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1991 Audi 100 (C4-4A) Service and Repair Manual PDF Download
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Basic Information Identification Make: Audi Model: 100 Year: 1991 Codes Chassis Code: C4-4A Introduction Market Position Segment: Executive Sedan / Luxury Mid-size Sedan Brand Perception: Premium, advanced engineering, quattro all-wheel...
Tipo: car
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SKU: 81771
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Audi
car
Manual
Repair Guide
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| Basic Information | |
| Identification | |
| Make: | Audi |
| Model: | 100 |
| Year: | 1991 |
| Codes | |
| Chassis Code: | C4-4A |
| Introduction | |
| Market Position | |
| Segment: | Executive Sedan / Luxury Mid-size Sedan |
| Brand Perception: | Premium, advanced engineering, quattro all-wheel drive reputation |
| Competitive Analysis | |
| Key Competitors 1991: | BMW 5 Series (E34), Mercedes-Benz E-Class (W124), Lexus LS 400 (though higher segment), Cadillac DeVille |
| Key Features | |
| Drivetrain Options: | Front-wheel drive (FWD) and permanent all-wheel drive (quattro) |
| Platform Design: | C4 platform, known for robust construction and aerodynamic styling |
| Interior Quality: | High-quality materials, ergonomic design, advanced features for its time |
| Manual Details | |
| Coverage Areas | |
| All Models Variants: | Yes |
| Repair Scope: | A-Z (All Repairs) |
| Page Count | |
| Estimated Pages: | Extensive (typical for factory service manuals, often 1000+ pages) |
| Manual Type | |
| Type: | Factory Service Manual (FSM) |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Powertrain: | Engine mechanical, engine electrical, fuel system, ignition system, exhaust system, transmission (manual and automatic), drivetrain, clutch |
| Chassis: | Suspension (front and rear), steering system, braking system (including ABS), wheels and tires |
| Body And Interior: | Body construction, exterior trim, doors, windows, interior trim, seats, climate control system (HVAC), audio system |
| Electrical And Electronics: | Wiring diagrams, lighting, instruments, charging system, starting system, power accessories, control modules, diagnostic trouble codes (DTCs) |
| Procedures Included | |
| Maintenance: | Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections |
| Repair And Rebuild: | Engine overhaul, transmission overhaul, component replacement, system diagnostics, electrical repairs, body panel repair |
| Diagnostics And Troubleshooting: | Step-by-step diagnostic procedures, fault finding charts, symptom-based troubleshooting |
| Technical Depth | |
| Depth: | Comprehensive; covers basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures |
| Manual Specifications | |
| File Format | |
| Digital Format: | |
| Print Quality | |
| Scan Quality: | High-resolution (assumed, based on description of dealership use) |
| Binding Type | |
| Binding: | N/A (Digital PDF Download) |
| Paper Type | |
| Paper Quality: | N/A (Digital PDF Download) |
| Engine Specifications | |
| Primary Engine 1 | |
| Engine Code And Type: | AAH (2.8L SOHC V6 90°) |
| Displacement Liters: | 2.8 |
| Horsepower Ps: | 172 PS @ 5500 rpm (approximate, varies slightly by market/spec) |
| Torque Nm: | 245 Nm @ 3000 rpm (approximate) |
| Fuel System: | Bosch Motronic fuel injection (typically Motronic M2.3 or M2.4) |
| Ignition System: | Electronic ignition with distributor |
| Valve Train: | SOHC (Single Overhead Camshaft) per bank, 2 valves per cylinder |
| Other Available Engines | |
| Engine Options: | 5-cylinder gasoline engines (e.g., 2.3E, 2.3E-20V), 5-cylinder diesel engines (e.g., 2.5 TDI), 2.2L 5-cylinder gasoline (prior to C4 in some markets), potentially turbo variants in some regions (e.g., S4 variants). |
| Transmission | |
| Standard | |
| Transmission Options: | 5-speed manual transmission |
| Optional | |
| Transmission Options: | 4-speed automatic transmission (ZF 4HP22 or similar) |
| Features | |
| AWD System: | Torsen T-3 center differential for quattro models, typically with rear open differential (early models) or optional rear limited-slip differential (LSD). |
| Maintenance | |
| Manual Transmission Fluid Spec: | API GL-4 or GL-5, SAE 75W-90 (Check manual for exact spec) |
| Automatic Transmission Fluid Spec: | G 052 162 A1 (or equivalent Dexron-III compatible fluid, consult manual for specific Audi specification) |
| Dimensions | |
| Exterior | |
