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Audi RS2 Avant 1983-1991 Workshop Service Repair Manual

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The Audi RS2 Avant, produced from 1994 to 1996, represents a significant milestone in automotive engineering, blending the practicality of an estate car with the performance capabilities of a sports...
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Type: Car
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Sku: 147657
Audi RS2 Avant 1983-1991 Workshop Service Repair Manual
The Audi RS2 Avant, produced from 1994 to 1996, represents a significant milestone in automotive engineering, blending the practicality of an estate car with the performance capabilities of a sports car. Developed in collaboration with Porsche, this limited-production model, with only approximately 662 units built, is based on the Audi 80 Avant (Type 8C/B4) and manufactured at Porsche's Zuffenhausen plant. It features a potent 2.2-liter inline 5-cylinder turbocharged engine producing 315 horsepower and 310 lb-ft of torque, paired with a 6-speed manual transmission and Audi's renowned Quattro all-wheel-drive system. Its unique positioning as one of the first 'super-estates' has cemented its status as a highly sought-after collector's item, celebrated by automotive press for its groundbreaking performance and versatility. This comprehensive workshop service repair manual in English provides detailed information essential for the maintenance, diagnosis, and repair of the Audi RS2 Avant. It covers a wide array of systems, including engine mechanicals and management, transmission and drivetrain, chassis, suspension, steering, brakes, ABS, and the electrical system. The manual includes procedures for routine maintenance, advanced repair and rebuilds, diagnostic troubleshooting, and offers full specifications and torque settings. Designed for owners with basic mechanical skills and independent auto service professionals, this manual empowers users with dealer-level specifications, enabling informed vehicle care and repair.
🏷️ Basic Information
Identification
Make:
Audi
Model:
RS2 Avant
Generation:
B4 (Type 8C)
Production Years Covered:
1983-1991
Codes
Chassis Code:
Type 8C
👋 Introduction
Market Position
Target Audience:
Owners with basic mechanical skills and independent auto service professionals.
Competitive Advantage:
Provides dealer-level specifications and procedures, enabling informed discussions with technicians and DIY repairs.
Key Features
Access Method:
Instant download upon payment, eliminating shipping costs and waiting times.
Digital Convenience:
Viewable on PCs, Macs, and various devices including phones and e-readers.
Empowerment:
Empowers owners to understand their vehicle, diagnose issues, and communicate effectively with mechanics.
📋 Manual Details
Coverage Areas
General Info:
Included
Engine Service And Overhauling:
Included
Transmission:
Included
Chassis:
Included
Body:
Included
Wiring:
Included
Fuel System:
Included
Emission Control:
Included
Induction:
Included
Mechanical:
Included
Control System:
Included
Transmission And Differentials:
Included
Troubleshooting And Diagnostics:
Included
Steering And Suspension:
Included
Brakes:
Included
ABS:
Included
Full Specifications And Torque Settings:
Included
Service Work:
Included
Page Count
Estimated Page Count:
Comprehensive (exact count not specified, but covers all listed areas extensively)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full overhaul, component testing, timing, lubrication, cooling system service.
Engine Management:
Fuel injection, ignition system, sensors, actuators, ECU diagnostics.
Transmission And Drivetrain:
Manual and automatic transmission service, differential overhaul, driveshaft and CV joint maintenance.
Suspension And Steering:
Front and rear suspension component replacement, alignment procedures, power steering system service.
Brakes And ABS:
Brake system service (discs, pads, calipers), hydraulic system repair, ABS component testing and diagnosis.
Electrical System:
Wiring diagrams, component testing, alternator, starter motor, battery system, lighting, instrumentation.
Body And Chassis:
Body panel repair, interior trim, doors, windows, seals, structural components.
Fuel And Emission Systems:
Fuel tank, lines, pump, injectors, exhaust system, emission control devices.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, belt adjustments, spark plug replacement.
Diagnostic Procedures:
Symptom-based troubleshooting, fault code interpretation, component testing methods.
Repair And Rebuild:
Detailed step-by-step instructions for component disassembly, repair, and reassembly.
Torque Specifications:
Precise torque values for all critical fasteners.
Wiring Diagram Tracing:
Detailed wiring diagrams with specific terminal pin connections and expected readings.
