn sữa chữa chuyên biệt cho các hạng mục sửa chữa liên quan đến phần thân vỏ, đảm bảo hiệu quả, chính xác
Service Body Repairs Audi TT 2007 ➤ Edition 09.2009 Service Department Technical Information Service Repair Group overview for Body Repairs Repair Group 00 - Technical data 50 - Body - front 51 - Body - centre 53 - Body - rear Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed All rights reserved No reproduction without prior agreement from publisher Copyright © 2010 Audi AG, Ingolstadt A008JKI0120 Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Contents 00 - Technical data 2.1 2.2 6.1 8.1 8.2 8.3 8.4 9.1 10 10.1 10.2 10.3 10.4 10.5 11 11.1 11.2 General notes Vehicle identification data Type plate and vehicle identification number Vehicle data sticker Expanded foam inserts General notes on repairs to aluminium parts General notes on repairs to steel parts Body construction Aluminium panels Corrosion protection Bonded joints Bonded joints Spot-welded/bonded joints Inspecting and repairing bonded joints Repair methods for replacing body parts Body panel gaps/shut lines Body - front and centre Body dimensions Floor group, front Floor group, rear Body - front Body - centre Body - rear Straightening jig Overview Portal gauge 1 2 8 10 11 11 11 11 11 12 12 15 15 16 17 19 20 21 21 34 50 - Body - front 36 1.1 1.2 2.1 2.2 3.1 3.2 4.1 4.2 5.1 5.2 6.1 6.2 Longitudinal member, upper part with console (Coupé and Roadster identical) Tools Procedure Support, left-side - Renewal (Coupé and Roadster identical) Tools Procedure Support, right-side - Renewal (Coupé and Roadster identical) Tools Procedure Upper longitudinal member for wheel housing - Renewal (Coupé and Roadster identical) Tools Procedure Suspension strut mounting - Renewal (Coupé and Roadster identical) Tools Procedure Longitudinal member for wheel housing, upper, inner - Renewal (Coupé and Roadster identical) Tools Procedure Front longitudinal member - Renewal (Coupé and Roadster identical) Contents 36 36 37 43 43 44 46 46 47 50 50 51 55 55 56 62 62 63 65 i Audi TT 2007 ➤ Body Repairs - Edition 09.2009 7.1 7.2 8.1 8.2 9.1 9.2 Tools Procedure Front longitudinal member - Partial renewal (Coupé and Roadster identical) Tools Procedure Longitudinal member (front section) - Renewal (Coupé and Roadster identical) Tools Procedure 65 66 70 70 71 73 73 74 51 - Body - centre 77 1.1 1.2 2.1 2.2 2.3 3.1 3.2 4.1 4.2 5.1 5.2 6.1 6.2 7.1 7.2 8.1 8.2 9.1 9.2 10 10.1 10.2 11 11.1 11.2 12 12.1 12.2 13 13.1 Roof - Renewal Tools Procedure Roof side member - Renewal Tools Procedure Foam-filling roof side member Outer roof frame - Renewal (Roadster) Tools Procedure Front roof cross member - Renewal Tools Procedure Rear roof frame - Renewal Tools Procedure Outer A-pillar - Renewal Tools Procedure Reinforcement tube and inner A-pillar - Renewal (Roadster) Tools Procedure Inner A-pillar - Renewal (Coupé and Roadster) Tools Procedure Inner B-pillar - Renewal (Roadster) Tools Procedure Outer side member - Renewal Tools Procedure Inner side member - Partial renewal (old part section) Tools Procedure Inner side member - Renewal (Roadster) Tools Procedure Floor panel - Renewal (Coupé and Roadster identical) Tools 77 77 78 88 88 89 91 102 102 103 107 107 107 110 110 110 114 114 115 122 122 123 128 128 129 135 135 136 141 141 142 149 149 150 154 154 155 165 165 53 - Body - rear 168 1.1 ii Contents Rear cross panel (top section) - Renewal (Coupé and Roadster identical) 168 Tools 168 Audi TT 2007 ➤ Body Repairs - Edition 09.2009 1.2 2.1 2.2 3.1 3.2 4.1 4.2 5.1 5.2 6.1 6.2 7.1 7.2 8.1 8.2 9.1 9.2 10 10.1 10.2 11 11.1 11.2 12 12.1 12.2 Procedure Cross panel (inner section) - Renewal (Coupé and Roadster identical) Tools Procedure Rain channel - Partial renewal Tools Procedure Rear suspension strut mounting - Renewal (Coupé and Roadster identical) Tools Procedure Rear longitudinal member - Partial renewal (Coupé and Roadster identical) Tools Procedure Side panel - Renewal (Coupé) Tools Procedure Side panel - Renewal (Roadster) Tools Procedure Inner side panel - Renewal Tools Procedure Rear wheel housing - Partial renewal (Coupé and Roadster identical) Tools Procedure Rear wheel housing - Renewal (Coupé and Roadster identical) Tools Procedure Spare wheel well - Partial renewal (Coupé and Roadster identical) Tools Procedure Spare wheel well - Renewal (Coupé and