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1994-1995 Audi Avant RS2 Workshop Service Repair Manual

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The Audi RS2 Avant, produced between 1994 and 1995, represents a unique collaboration between Audi and Porsche, creating an exclusive, high-performance estate car. Built upon the Audi 80/90 Avant (Type...
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Tipo: Car
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SKU: 149554
1994-1995 Audi Avant RS2 Workshop Service Repair Manual
The Audi RS2 Avant, produced between 1994 and 1995, represents a unique collaboration between Audi and Porsche, creating an exclusive, high-performance estate car. Built upon the Audi 80/90 Avant (Type 89 chassis) and manufactured at Porsche's Rossle-Bau facility, this model is renowned for its exceptional performance, largely thanks to Porsche's significant tuning of the powertrain, suspension, and brakes. It features a 2.2-liter, 5-cylinder turbocharged engine producing 315 PS, paired with a Getrag 6-speed manual transmission and Audi's Quattro all-wheel-drive system. Its distinctive styling, including Porsche-sourced body enhancements, further sets it apart, blending practicality with supercar-level capabilities, making it a highly sought-after collector's item. This comprehensive workshop service repair manual provides factory-level detail essential for the maintenance and repair of your Audi RS2 Avant. It covers all major mechanical and electrical systems, including detailed procedures for engine overhaul, transmission and drivetrain maintenance, brake system servicing, suspension and steering, and electrical component diagnosis. The manual also includes scheduled maintenance guidelines, troubleshooting advice, and critical technical specifications such as torque settings and fluid capacities. Its scope is designed to assist both professional technicians and dedicated enthusiasts in keeping this iconic vehicle in optimal condition, ensuring its performance and longevity.
🏷️ Basic Information
Identification
Make:
Audi
Model:
RS2 Avant
Year:
1994-1995
Codes
Chassis Code:
PO (Type 89 Avant base)
Engine Code:
ADU
👋 Introduction
Market Position
Positioning:
Exclusive, high-performance estate car, a collaboration between Audi and Porsche.
Competitive Analysis
Competitors:
BMW M5 Touring (E34), Mercedes-Benz 500E/E500 Estate (W124 - though not a direct estate competitor in this era, conceptually similar performance segment).
Key Features
Performance Focus:
Enhanced performance via Porsche-tuned engine and chassis.
Distinctive Styling:
Porsche-sourced front bumper with integrated fog/turn signals, larger alloy wheels, body kit.
Practicality And Performance:
Combines the practicality of an Audi Avant with supercar-level performance.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive factory service and repair
Page Count
Estimated Page Count:
Likely 1000+ pages (typical for full workshop manuals of this era and complexity)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English (Primary)
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical (disassembly, assembly, inspection, overhaul), lubrication, cooling, fuel injection (Bosch Motronic 2.3.2), ignition, emissions control.
Transmission:
Manual transmission (Getrag G360) overhaul, clutch, driveshafts, differential.
Drivetrain:
Quattro all-wheel-drive system (center differential, rear differential, front axle).
Brakes:
Brake system overhaul (front and rear discs, calipers - Alcon), ABS (Bosch ABS 2S).
Suspension:
Front and rear suspension components, steering system, alignment specifications.
Electrical:
Engine management system, lighting, instrumentation, power windows, mirrors, central locking, audio system, wiring diagrams.
Body:
Body panel removal and installation, interior trim, bumpers, glass, seals, corrosion protection.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, belt adjustments, spark plug replacement.
Repair:
Detailed step-by-step repair procedures for all major mechanical and electrical components.
Troubleshooting:
Diagnostic procedures and troubleshooting guides for common issues, fault codes.
Rebuilding:
Complete engine rebuild procedures, transmission overhaul, differential rebuild.
Specification Data:
Torque specifications, clearances, tolerances, fluid capacities, electrical specifications.
