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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 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...
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Audi 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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