1991 AUDI 100 And AVANT 4A 4A2 2A5 Service And Repair Manual
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🏷️ Basic Information Identification Make: Audi Model: 100 / 100 Avant Year: 1991 Chassis Codes: 4A (Sedan), 4A2 (Sedan), 2A5 (Avant - likely an internal or variant code, 4A chassis generally applies to Avant as well) Market Segment: Executive/Mid-size Luxury 👋 Introduction Market Position Positioning: The Audi 100 (Typ 4A) represented Audi's entry into the more premium mid-size sedan and wagon segment, competing with established European luxury brands. Competitive Analysis Competitors: BMW 5 Series, Mercedes-Benz E-Class, Volvo 240/740/940 series, Saab 9000. Key Features Audi Advancements: Known for its aerodynamic styling, advanced Quattro all-wheel-drive system, and a focus on build quality and driver comfort. Manual Purpose Purpose: To provide technicians and knowledgeable owners with the precise factory-level repair and maintenance procedures for the 1991 Audi 100/Avant. 📋 Manual Details Coverage Areas Primary Coverage: All 1991 Audi 100 and 100 Avant models Repair Scope: Comprehensive A-Z, vehicle-specific Page Count Estimated Page Count: Likely 800-1200+ pages (typical for comprehensive dealer-level manuals of this era) Manual Type Type: Service and Repair Manual Language Language: English Format Format: Print 📖 Manual Coverage Systems Covered Engine: Engine mechanical, diagnostics, fuel injection, ignition, emissions, cooling, lubrication, timing Transmission: Manual and Automatic transmission overhaul, diagnostics, operation, fluids Drivetrain: Front-wheel drive, Quattro all-wheel drive system (differentials, driveshafts, hubs) Suspension: Front and rear suspension components, alignment, shocks, springs, bushings Brakes: Hydraulic system, ABS (if equipped), brake pads, rotors, calipers, lines, master cylinder Steering: Power steering system, steering rack, tie rods, column Electrical: Complete wiring diagrams, starter, alternator, battery, lighting, instruments, power windows, locks, mirrors, climate control electronics Body: Body panel removal/installation, interior trim, glass, seals, chassis components HVAC: Heating, Ventilation, and Air Conditioning system operation, diagnostics, component replacement Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, tune-ups Diagnostics: Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD I era) Repair: Component disassembly, reassembly, adjustment, and replacement for all systems Technical Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values Technical Depth Depth: Dealer-level comprehensive, covering everything from routine maintenance to full engine and transmission rebuilds. Diagnostic Tools: Information on necessary special tools and diagnostic equipment for effective repair. 📊 Manual Specifications File Format Format: Printed Publication Print Quality Quality: High-quality, durable paper stock, clear diagrams and text. Binding Type Binding: Likely a sturdy comb or perfect binding, designed for workshop use. Paper Type Paper Quality: Durable, often coated paper to resist grease and workshop grime. ⚙️ Engine Specifications Primary Engine Engine Type: Inline 5-cylinder, naturally aspirated Displacement: 2.3 Liters (2309 cc) Bore X Stroke: 76.4 mm x 101.0 mm Compression Ratio: 10.0:1 (typical) Performance Horsepower: 130 PS (96 kW) @ 5,500 rpm (typical for the 2.3E) Torque: 182 Nm (134 lb-ft) @ 4,000 rpm (typical for the 2.3E) Fuel System Injection: Bosch KE-Jetronic CIS-E (CIS-Electronic Fuel Injection) Fuel Type: Unleaded Gasoline (Premium recommended) Engine Management Ignition: Electronic Ignition system (e.g., Digifant or similar) Emissions Control: Catalytic Converter, Lambda