Engine Mechanical:
Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing belt, oil pump, cooling system.
Engine Performance:
Fuel injection system (KE-Jetronic variants, fuel pump, injectors, fuel pressure regulator), ignition system (distributor, coils, spark plugs), emissions control, engine diagnostics.
Transmission:
Manual and Automatic transmission (identification, operation, disassembly, assembly, adjustments, torque converter, clutch, shifter mechanism).
Drivetrain:
Front-wheel drive, Quattro all-wheel drive system (differentials, driveshafts, CV joints).
Suspension:
Front and rear suspension components (struts, shock absorbers, control arms, bushings, anti-roll bars), alignment specifications.
Steering:
Power steering system (pump, rack and pinion, hydraulic lines, fluid), steering column, steering wheel.
Brakes:
Front and rear brake systems (discs, pads, calipers, master cylinder, brake booster, ABS system, parking brake).
Electrical System:
Battery, alternator, starter motor, wiring harnesses, fuses, relays, lighting circuits (exterior lamps, interior lamps, headlamp beam adjustment).
Body And Interior:
Body panels, doors, windows, locks, seat adjustments, seat belts, interior trim, defoggers, heating and ventilation (HVAC).
Comfort Systems:
Cruise control, power windows, power mirrors, central locking, memory column, seat heating (if equipped).
Infotainment:
Radio system (wiring, antenna, speakers), potentially navigation system (if equipped).
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, brake pad inspection.
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common and uncommon issues, diagnostic trouble codes (DTCs) interpretation (if OBD-I applicable), wiring diagram analysis.
Repair And Rebuild:
Detailed instructions for engine overhaul, transmission rebuild, suspension component replacement, brake caliper overhaul, electrical component repair.
Installation And Adjustment:
Component installation procedures, alignment adjustments, timing belt tensioning, clutch adjustment.
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, tolerances, and assembly sequences.
Service Intervals Engine Oil
Interval Miles:
7,500 - 10,000 miles or 12 months (whichever comes first) with synthetic oil.
Interval Km:
12,000 - 16,000 km or 12 months (whichever comes first) with synthetic oil.
Service Intervals Timing Belt
Interval Miles:
60,000 miles (96,000 km) or 4-5 years. Critical component, failure causes severe engine damage.
Service Intervals Transmission Fluid
Interval Miles Manual:
Check for leaks, change if contaminated or at high mileage (e.g., 80,000 - 100,000 miles).
Interval Miles Automatic:
Check fluid level and condition regularly. Change fluid and filter every 30,000 - 50,000 miles.
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
ATF Dexron II/III or Pentosin CHF 11S (confirm specific requirement).
Engine:
Coolant flange leaks (plastic), vacuum hose deterioration, timing belt tensioner wear, distributor O-ring leaks, possible valve stem seal wear leading to oil consumption.
Electrical:
Headlight switch failures, intermittent electrical gremlins due to aged wiring and grounds, ABS sensor issues.
Suspension:
Worn control arm bushings, sagging front springs, worn tie rod ends.
Fuel System:
Failing fuel pressure regulator on KE-Jetronic systems, injector seal leaks.
Maintenance Schedule Highlights
Spark Plugs:
Replace every 30,000 miles (platinum plugs may last longer).
Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Cabin Filter:
If equipped, replace annually.