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1991 Audi 100 (C3-44) Service and Repair Manual

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🏷️ Basic Information Identification Make: Audi Model: 100 Year: 1991 Codes Chassis Code: C3-44 👋 Introduction Market Position Positioning: The 1991 Audi 100 represented Audi's upscale offering in the executive sedan segment, competing with established European and American luxury brands. Competitive Analysis Competitors: Competed with vehicles such as the BMW 5 Series, Mercedes-Benz E-Class, and Volvo 240/740. Key Features Aerodynamics: The C3 platform was renowned for its advanced aerodynamics, contributing to fuel efficiency and reduced wind noise. Quattro AWD: Availability of the iconic Quattro all-wheel-drive system, a hallmark of Audi's performance and handling capabilities. Interior Design: Focus on high-quality materials, ergonomic design, and comfortable seating for a premium feel. 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z Page Count Estimated Page Count: 800+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnostic, repair, and overhaul procedures for gasoline engines, including fuel injection systems (KE-Jetronic), ignition systems, emissions control, cooling, and lubrication. Transmission: Comprehensive coverage of manual and automatic transmissions, including clutch operation, gear shifting mechanisms, torque converter systems, transmission fluid maintenance, and internal component repair. Brakes: In-depth information on hydraulic brake systems, ABS (Anti-lock Braking System) diagnosis and repair, parking brake systems, brake fluid specifications, and component replacement (master cylinder, calipers, rotors). Suspension Steering: Detailed procedures for front and rear suspension components (struts, shocks, control arms, bushings), steering system diagnosis and repair (power steering pump, rack and pinion), wheel alignment specifications. Electrical Electronics: Extensive coverage of the vehicle's electrical system, including wiring diagrams, battery, starting system, charging system (alternator), lighting, instrumentation, power windows, central locking, and electronic control units (ECUs). Climate Control: Diagnosis and repair of HVAC (Heating, Ventilation, and Air Conditioning) systems, including refrigerant handling, compressor service, blower motor, and climate control panel operations. Body Chassis: Information on body panel repair, door mechanisms, interior trim removal and installation, glass replacement, and chassis component maintenance. Procedures Included Maintenance: Regular service intervals, oil change procedures, filter replacements (oil, air, fuel), spark plug service, coolant flushes, brake inspections, and general preventative maintenance tasks. Diagnostics: Systematic troubleshooting guides, symptom-based diagnostics, fault code interpretation (where applicable), and diagnostic test procedures for all major systems. Repair: Step-by-step instructions for component removal, installation, and overhaul for all major mechanical and electrical systems. Torque Specifications: Detailed torque specifications for all critical fasteners, bolts, and nuts across various vehicle systems. Wiring Diagrams: Comprehensive and detailed electrical wiring diagrams for all vehicle circuits. Technical Depth Depth: Complete factory-level repair and diagnostic information, suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution, searchable text and clear diagrams for easy navigation and printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: Various, common include 2.3L 5-cylinder (NG, NF) Engine Type: Inline 5-cylinder, 20-valve (typically) Displacement: 2309 cc (2.3 Liters) Performance Horsepower: Approximately 130-136 hp @ 5600 rpm (depending on specific engine variant and market) Torque: Approximately 140-145 lb-ft @ 3000-3500 rpm (depending on specific engine variant and market) Fuel System Fuel Injection: Bosch KE-Jetronic CIS-E (Continuous Injection System - Electronic) Fuel Type: Unleaded Gasoline Cooling System Coolant Type: Ethylene Glycol based coolant (e.g., G11 specification) Lubrication Oil Capacity: Approximately 4.5 - 5.0 liters (with filter change, depending on engine variant) Recommended Oil Viscosity: 10W-40 or 15W-40 (refer to manual for specific ambient temperature ranges) 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission (e.g., ZF 4HP22) Features AWD System: Optional Quattro permanent all-wheel drive system available with both manual and automatic transmissions. Fluid Specifications Auto Atf Type: Dexron III or equivalent (check manual for exact specification) Fluid Specifications Manual Gear Oil Type: API GL-4 SAE 75W-90 or SAE 80W-90 (check manual for specific axle/transmission type) 📐 Dimensions Exterior Length: Approximately 4780 mm (188.2 inches) Width: Approximately 1770 mm (69.7 inches) Height: Approximately 1420 mm (55.9 inches) Wheelbase Wheelbase: Approximately 2687 mm (105.8 inches) Weights Curb Weight: Approximately 1350 - 1550 kg (2976 - 3417 lbs) depending on configuration Gross Vehicle Weight: Varies by model/engine, refer to VIN plate Wheels Tires Wheel Bolt Pattern: 5x112mm Standard Tire Size: Typically 195/65R15 or 205/60R15 (check specific model) 🛡️ Safety Features Ratings Crash Test Data: Limited standardized crash test data from this era compared to modern standards. Audi emphasized safety through its 'Procon-ten' system. Active Features ABS: Optional Anti-lock Braking System (ABS) available on many models. AWD: Quattro all-wheel-drive system offered significant improvements in traction and stability. Passive Features Airbags: Driver's airbag typically optional or standard on higher trims; passenger airbag was less common. Seatbelts: Front and rear seat belts, with front seat belt pretensioners often standard. Procon Ten: Audi's proprietary 'Procon-ten' passive safety system, which tightened seatbelts and moved the...