Roadster) Tools Procedure Contents 169 173 173 173 177 177 178 183 183 184 186 186 186 189 189 190 202 202 203 211 211 212 217 217 218 222 222 222 226 226 227 230 230 230 iii Audi TT 2007 ➤ Body Repairs - Edition 09.2009 iv Contents Audi TT 2007 ➤ Body Repairs - Edition 09.2009 00 – Technical data General notes This Manual describes only selected repair operations A de‐ scription is given where the repair method differs from the original manufacturing process Where the repair operation is not described: Separate the original joint and repair using a replacement part If no description is given for any sub-parts supplied, these should be matched up and butt welded with an SG continuous seam Please refer to the information in the Workshop Manual ⇒ General Information; Body Repairs, General Body Repairs General notes Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Vehicle identification data 2.1 Type plate and vehicle identification number The vehicle identification number -B- (chassis number) is stam‐ ped on the flange in the plenum chamber The type plate -A- is attached to the wing mounting flange (rightside) Rep Gr.00 - Technical data Audi TT 2007 ➤ Body Repairs - Edition 09.2009 2.2 Vehicle data sticker The vehicle data sticker is located in the spare wheel well at the rear of the vehicle Vehicle identification data Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Expanded foam inserts Various body cavities of the Audi TT 2007 are fitted with expanded foam inserts The foam inserts reduce the noise transmitted to the interior when driving These pre-moulded parts are fitted during body manufacture and subsequently increase their volume in the paint shop drying oven at approx 180 °C after priming Caution The replacement foam inserts expand only after reaching about 180°C For this reason, an additional filler foam is used when performing repairs Filler foam required for repairs: D 506 KG1 A3 As the required temperatures cannot be achieved under normal workshop conditions, proceed as follows: Remove residue of foam material on vehicle Restore paint coating; apply two coats (wet on wet) of glass/paint primer D 009 200 02 if necessary, flash-off time approx.10 mi‐ nutes Requirement Before continuing with this procedure, ensure that the replace‐ ment panel is ready for installation, i.e cut to shape, matched up to the vehicle, corrosion protection applied Renewing expanded foam insert Fix expanded foam insert to vehicle Apply filler foam D 506 KG1 A3 to replacement panel Secure new part in position Gently press in new part in vicinity of expanded foam insert until it makes contact, and then weld into place The foam hardens within 25 minutes Do not weld (SG) within 15 mm of the foam insert (on either side) After painting the vehicle the repaired area must be cavity-sealed Location of expanded foam parts Rep Gr.00 - Technical data Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Replacement part ♦ Wheel housing liner Preparing new part – Prepare joint on body side for joddle-joining using pneumatic punch and offset tool -VAS 1996- – Transfer separating cut to new part plus 15 mm for overlap Cut off hatched area – Drill holes for SG plug weld seam using drill -VAS 5830- Rear wheel housing - Partial renewal (Coupé and Roadster identical) 219 Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Welding in – Weld in new part using shielded arc welding equipment 250A -VAS 6045A- : SG continuous seam – Weld in new part from inside using shielded arc welding equip‐ ment 250A -VAS 6045A- : SG plug weld seam 220 Rep Gr.53 - Body - rear Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Rear wheel housing - Partial renewal (Coupé and Roadster identical) 221 Audi TT 2007 ➤ Body Repairs - Edition 09.2009 RO: 53 69 55 52 10 Rear wheel housing - Renewal (Coupé and Roadster identical) WARNING Always observe safety precautions Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes 10.1 Tools Special tools and workshop equipment required ♦ Resistance spot welder -VAS 6239 A♦ Resistance spot welder -VAS 6525♦ Resistance spot welder -VAS 6530♦ Resistance spot welder -VAS 6535♦ Resistance spot welder -VAS 6545♦ Drill -VAS 5830♦ Spot weld breaker -V.A.G 1731- ♦ Pneumatic sabre saw -V.A.G 1523A- 10.2 Procedure Cutting locations • Outer side panel already cut out • Inner side panel already cut out 222 