Sensor (O2 sensor), EGR (Exhaust Gas Recirculation) 🔧 Transmission Standard Standard Transmission: 5-speed Manual Optional Optional Transmission: 4-speed Automatic (ZF 4HP22) Features Drivetrain Options: Front-Wheel Drive (FWD) standard, Quattro All-Wheel Drive (AWD) optional on most models. Fluid Type Automatic Transmission Fluid: Dexron III or equivalent (refer to manual for specific Audi part number) Manual Transmission Fluid: Gear Oil GL-4 75W-90 or similar (refer to manual) Differential Fluid: API GL-5 75W-90 or similar (refer to manual) 📐 Dimensions Exterior Length: Approx. 4790 mm (Sedan) / 4817 mm (Avant) Width: Approx. 1778 mm Height: Approx. 1410 mm (Sedan) / 1450 mm (Avant) Wheelbase: Approx. 2760 mm Wheel Bolt Pattern: 5x112 Weights Curb Weight: Approx. 1450-1550 kg (depending on drivetrain and equipment) Gross Vehicle Weight: Refer to vehicle's VIN plate/sticker 🛡️ Safety Features Ratings Crash Test Era Context: Testing standards in 1991 were less stringent than today; specific NCAP ratings are unlikely to be readily available but the vehicle was designed with European safety standards of the time in mind. Active Features ABS: Anti-lock Braking System (ABS) often standard or optional on higher trims/Quattro models. Passive Features Airbags: Driver's airbag typically standard for 1991. Passenger airbag less common for this year/model. Seatbelts: Three-point inertia-reel seatbelts, height-adjustable front belts. Body Structure: Designed with crumple zones and a safety cage for occupant protection. 💡 Technology Features Infotainment Audio System: Factory-installed Audi sound systems, often with cassette player and AM/FM radio. Pre-wiring for CD changer might be present on later models. Driver Assistance ABS Implementation: ABS was a significant technology for its time, improving braking stability and reducing stopping distances under hard braking. Connectivity Pre Wiring: Limited by modern standards, but might have provisions for early cellular phones or aftermarket cruise control installations. Comfort Features Power Accessories: Power windows, power locks, and power mirrors were available, often standard on higher trims. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 10,000-15,000 km or 6-12 months (refer to manual...
4A (Sedan), 4A2 (Sedan), 2A5 (Avant - likely an internal or variant code, 4A chassis generally applies to Avant as well)
Market Segment:
Executive/Mid-size Luxury
👋 Introduction
Market Position
Positioning:
The Audi 100 (Typ 4A) represented Audi's entry into the more premium mid-size sedan and wagon segment, competing with established European luxury brands.
Competitive Analysis
Competitors:
BMW 5 Series, Mercedes-Benz E-Class, Volvo 240/740/940 series, Saab 9000.
Key Features
Audi Advancements:
Known for its aerodynamic styling, advanced Quattro all-wheel-drive system, and a focus on build quality and driver comfort.
Manual Purpose
Purpose:
To provide technicians and knowledgeable owners with the precise factory-level repair and maintenance procedures for the 1991 Audi 100/Avant.
📋 Manual Details
Coverage Areas
Primary Coverage:
All 1991 Audi 100 and 100 Avant models
Repair Scope:
Comprehensive A-Z, vehicle-specific
Page Count
Estimated Page Count:
Likely 800-1200+ pages (typical for comprehensive dealer-level manuals of this era)
Electronic Ignition system (e.g., Digifant or similar)
Emissions Control:
Catalytic Converter, Lambda Sensor (O2 sensor), EGR (Exhaust Gas Recirculation)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual
Optional
Optional Transmission:
4-speed Automatic (ZF 4HP22)
Features
Drivetrain Options:
Front-Wheel Drive (FWD) standard, Quattro All-Wheel Drive (AWD) optional on most models.