Special Tools:
Identification of specific tools required for certain procedures.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to advanced engine and transmission overhauling, suitable for independent professionals and informed owners.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Print Quality
Printability:
Printable on demand, allowing for individual page printing to avoid soiling.
Binding Type
Binding:
Not applicable (digital format)
Paper Type
Paper Quality:
Not applicable (digital format)
Searchability
Text Searchability:
Likely searchable text within the PDF for quick information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 5-cylinder, 20-valve, turbocharged and intercooled
Engine Code:
ADU (typically associated with this model's powertrain)
Displacement:
2.2 Liters (2226 cc)
Bore X Stroke:
81.0 mm x 86.4 mm (typical for this engine family)
Compression Ratio:
8.5:1 (typical for turbocharged application)
Performance
Horsepower:
315 hp @ 6000 rpm (for the RS2 Avant)
Torque:
310 lb-ft (420 Nm) @ 3000 rpm (for the RS2 Avant)
Fuel System
Fuel Delivery:
Bosch Motronic electronic fuel injection (EFI) with turbocharging
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
🔧 Transmission
Standard
Type:
6-speed manual transmission (Getrag G360 variant, modified)
Optional
Type:
Not applicable (only manual was offered in the RS2)
Features
Drivetrain:
Audi Quattro permanent all-wheel drive system
📐 Dimensions
Exterior
Length:
approx. 4500 mm
Width:
approx. 1720 mm
Height:
approx. 1430 mm
Weights
Curb Weight:
approx. 1630 kg
Gross Vehicle Weight Rating:
approx. 2200 kg
🛡️ Safety Features
Ratings
Crash Safety Era:
Vehicles from this era had less stringent standardized crash testing compared to modern standards.
Active Features
ABS:
Anti-lock Braking System (ABS) - standard
Traction Control:
Traction control system (ASR - Anti-Slip Regulation) may be present on some later models, but not standard on all.
Passive Features
Airbags:
Driver airbag was optional or standard depending on market and final build date. Passenger airbag was rare for the period.
Seatbelts:
Front and rear seatbelts, possibly with pre-tensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory fitted premium sound system, often with cassette player and amplifier.
Climate Control:
Automatic climate control system.
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Original Connectivity:
No modern connectivity features like Bluetooth or USB were standard; may have provisions for aftermarket additions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 - 10,000 miles or 12 months, whichever comes first (typical for performance vehicles of the era).
Timing Belt Replacement:
Every 50,000 - 60,000 miles or 5 years (critical due to interference engine design).
Fluid Specifications
Engine Oil Type:
Fully synthetic 5W-40 or 0W-40 (meeting VW 502.00/505.00 specifications).
Coolant Type:
G12 (or equivalent purple coolant) with a 50/50 mix of antifreeze and distilled water.
Transmission Fluid:
Refer to manual for specific G360 gearbox fluid. Typically a GL-4 rated gear oil.
Brake Fluid Type:
DOT 4
Known Issues
Turbocharger Wear:
Potential for turbocharger wear and oil leaks over time, especially if not maintained.
Suspension Bushings:
Wear in suspension bushings and control arm mounts can lead to imprecise handling.
Ignition System:
Older ignition components (coils, plugs) can degrade, leading to misfires.
Electrical Connectors:
Corrosion or degradation of electrical connectors, especially in older vehicles.
📚 Vehicle History
Brand Heritage
Audi Performance Division:
Developed by quattro GmbH (now Audi Sport GmbH) in collaboration with Porsche.
Model Evolution
Based On:
Based on the Audi 80 Avant (Type 8C/B4).
Unique Positioning:
Considered one of the first 'super-estates' or 'fast estates', blending practicality with supercar performance.
Production
Production Period:
1994-1996
Manufacturing Location:
Manufactured at Porsche's Zuffenhausen plant in Germany.
Production Volume:
Limited production run, approximately 662 units were built.
🏆 Awards & Recognition
Recognitions
Automotive Press:
Widely praised by automotive press at the time for its performance and practicality, often cited as a pioneer in the high-performance estate segment.
Collector Status:
Highly sought-after by collectors and enthusiasts due to its rarity and performance pedigree.
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