| Length Mm: | 4787 mm (approx.) |
| Width Mm: | 1778 mm (approx.) |
| Height Mm: | 1430 mm (approx.) |
| Weights | |
| Curb Weight Kg: | 1450 - 1600 kg (depending on engine and drivetrain) |
| Gross Vehicle Weight Rating Kg: | Approx. 2000 - 2150 kg |
| Cargo | |
| Trunk Volume Liters: | Approximately 550 liters (sedan) |
| Safety Features | |
| Ratings | |
| Crash Test Data Availability: | Limited public data for 1991 models, but designed to meet European safety standards of the era. |
| Active Features | |
| ABS: | Anti-lock Braking System (ABS) available/standard on many models |
| Traction Control: | Traction Control System (ASR - Automatic Slip Regulation) available on some quattro models |
| Passive Features | |
| Airbags: | Driver-side airbag standard on many models, passenger airbag optional or unavailable depending on market and configuration. |
| Seatbelts: | Front and rear seatbelts, pre-tensioners for front seatbelts on some models |
| Body Structure: | Integrated safety cage, crumple zones |
| Technology Features | |
| Infotainment | |
| Audio System: | Factory AM/FM stereo cassette player, optional CD player, often with premium speaker systems (e.g., Bose on higher trims). |
| Climate Control Tech: | Manual or optional automatic climate control (Climatronic). |
| Driver Assistance | |
| Cruise Control: | Standard or optional cruise control |
| Connectivity | |
| Connectivity Features: | N/A (No modern connectivity features like Bluetooth or USB) |
| Lighting | |
| Headlights: | Halogen headlights, aerodynamic design for the era. |
| Maintenance | |
| Service Intervals Gasoline | |
| Oil Change Interval: | Typically 10,000 km or 6 months (whichever comes first), though consult the specific manual for precise intervals and oil type. |
| Spark Plug Replacement: | e.g., 30,000 - 60,000 km depending on plug type (e.g., copper vs. platinum/iridium). |
| Timing Belt Replacement: | Crucial for V6 and 5-cylinder engines. Typically 60,000 - 90,000 km or 5-7 years. Failure causes catastrophic engine damage. |
| Service Intervals Diesel | |
| Diesel Fuel Filter: | Recommended replacement every 20,000 - 40,000 km |
| Fluid Specifications | |
| Engine Oil Spec: | VW 500 00, 501 01, or 502 00 (depending on specific engine and oil formulation), typically SAE 5W-40 or 10W-40. Consult manual for exact spec. |
| Coolant Spec: | G 11 specification (blue/green coolant), often a 50/50 mix with distilled water. |
| Brake Fluid Spec: | DOT 3 or DOT 4 |
| Known Issues | |
| Engine Mechanical: | Timing belt failure (critical), oil leaks from seals and gaskets (valve cover, oil pan), potential for head gasket issues with age. |
| Electrical: | Degradation of wiring insulation (especially around engine bay), failure of dashboard illumination, HVAC control issues, central locking problems, vacuum hose degradation affecting climate control. |
| Suspension: | Worn control arm bushings, ball joints, tie rod ends, rear torsion beam bushings (if applicable), strut/shock absorber wear. |
| Fuel System: | Clogged fuel injectors, failing fuel pumps, aging fuel lines. |
| Climate Control: | Vacuum leaks affecting mode control, blower motor resistor failure, compressor clutch issues. |
| Vehicle History | |
| Brand Heritage | |
| Audi Heritage: | Founded in 1910, known for engineering innovation, advanced automotive technology, and performance. |
| Model Evolution | |
| Audi 100 Evolution: | The C4 generation, launched in 1991, represented a significant redesign from the C3, featuring a more rounded, aerodynamic body, improved interior, and upgraded powertrain options, including the introduction of the V6 engine as a primary offering. |
| Production | |
| Production Period: | 1991 - 1994 (for C4 generation Audi 100) |
| Manufacturing Locations: | Germany (primary), also potentially in other Volkswagen Group facilities. |
| Model Line Notes | |
| Evolution To A6: | The C4 generation Audi 100 was facelifted and renamed Audi A6 in 1994, marking a shift in Audi's naming convention. |
| Awards & Recognition | |
| Recognitions | |
| Industry Recognition: | The C4 generation was generally well-regarded for its build quality, driving dynamics (especially quattro models), and comfort, often reviewed favorably against its German and Japanese luxury competitors. |
| Ratings | |
| Reliability Perception: | Mixed; while mechanically robust, complex European electronics can be a source of issues if not maintained. Critical to adhere to maintenance schedules, especially for the timing belt. |