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Audi RS2 Avant 1994 1995 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Audi Model: RS2 Avant Production Years: 1994-1995 Codes Platform Code: PO4 Generation Generation Designation: B4 (8C) Avant basis 👋 Introduction Market Position Vehicle Class: High-performance...
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Audi RS2 Avant 1994 1995 Workshop Service Manual for RepairAudi RS2 Avant 1994 1995 Workshop Service Manual for RepairAudi RS2 Avant 1994 1995 Workshop Service Manual for RepairAudi RS2 Avant 1994 1995 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Audi
Model:
RS2 Avant
Production Years:
1994-1995
Codes
Platform Code:
PO4
Generation
Generation Designation:
B4 (8C) Avant basis
👋 Introduction
Market Position
Vehicle Class:
High-performance compact executive estate car (wagon).
Niche Appeal:
Iconic model developed in collaboration with Porsche, known for its blistering performance and practical usability.
Competitive Analysis
Key Competitors:
BMW M3 Touring (E36), Mercedes-Benz E36 AMG Estate (S124), Lancia Delta Integrale Evoluzione.
Key Features
Performance Focus:
Engineered for extreme performance, blending Audi's Quattro system with Porsche's powertrain and chassis expertise.
Exclusive Model:
Limited production run, making it a sought-after collector's item.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual
Language:
English
Format:
PDF
Page Count:
917
Download Type:
Instant Download
Printability:
Yes
Software Requirement:
Adobe Reader
Compatibility:
Windows, Mac, Linux OS
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul, repair, and diagnostics for the 2.2L turbocharged inline-5 engine.
Engine Management:
Ignition system, fuel injection system (Bosch Motronic), sensors, actuators, and ECU diagnostics.
Drivetrain:
Manual transmission (01E), Quattro all-wheel-drive system (center differential, viscous coupling, rear differential).
Suspension:
Front and rear suspension components, alignment specifications, and replacement procedures.
Brakes:
Front and rear brake system (including Porsche-sourced Brembo calipers), ABS system.
Steering:
Power steering system, steering rack, and components.
Electrical:
Wiring diagrams, lighting, instrumentation, starter, alternator, battery, fuses, relays, and comfort electronics.
Bodywork:
Body panel removal and installation, doors, windows, bumpers, and trim.
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair.
Fuel System:
Fuel tank, fuel pump, fuel lines, and fuel filter.
Procedures Included
Maintenance:
Routine maintenance tasks, service intervals, fluid changes, and inspections.
Diagnostics:
Troubleshooting guides, fault code interpretation, and diagnostic procedures for all major systems.
Repair:
Detailed step-by-step repair procedures for component replacement and overhaul.
Disassembly Assembly:
Comprehensive instructions for disassembling and reassembling all vehicle components.
Adjustment:
Precise instructions for adjusting various vehicle systems, including engine idle, timing, and suspension.
Installation:
Procedures for installing new or replacement parts and components.
Technical Depth
Depth Level:
Comprehensive, from basic maintenance to full engine rebuilds and complex electrical diagnostics.
Detail Level:
Step-by-step procedures, pictorial diagrams, exploded views, and detailed illustrations.
Special Tools:
References to specific Audi and Porsche special service tools with illustrations of their usage.
Technical Data:
Service data, specifications, tightening torques, wear limits, and factory specifications.
📊 Manual Specifications
File Quality
File Format:
PDF
Print Quality:
High resolution, printable pages.
Searchability:
Likely text-searchable within PDF, though not explicitly stated.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
ABY
Configuration:
2.2-liter turbocharged inline-5 cylinder (I5)
Displacement:
2226 cc
Aspiration:
Turbocharged with intercooler
Bore X Stroke:
81.0 mm x 86.4 mm
Compression Ratio:
8.5:1
Performance
Horsepower:
315 PS (311 hp; 232 kW) at 6500 rpm
Torque:
410 Nm (302 lb-ft) at 4500 rpm
Fuel System
Fuel Delivery:
Bosch Motronic M2.3.2 fuel injection
Fuel Type:
Unleaded gasoline, minimum 95 RON
Notes
Engine Development:
Based on the Audi 20-valve 5-cylinder engine, significantly upgraded by Porsche.
🔧 Transmission
Standard
Type:
6-speed manual transmission
Transmission Code:
01E
Optional
Type:
N/A
Features
Drivetrain:
Permanent all-wheel drive (Quattro)
Gear Ratios:
Specific gear ratios detailed within the manual.
📐 Dimensions
Exterior
Length:
4410 mm (173.6 in)
Width:
1700 mm (66.9 in)
Height:
1420 mm (55.9 in)
Weights
Curb Weight:
Approx. 1595 kg (3516 lbs)
Gross Weight Rating:
Not specified, consult manual.
Towing Capacity:
Not specified.
🛡️ Safety Features
Ratings
Crash Test Results:
No official ANCAP/Euro NCAP ratings for this specific era, but based on robust B4 chassis.
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
AWD:
Standard Quattro permanent all-wheel drive system for enhanced traction and stability.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point inertia-reel seatbelts with front-seat belt tensioners.
Body Structure:
Reinforced chassis and body structure from the Audi 80/90 Avant.
💡 Technology Features
Infotainment
Audio System:
Factory Audi/Bose sound system options available, though typically single-DIN units.
Navigation:
N/A (period appropriate)
Driver Assistance
Cruise Control:
Optional feature.
Climate Control:
Manual or optional automatic climate control (Climatronic).
Connectivity
Connectivity Features:
N/A (period appropriate)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual, typically 10,000-15,000 km or 12 months for synthetic oil.
Timing Belt Interval:
Crucial item, typically 90,000-120,000 km or 5-7 years. Consult manual for exact interval and associated components (tensioners, water pump).
Fluid Specifications
Engine Oil:
Refer to manual for specific viscosity and API/ACEA specifications (e.g., 5W-40 or 5W-50 synthetic).
Coolant:
G12 or G12+ ethylene glycol based coolant (pink/red) or equivalent, mixed with distilled water.
Brake Fluid:
DOT 4 or DOT 5.1 brake fluid.
Transmission Fluid:
GL-4 or GL-5 gear oil. Specific viscosity to be confirmed in manual.
Differential Fluid:
GL-5 gear oil. Specific viscosity to be confirmed in manual.
Known Issues
Engine:
Turbocharger wear, oil leaks (valve cover gaskets, oil pan), potential for cylinder head gasket issues if overheated.
Suspension:
Worn control arm bushings, ball joints, and shock absorbers due to performance demands.
Electrical:
Aging wiring harnesses, sensor failures (e.g., MAF sensor), intermittent electrical gremlins.
Body:
Rust in common Audi areas of the era (wheel arches, sills), door seal degradation.
📚 Vehicle History
Brand Heritage
Audi Performance History:
Audi's long history of rally success with Quattro, culminating in this road-going performance icon.
Model Evolution
Development Collaboration:
A joint venture between Audi Sport and Porsche, utilizing Porsche's expertise in engine tuning, suspension, and braking.
Basis Model:
Based on the Audi RS2 Avant, which itself was derived from the Audi 80 Avant (B4 platform).
Production
Production Period:
March 1994 - July 1995
Production Volume:
Approximately 2,891 units produced.
Manufacturing Location:
Zuffenhausen, Germany (Porsche's plant).
🏆 Awards & Recognition
Recognitions
Critical Acclaim:
Widely praised at the time for its groundbreaking performance and practicality, often cited as one of the fastest estate cars of its era.
Collector Status:
Considered a modern classic and a highly desirable performance car, earning it significant collector status.
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