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1994 1995 Audi RS2 Workshop Manual

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The Audi RS2 Avant, produced between 1994 and 1995 under the Type 8C chassis code, represents a unique collaboration between Audi and Porsche. This high-performance estate car, powered by a...
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1994 1995 Audi RS2 Workshop Manual
The Audi RS2 Avant, produced between 1994 and 1995 under the Type 8C chassis code, represents a unique collaboration between Audi and Porsche. This high-performance estate car, powered by a 2.2-liter turbocharged inline-5 engine producing over 300 horsepower and featuring the renowned Quattro all-wheel-drive system, is celebrated for its exceptional blend of practicality and supercar-level performance. Its limited production numbers and distinctive engineering, including Porsche-tuned components and assembly, have cemented its status as a highly sought-after vehicle among performance car enthusiasts and collectors seeking a rare and capable estate. This comprehensive workshop manual offers detailed guidance for the Audi RS2 Avant, covering a vast array of systems and procedures. It includes in-depth information on engine mechanicals, fuel injection, turbocharging, the 6-speed manual transmission, drivetrain, suspension, brakes, steering, and the electrical system. The manual provides routine maintenance schedules, diagnostic procedures, repair and rebuild instructions, and essential technical specifications. With over 1500 pages of content, this English-language resource is designed to assist owners, mechanics, and technicians in effectively maintaining, diagnosing, and repairing the vehicle, ensuring its optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Audi
Model:
RS2 Avant
Year:
1994-1995
Codes
Chassis Code:
Type 8C
Engine Code Prefix:
ADU
👋 Introduction
Market Position
Segment:
High-performance estate car (station wagon), often considered a supercar in disguise.
Competitive Analysis
Competitors:
BMW M3 Touring (E36) (though rare), Porsche 911 (964/993) in terms of performance, other potent European performance sedans/estates.
Key Features
Unique Selling Proposition:
Collaboration between Audi and Porsche, 300+ horsepower from a modified 5-cylinder engine, all-wheel drive, practical estate body style, limited production numbers.
Target Audience
Enthusiasts:
Performance car enthusiasts, Audi collectors, those seeking a unique and highly capable performance estate.
📋 Manual Details
Coverage Areas
Scope:
Comprehensive workshop manual for the Audi RS2 Avant.
Page Count
Approximate Pages:
1500+
Manual Type
Type:
Workshop Manual / Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF (likely digital download for sales purposes)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, inspection, cylinder head, pistons, crankshaft, camshafts, valve timing.
Engine Management:
Fuel injection system (Bosch Motronic), ignition system, sensors, actuators, emissions control.
Turbocharging:
K24 turbocharger, intercooler system, wastegate, boost control, diagnosis.
Transmission:
6-speed manual transmission (Getrag G360), clutch system, differential, driveshafts, propshaft.
Drivetrain:
Quattro permanent four-wheel drive system, Torsen center differential, viscous coupling, axle shafts.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, anti-roll bars, alignment specifications.
Brakes:
Front and rear disc brakes, ABS (Anti-lock Braking System), brake lines, calipers, master cylinder, hydraulic system.
Steering:
Power steering system, steering rack, steering column, hydraulic pump.
Electrical System:
Battery, alternator, starter motor, lighting, fuses, relays, wiring diagrams, ECUs.
Body And Trim:
Exterior body panels, interior trim, seats, doors, windows, sunroof, body repairs, corrosion protection.
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair.
Procedures Included
Maintenance:
Routine maintenance tasks, oil changes, filter replacements, spark plug replacement, fluid checks and changes.
Diagnostics:
Fault finding, troubleshooting guides for common issues, OBD-I diagnostic procedures.
Repair And Rebuild:
Detailed step-by-step instructions for component disassembly, repair, and reassembly.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Specifications:
Torque specifications, clearances, tolerances, test values.
Technical Depth
Depth:
Full workshop level, suitable for professional technicians and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Likely text-searchable (if scanned professionally).
Print Quality
Quality:
Dependent on source, but generally high-quality technical diagrams and text.
Binding Type
Binding:
N/A (for PDF format)
Paper Type
Paper Quality:
N/A (for PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-5 Cylinder, 20-valve, DOHC, turbocharged and intercooled.