Technical Depth
Depth:
Factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF (depending on scan quality)
Print Quality
Printability:
Printable pages
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-5, turbocharged, intercooled
Displacement:
2226 cc (2.2 Liters)
Bore X Stroke:
81.0 mm x 86.4 mm
Compression Ratio:
8.5:1
Valvetrain:
DOHC, 4 valves per cylinder (20 valves total)
Performance
Horsepower:
315 PS (311 bhp; 232 kW) at 6000 rpm
Torque:
450 Nm (332 lb-ft) at 2700 rpm
Redline:
6500 rpm (approx.)
Fuel System
Fuel Delivery:
Bosch Motronic 2.3.2 electronic fuel injection
Fuel Type:
Unleaded gasoline (95 RON recommended)
Turbocharger
Turbocharger Details:
K24 turbocharger with intercooler, boost pressure 1.3 bar (18.85 psi) absolute.
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Gearbox Manufacturer:
Getrag (Model G360)
Features
Drivetrain:
Permanent All-Wheel Drive (Quattro) with Torsen center differential.
Clutch:
Hydraulically operated single dry plate clutch.
📐 Dimensions
Exterior
Length:
4,408 mm (173.5 in)
Width:
1,720 mm (67.7 in) (excluding mirrors)
Height:
1,405 mm (55.3 in)
Wheelbase:
2,610 mm (102.8 in)
Weights
Curb Weight:
1,520 kg (3,351 lbs)
Gross Vehicle Weight:
2,100 kg (4,630 lbs)
Cargo
Cargo Volume:
Approx. 460 liters (rear seats up), expandable with seats folded.
🛡️ Safety Features
Ratings
Safety Certification:
No formal Euro NCAP or NHTSA ratings available for this specific model due to era.
Active Features
ABS:
Bosch ABS 2S (Anti-lock Braking System)
Passive Features
Airbags:
Driver airbag (standard), optional passenger airbag.
Seatbelts:
Front and rear seatbelts, front pre-tensioners.
Body Construction:
Reinforced safety cell, crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory Audi Gamma CD/Radio system or similar period-appropriate units.
Driver Assistance
ABS:
Bosch ABS 2S system.
Connectivity
Connectivity Features:
Limited by era; primarily focused on in-car entertainment and basic vehicle functions. No modern smartphone integration or navigation systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000-15,000 km or 12 months (recommend checking original manual).
Timing Belt Interval:
Every 80,000-100,000 km or 5-7 years (critical due to interference engine design).
Spark Plug Replacement:
Every 30,000-60,000 km (depending on plug type, copper vs. platinum).
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-40 or 10W-40 (synthetic recommended for performance).
Engine Oil Capacity:
Approx. 5.0 liters (4.2 US quarts) with filter change.
Coolant Type:
G12 (Audi/VW specific pink coolant) or equivalent ethylene glycol-based coolant.
Transmission Fluid Type:
SAE 75W-90 GL-5 gear oil.
Differential Fluid Type:
SAE 75W-90 GL-5 gear oil (for front and rear differentials).
Brake Fluid Type:
DOT 4
Known Issues
Common Problems:
Turbocharger wear/failure, oil leaks (e.g., valve cover gaskets, oil cooler seals), suspension component wear, ABS sensor issues, ECU (Engine Control Unit) failures, paint delamination (common for the era).
Performance Tuning Challenges:
Over-reliance on boost can stress original components; requires careful management.
📚 Vehicle History
Brand Heritage
Heritage Connection:
Builds on Audi's reputation for Quattro all-wheel drive technology and practical estate cars.
Model Evolution
Predecessor Influence:
Based on the Audi 80/90 Avant (Type 89 chassis).
Porsche Collaboration:
Developed and built by Porsche in their Rossle-Bau facility in Zuffenhausen, Germany. Porsche engineers significantly modified the powertrain, suspension, brakes, and body.
Production
Production Period:
March 1994 to June 1995
Production Volume:
Approximately 1,777 units produced.
Manufacturing Location:
Rossle-Bau facility, Zuffenhausen, Germany.
🏆 Awards & Recognition
Recognitions
Performance Accolades:
Widely regarded as an automotive icon, a unique homologation special, and one of the fastest estate cars of its time. Often cited in 'greatest cars' lists.
Ratings
Collector Status:
Highly sought after by collectors and enthusiasts, commanding significant value.
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