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Stichworte: 100 1991 44 Audi C3 Car
1991 Audi 100 (C3-44) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Audi
Model:
100
Year:
1991
Codes
Chassis Code:
C3-44
👋 Introduction
Market Position
Positioning:
The 1991 Audi 100 represented Audi's upscale offering in the executive sedan segment, competing with established European and American luxury brands.
Competitive Analysis
Competitors:
Competed with vehicles such as the BMW 5 Series, Mercedes-Benz E-Class, and Volvo 240/740.
Key Features
Aerodynamics:
The C3 platform was renowned for its advanced aerodynamics, contributing to fuel efficiency and reduced wind noise.
Quattro AWD:
Availability of the iconic Quattro all-wheel-drive system, a hallmark of Audi's performance and handling capabilities.
Interior Design:
Focus on high-quality materials, ergonomic design, and comfortable seating for a premium feel.
📋 Manual Details
Coverage Areas
Coverage Scope:
All models and all repairs A-Z
Page Count
Estimated Page Count:
800+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostic, repair, and overhaul procedures for gasoline engines, including fuel injection systems (KE-Jetronic), ignition systems, emissions control, cooling, and lubrication.
Transmission:
Comprehensive coverage of manual and automatic transmissions, including clutch operation, gear shifting mechanisms, torque converter systems, transmission fluid maintenance, and internal component repair.
Brakes:
In-depth information on hydraulic brake systems, ABS (Anti-lock Braking System) diagnosis and repair, parking brake systems, brake fluid specifications, and component replacement (master cylinder, calipers, rotors).
Suspension Steering:
Detailed procedures for front and rear suspension components (struts, shocks, control arms, bushings), steering system diagnosis and repair (power steering pump, rack and pinion), wheel alignment specifications.
Electrical Electronics:
Extensive coverage of the vehicle's electrical system, including wiring diagrams, battery, starting system, charging system (alternator), lighting, instrumentation, power windows, central locking, and electronic control units (ECUs).
Climate Control:
Diagnosis and repair of HVAC (Heating, Ventilation, and Air Conditioning) systems, including refrigerant handling, compressor service, blower motor, and climate control panel operations.
Body Chassis:
Information on body panel repair, door mechanisms, interior trim removal and installation, glass replacement, and chassis component maintenance.
Procedures Included
Maintenance:
Regular service intervals, oil change procedures, filter replacements (oil, air, fuel), spark plug service, coolant flushes, brake inspections, and general preventative maintenance tasks.
Diagnostics:
Systematic troubleshooting guides, symptom-based diagnostics, fault code interpretation (where applicable), and diagnostic test procedures for all major systems.
Repair:
Step-by-step instructions for component removal, installation, and overhaul for all major mechanical and electrical systems.
Torque Specifications:
Detailed torque specifications for all critical fasteners, bolts, and nuts across various vehicle systems.
Wiring Diagrams:
Comprehensive and detailed electrical wiring diagrams for all vehicle circuits.
Technical Depth
Depth:
Complete factory-level repair and diagnostic information, suitable for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution, searchable text and clear diagrams for easy navigation and printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
Various, common include 2.3L 5-cylinder (NG, NF)
Engine Type:
Inline 5-cylinder, 20-valve (typically)
Displacement:
2309 cc (2.3 Liters)
Performance
Horsepower:
Approximately 130-136 hp @ 5600 rpm (depending on specific engine variant and market)
Torque:
Approximately 140-145 lb-ft @ 3000-3500 rpm (depending on specific engine variant and market)
Fuel System
Fuel Injection:
Bosch KE-Jetronic CIS-E (Continuous Injection System - Electronic)
Fuel Type:
Unleaded Gasoline
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., G11 specification)
Lubrication
Oil Capacity:
Approximately 4.5 - 5.0 liters (with filter change, depending on engine variant)
Recommended Oil Viscosity:
10W-40 or 15W-40 (refer to manual for specific ambient temperature ranges)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission (e.g., ZF 4HP22)
Features
AWD System:
Optional Quattro permanent all-wheel drive system available with both manual and automatic transmissions.