Fluid Type
Automatic Transmission Fluid:
Dexron III or equivalent (refer to manual for specific Audi part number)
Manual Transmission Fluid:
Gear Oil GL-4 75W-90 or similar (refer to manual)
Differential Fluid:
API GL-5 75W-90 or similar (refer to manual)
📐 Dimensions
Exterior
Length:
Approx. 4790 mm (Sedan) / 4817 mm (Avant)
Width:
Approx. 1778 mm
Height:
Approx. 1410 mm (Sedan) / 1450 mm (Avant)
Wheelbase:
Approx. 2760 mm
Wheel Bolt Pattern:
5x112
Weights
Curb Weight:
Approx. 1450-1550 kg (depending on drivetrain and equipment)
Gross Vehicle Weight:
Refer to vehicle's VIN plate/sticker
🛡️ Safety Features
Ratings
Crash Test Era Context:
Testing standards in 1991 were less stringent than today; specific NCAP ratings are unlikely to be readily available but the vehicle was designed with European safety standards of the time in mind.
Active Features
ABS:
Anti-lock Braking System (ABS) often standard or optional on higher trims/Quattro models.
Passive Features
Airbags:
Driver's airbag typically standard for 1991. Passenger airbag less common for this year/model.
Seatbelts:
Three-point inertia-reel seatbelts, height-adjustable front belts.
Body Structure:
Designed with crumple zones and a safety cage for occupant protection.
💡 Technology Features
Infotainment
Audio System:
Factory-installed Audi sound systems, often with cassette player and AM/FM radio. Pre-wiring for CD changer might be present on later models.
Driver Assistance
ABS Implementation:
ABS was a significant technology for its time, improving braking stability and reducing stopping distances under hard braking.
Connectivity
Pre Wiring:
Limited by modern standards, but might have provisions for early cellular phones or aftermarket cruise control installations.
Comfort Features
Power Accessories:
Power windows, power locks, and power mirrors were available, often standard on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 km or 6-12 months (refer to manual for exact specification).
Timing Belt Replacement:
Critical component. Recommended replacement interval around 90,000 - 120,000 km or 5-7 years (highly important for the 5-cylinder engine).
Spark Plugs:
Check and replace as needed, typically every 30,000-60,000 km depending on type (e.g., standard copper vs. platinum).
Fluid Specifications
Engine Oil Grade:
SAE 5W-30 or 5W-40 synthetic or semi-synthetic meeting API SG/SH specifications is common. Check manual for exact Audi approval.
Engine Oil Capacity:
Approx. 4.2 - 4.5 Liters (with filter)
Coolant Type:
G11 (blue/green) ethylene glycol-based coolant. Mixture ratio 50:50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Fuel System Reliability:
Bosch CIS-E can be sensitive to vacuum leaks; distributor rebuilds or seal replacements may be needed over time.
Electrical System:
Aging wiring harnesses, particularly grounds, and connector issues can lead to intermittent faults.
Suspension Bushings:
Worn suspension bushings (control arms, sway bars) are common due to age and mileage, impacting ride and handling.
Climate Control:
HVAC blower motor resistors, vacuum actuators for blend doors, and AC compressor clutch failures can occur.
📚 Vehicle History
Brand Heritage
Audi Legacy:
Audi's history is rooted in engineering excellence, particularly in quattro all-wheel drive technology and innovative drivetrain solutions.
Model Evolution
Typ 4A Introduction:
The Typ 4A Audi 100 was introduced in late 1990 for the 1991 model year, replacing the Typ 44 (C3) generation. It featured a completely new platform and design.
Design Philosophy:
Emphasis on aerodynamics (hence '100' signifying its aerodynamic drag coefficient), comfort, and advanced technology for its time.
Production
Manufacturing Location:
Ingolstadt, Germany
Generations Impact:
This generation (Typ 4A) laid the groundwork for the subsequent Audi A6, showcasing Audi's emerging design language and technological prowess.
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The Audi 100 generation received accolades for its design, comfort, and engineering, particularly its aerodynamic efficiency which was class-leading for its time.
Ratings
Design Awards:
While specific awards for the 1991 model might be hard to pinpoint, the overall Typ 4A design was considered a significant advancement and influenced subsequent automotive styling.