Displacement:
2226 cc (2.2 Liters)
Bore X Stroke:
81.0 mm x 86.4 mm
Compression Ratio:
9.0:1
Turbocharger:
Garrett K24
Boost Pressure:
Approx. 1.4 bar (1.1 bar overboost)
Performance
Horsepower:
315 PS (311 bhp) @ 6000 rpm
Torque:
410 Nm (302 lb-ft) @ 3000-4000 rpm
Fuel System
Injection:
Bosch Motronic M2.3.2 Fuel Injection
Fuel Type:
Unleaded Premium Gasoline (95-98 RON / 91-93 AKI)
Engine Oil
Oil Specification:
API SG or ACEA A3/B3 (e.g., 5W-40, 10W-40)
Oil Capacity:
5.5 Liters (with filter change)
🔧 Transmission
Standard
Type:
6-speed Manual
Manufacturer:
Getrag
Model Code:
G360
Optional
Type:
None
Features
Drivetrain:
All-Wheel Drive (Quattro)
Fluid Specifications
Manual Transmission Fluid:
GL-4/GL-5 Gear Oil (e.g., SAE 75W-90)
Fluid Capacity
Manual Transmission Fluid Capacity:
Approx. 2.0 Liters
📐 Dimensions
Exterior
Length:
4708 mm (185.35 in)
Width:
1715 mm (67.52 in)
Height:
1420 mm (55.91 in)
Wheelbase:
2613 mm (102.87 in)
Front Track:
1472 mm (57.95 in)
Rear Track:
1476 mm (58.11 in)
Cargo
Cargo Volume:
Approx. 460-1400 Liters (with rear seats folded)
Weights
Curb Weight:
1590 kg (3505 lbs)
Gross Vehicle Weight:
2100 kg (4630 lbs)
Towing Capacity:
1800 kg (3968 lbs)
Wheels And Tires
Wheel Size:
17 x 7.5J
Wheel Bolt Pattern:
5x112
Tire Size Standard:
245/40 ZR17
🛡️ Safety Features
Ratings
Crash Testing:
No official Euro NCAP or NHTSA ratings for this specific model/era, but built to high standards of its time.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
AWD:
Standard Quattro all-wheel-drive system for enhanced traction.
Passive Features
Airbags:
Driver airbag standard, passenger airbag often optional or standard in later production.
Seatbelts:
Three-point seatbelts with pre-tensioners for front occupants.
Body Structure:
Reinforced safety cage, crumple zones.
💡 Technology Features
Infotainment
Head Unit:
Original Audi Gamma CC cassette radio with CD changer control (optional).
Speakers:
Typically 8-speaker system.
Driver Assistance
Cruise Control:
Optional cruise control system.
Parking Sensors:
Not available.
Connectivity
Connectivity Options:
None from the factory; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10,000 - 15,000 km or annually.
Timing Belt Replacement:
Every 90,000 - 120,000 km or 5 years (critical).
Spark Plug Replacement:
Every 40,000 - 60,000 km (depending on type).
Fluid Specifications
Coolant Specification:
G12 Plus (or equivalent G12/G13) VW TL 774 C
Brake Fluid Specification:
DOT 4
Power Steering Fluid:
G 002 000 (or Pentosin CHF 11S equivalent)
Known Issues
Turbocharger:
Potential wear or failure of the K24 turbocharger, especially if poorly maintained.
Engine Seals:
Aging rubber seals and gaskets can lead to oil leaks.
Quattro System:
Clutch packs in viscous couplings or differentials can wear over time.
ABS:
ABS control module and sensors can fail.
Bodywork:
Rust can be an issue in common areas like wheel arches, sills, and around windows.
Electrics:
Aging wiring harnesses and connectors can cause intermittent electrical faults.
📚 Vehicle History
Brand Heritage
Audi Performance:
Audi has a long history of performance vehicles and motorsport success, notably with Quattro technology.
Model Evolution
Based On:
Based on the Audi 80 Avant (Type 8C) platform, but significantly re-engineered.
Development:
Developed by Audi's performance division Quattro GmbH in collaboration with Porsche.
Porsche Input:
Porsche provided chassis tuning, brakes, mirrors, and other components, and assembled the cars.
Production
Production Period:
March 1994 to June 1996
Production Numbers:
Approximately 662 cars produced.
Manufacturing Location:
Heilbronn, Germany (Porsche's assembly plant).
🏆 Awards & Recognition
Recognitions
Historical Impact:
Often considered one of the first and most iconic 'hot wagons' or 'super wagons'.
Collector Status:
Highly sought after by collectors and enthusiasts for its rarity, performance, and unique Porsche collaboration.
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