Rep Gr.53 - Body - rear Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Note Protect adjacent aluminium parts adequately against sparks from welding and grinding operations; cover up or mask with adhesive tape as necessary – Separate original joint using spot weld breaker -V.A.G 1731- Replacement part ♦ Wheel housing liner Preparing new part – Drill holes for SG plug weld seam using spot weld breaker V.A.G 1731- 10 Rear wheel housing - Renewal (Coupé and Roadster identical) 223 Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Welding in – Weld in wheel housing liner using resistance spot welder -VAS 6239 A- : RP spot weld seam – Weld in wheel housing liner using shielded arc welding equip‐ ment 250A -VAS 6045A- : SG plug weld seam 224 Rep Gr.53 - Body - rear Audi TT 2007 ➤ Body Repairs - Edition 09.2009 10 Rear wheel housing - Renewal (Coupé and Roadster identical) 225 Audi TT 2007 ➤ Body Repairs - Edition 09.2009 RO: 53 80 55 50 11 Spare wheel well - Partial renewal (Coupé and Roadster identical) WARNING Always observe safety precautions Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes Note Protect adjacent aluminium parts adequately against sparks from welding and grinding operations; cover up or mask with adhesive tape as necessary 11.1 Tools Special tools and workshop equipment required ♦ Resistance spot welder -VAS 6239 A♦ Resistance spot welder -VAS 6525♦ Resistance spot welder -VAS 6530♦ Resistance spot welder -VAS 6535♦ Resistance spot welder -VAS 6545♦ Shielded arc welding equipment 250A -VAS 6045A♦ Drill -VAS 5830♦ Pneumatic punch and offset tool -VAS 1996- ♦ Spot weld breaker -V.A.G 1731- 226 Rep Gr.53 - Body - rear Audi TT 2007 ➤ Body Repairs - Edition 09.2009 ♦ Pneumatic sabre saw -V.A.G 1523A- 11.2 Procedure Cutting locations • Outer section of cross panel already cut out • Inner section of cross panel already cut out – Make separating cut with pneumatic sabre saw -V.A.G 1523Aso that body side of joint can be prepared for joddle-joining – Separate original joint using spot weld breaker -V.A.G 1731- 11 Spare wheel well - Partial renewal (Coupé and Roadster identical) 227 Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Replacement part ♦ Spare wheel well Preparing new part – Prepare joint on body side for joddle-joining using pneumatic punch and offset tool -VAS 1996- – Transfer separating cut plus 15 mm for overlap to new part – Drill mm ∅ holes for SG plug weld seam using drill -VAS 5830- Welding in – Weld in spare wheel well using shielded arc welding equip‐ ment 250A -VAS 6045A- : SG plug weld seam – Weld at separating cut using shielded arc welding equipment 250A -VAS 6045A- : SG continuous seam 228 Rep Gr.53 - Body - rear Audi TT 2007 ➤ Body Repairs - Edition 09.2009 11 Spare wheel well - Partial renewal (Coupé and Roadster identical) 229 Audi TT 2007 ➤ Body Repairs - Edition 09.2009 RO: 53 80 55 50 12 Spare wheel well - Renewal (Coupé and Roadster) WARNING Always observe safety precautions Safety notes ⇒ General Information; Body Repairs, General Body Repairs ; Safety notes Note Protect adjacent aluminium parts adequately against sparks from welding and grinding operations; cover up or mask with adhesive tape as necessary 12.1 Tools Special tools and workshop equipment required ♦ Resistance spot welder -VAS 6239 A♦ Resistance spot welder -VAS 6525♦ Resistance spot welder -VAS 6530♦ Resistance spot welder -VAS 6535♦ Resistance spot welder -VAS 6545♦ Shielded arc welding equipment 250A -VAS 6045A♦ Drill -VAS 5830♦ Spot weld breaker -V.A.G 1731- 12.2 Procedure Cutting locations • Upper section of cross panel already cut out • Inner section of cross panel already cut out – Separate original joint using spot weld breaker -V.A.G 1731- – Detach bolted joints 230 Rep Gr.53 - Body - rear Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Replacement part ♦ Spare wheel well Preparing new part – Drill mm ∅ holes for SG plug weld seam using spot weld breaker -V.A.G 1731- 12 Spare wheel well - Renewal (Coupé and Roadster) 231 Audi TT 2007 ➤ Body Repairs - Edition 09.2009 Welding in – Weld in spare wheel well using shielded arc welding equip‐ ment 250A -VAS 6045A- : SG plug weld seam – Re-secure bolted joints: tightening torque Nm 232 Rep Gr.53 - Body - rear Audi TT 2007 ➤ Body Repairs - Edition 09.2009 12 Spare wheel well - Renewal (Coupé and Roadster) 233