Fluid Specifications Auto
Atf Type:
Dexron III or equivalent (check manual for exact specification)
Fluid Specifications Manual
Gear Oil Type:
API GL-4 SAE 75W-90 or SAE 80W-90 (check manual for specific axle/transmission type)
📐 Dimensions
Exterior
Length:
Approximately 4780 mm (188.2 inches)
Width:
Approximately 1770 mm (69.7 inches)
Height:
Approximately 1420 mm (55.9 inches)
Wheelbase
Wheelbase:
Approximately 2687 mm (105.8 inches)
Weights
Curb Weight:
Approximately 1350 - 1550 kg (2976 - 3417 lbs) depending on configuration
Gross Vehicle Weight:
Varies by model/engine, refer to VIN plate
Wheels Tires
Wheel Bolt Pattern:
5x112mm
Standard Tire Size:
Typically 195/65R15 or 205/60R15 (check specific model)
🛡️ Safety Features
Ratings
Crash Test Data:
Limited standardized crash test data from this era compared to modern standards. Audi emphasized safety through its 'Procon-ten' system.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on many models.
AWD:
Quattro all-wheel-drive system offered significant improvements in traction and stability.
Passive Features
Airbags:
Driver's airbag typically optional or standard on higher trims; passenger airbag was less common.
Seatbelts:
Front and rear seat belts, with front seat belt pretensioners often standard.
Procon Ten:
Audi's proprietary 'Procon-ten' passive safety system, which tightened seatbelts and moved the steering wheel forward in a frontal collision.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with cassette player, often with premium speaker options.
Climate Control Tech:
Manual or optional automatic climate control systems.
Driver Assistance
Cruise Control:
Standard or optional cruise control system.
Connectivity
Early Tech:
While not featuring modern connectivity, the C3 platform represented advanced automotive technology for its time, particularly with Quattro and aerodynamic design.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 7,500 - 10,000 miles (12,000 - 15,000 km) or 12 months, whichever comes first, depending on driving conditions.
Timing Belt:
Crucial maintenance item. Typically recommended replacement every 60,000 miles (96,000 km) or 4-5 years for 5-cylinder engines.
Spark Plugs:
Replacement at intervals of approximately 30,000 miles (48,000 km).
Fluid Specifications
Coolant Capacity:
Approximately 7.0 - 7.5 liters (depending on engine variant)
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for precise specification)
Known Issues
Wiring Harness:
Degradation of wire insulation, particularly in engine bay and door jambs, leading to electrical gremlins.
Fuel Distribution Head:
Potential issues with the KE-Jetronic fuel distributor head requiring specialized diagnosis and repair.
Cooling System:
Leaks from hoses, radiator, and water pump are common due to age; thermostat housing can also be a source of leaks.
Suspension Components:
Wear in control arm bushings, ball joints, and tie rod ends can affect handling and steering feel.
Oil Leaks:
Common oil leaks from valve cover gaskets, oil pan gaskets, and the rear main seal.
Common Repairs
Timing Belt Replacement:
Critical preventative maintenance due to interference engine design.
ABS Sensor Replacement:
ABS wheel speed sensors can fail, leading to ABS warning lights.
📚 Vehicle History
Brand Heritage
Origin:
Audi AG, a German automobile manufacturer, known for its engineering and the pioneering Quattro all-wheel-drive system.
Model Evolution
C3 Generation:
The C3 generation of the Audi 100 (Type 44) was produced from 1982 to 1991. The 1991 model year is the final iteration of this generation.
Production
Manufacturing Location:
Ingolstadt, Germany (primary)
Lifespan:
The Audi 100 nameplate was used from 1968 to 1994 before being rebranded as the Audi A6.
🏆 Awards & Recognition
Recognitions
Design Awards:
The C3 platform was noted for its advanced aerodynamic design, often cited in automotive design discussions of the era.
Ratings
Reliability Perception:
While generally well-built, specific components and the complex KE-Jetronic system can require diligent maintenance to maintain reliability.
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