Market Position:
The Audi 200 of the 1991 model year represented Audi's upper-mid-range executive sedan, positioned against competitors like the BMW 5 Series and Mercedes-Benz E-Class. It emphasized Quattro all-wheel drive, refined interiors, and a more performance-oriented approach compared to some rivals.
Competitive Analysis:
Competed primarily on its advanced Quattro all-wheel-drive system, turbocharged engine options (in certain markets/trims), and German build quality. It offered a strong blend of performance and luxury for its era.
Key Features:
Available with 2.3L 5-cylinder naturally aspirated or turbocharged engines, standard or optional Quattro all-wheel drive, luxurious interior appointments, advanced (for the time) safety features, and a focus on aerodynamic design.
Systems Covered:
Engine mechanical, engine fuel & emissions, engine electrical, transmission (manual & automatic), driveline, steering, suspension, brakes, body & chassis, heating & air conditioning, electrical system, body interior, body exterior, maintenance, troubleshooting, diagnostic codes, specifications.
Estimated Page Count:
Approximately 1500-2000 (typical for full factory service manuals of this era)
Manual Type:
Factory Service Manual / Repair Manual
Engine Mechanical:
Complete overhaul procedures, cylinder head, block, pistons, crankshaft, camshaft, timing, valve train, lubrication system, cooling system.
Engine Fuel And Emissions:
Fuel injection systems (K-Jetronic, KE-Jetronic, CIS-E), fuel pumps, injectors, fuel lines, emission control systems (catalytic converter, EGR, O2 sensors).
Engine Electrical:
Ignition system, starter motor, alternator, battery, wiring diagrams, sensors (crankshaft, camshaft, coolant temp), ECU functions.
Transmission And Driveline:
Manual transmission (gearbox disassembly/assembly, clutch, synchros), Automatic transmission (torque converter, valve body, planetary gears, hydraulic system), differential, CV joints, driveshafts, Quattro AWD system (if applicable).
Suspension And Steering:
Front and rear suspension components (struts, shocks, control arms, bushings, springs), steering rack, power steering system, wheel alignment specifications.
Brakes:
Front and rear brake systems (disc brakes), ABS system (if equipped), hydraulic lines, master cylinder, calipers, brake pad/rotor replacement, bleeding procedures.
Body And Chassis:
Body construction, frame, panel removal/installation, door mechanisms, window regulators, convertible top (if applicable), chassis lubrication.
HVAC:
Heating and air conditioning system operation, refrigerant, compressor, blower motor, control panels, ducting, leak testing.
Electrical System And Accessories:
Lighting system, power windows, power locks, mirrors, central locking, radio, dashboard instruments, warning lights, fuses, relays, battery charging system.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, belt inspection/replacement, fluid checks and changes.
Repair:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation across all covered systems.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting, fault code interpretation, common problems and their solutions.
Diagnostics:
Procedures for diagnosing issues with engine management, fuel systems, ignition, ABS, and other electronic components. Includes OBD-I diagnostic connector location and basic codes.
Technical Depth:
Comprehensive. Covers everything from basic fluid level checks and filter changes to full engine rebuilds, transmission overhauls, and complex electrical system diagnostics.
Engine Displacement 1:
2.3 Liters (2309 cc)
Engine Configuration 1:
Inline 5-cylinder, SOHC
Engine Code 1:
NG (Naturally Aspirated, CIS-E Fuel Injection)
Horsepower 1 Na:
Approx. 134 hp @ 5500 rpm
Torque 1 Na:
Approx. 145 lb-ft @ 3500 rpm
Engine Code 2:
KG (Turbocharged, K-Jetronic Fuel Injection)
Horsepower 1 Turbo:
Approx. 165 hp @ 5500 rpm
Torque 1 Turbo:
Approx. 200 lb-ft @ 3000 rpm
Fuel Injection System Na:
Bosch CIS-E (Continuous Injection System - Electronic Control)
Fuel Injection System Turbo:
Bosch K-Jetronic (Continuous Injection System - Mechanical)
Fuel Type:
Unleaded Gasoline (Premium Octane Recommended)
Oil Change Interval:
Typically every 7,500-10,000 miles (12,000-15,000 km) or annually, whichever comes first. Consult manual for specific intervals based on driving conditions.
Timing Belt Replacement Interval:
Every 60,000 miles (96,000 km) or 4-5 years for the 5-cylinder engines. Critical to replace to prevent severe engine damage.
Engine Oil Specification:
API SG or higher, SAE 5W-40 or 10W-40 recommended depending on climate. Check manual for exact viscosity and API rating.
Coolant Specification:
G11 (blue/green) ethylene glycol-based antifreeze mixed 50/50 with distilled water. Specific capacity varies by engine/radiator size.
Transmission Fluid Manual:
GL-4 Gear Oil, SAE 75W-90 or 80W-90. Capacity approx. 2.1-2.3 liters.
Transmission Fluid Automatic:
Dexron III (or equivalent ATF). Capacity approx. 3.5-4.0 liters for fluid change.
Brake Fluid Specification:
DOT 3 or DOT 4.
Common Issues 1:
Fuel distributor leaks/malfunctions (especially K-Jetronic), ignition module failures, ABS sensor failures, timing belt tensioner issues, cooling system leaks (water pump, hoses), CV joint wear, minor electrical gremlins.
Common Issues 2:
Head gasket leaks, differential seals, door lock actuators, power window motors, exhaust system corrosion.
Oil Filter Part Number Example:
Mann-Filter W 917/2 or equivalent (verify for specific engine)
Air Filter Part Number Example:
Mann-Filter C 24 202 or equivalent (verify for specific engine)
