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Audi 100 Workshop Service And Repair Manual 1986
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Basic Information Identification Make: Audi Model: 100 Model Generation: Third Generation (Type 443/444) Model Year: 1986 Codes Chassis Code: Type 443/444 Introduction Market Position Market Segment: Executive/Luxury Sedan and Wagon....
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UGS: 91351
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Manual
Repair Guide
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| Basic Information | |
| Identification | |
| Make: | Audi |
| Model: | 100 |
| Model Generation: | Third Generation (Type 443/444) |
| Model Year: | 1986 |
| Codes | |
| Chassis Code: | Type 443/444 |
| Introduction | |
| Market Position | |
| Market Segment: | Executive/Luxury Sedan and Wagon. Positioned as Audi's flagship model in its era, competing with Mercedes-Benz E-Class and BMW 5 Series. |
| Competitive Analysis | |
| Key Competitors 1986: | Mercedes-Benz W124 E-Class, BMW E28 5 Series, Volvo 700 Series, Saab 9000. |
| Key Features | |
| Aerodynamics: | Praised for its aerodynamic design, contributing to fuel efficiency and quietness. |
| Quattro AWD: | Introduction and increasing availability of the legendary quattro all-wheel-drive system, a significant differentiator. |
| Build Quality: | Known for solid build quality and robust construction characteristic of German luxury vehicles of the period. |
| Torsion Beam Suspension: | Innovation in rear suspension design (torsion beam axle in some front-drive models) for packaging and handling. |
| Manual Details | |
| Coverage Areas | |
| Primary Market: | Global (likely North America & Europe emphasis based on model year) |
| Included Variants: | Sedan (Saloon), Avant (Wagon) |
| Page Count | |
| Estimated Page Count: | 1500-2000+ pages (typical for comprehensive workshop manuals of this era) |
| Manual Type | |
| Manual Type: | Workshop Service and Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Engine assembly, cylinder head, pistons, crankshaft, camshafts, timing, lubrication system, cooling system, fuel injection system (CIS-E). |
| Engine Management: | Ignition system, electronic engine control unit (ECU) diagnostics and wiring diagrams, sensor functions. |
| Transmission Manual: | Clutch, gearbox overhaul, shift mechanism, drive shafts, differential. |
| Transmission Automatic: | Automatic transmission (e.g., ZF 4HP-22) overhaul, hydraulic control, torque converter, valve body, shift solenoids. |
| Suspension: | Front suspension (MacPherson struts, control arms), rear suspension (independent trailing arms/semi-trailing arms), shock absorbers, springs, wheel bearings. |
| Steering: | Power steering system, steering rack, steering column, hydraulic pump, steering fluid. |
| Brakes: | Front and rear disc brakes, brake calipers, master cylinder, brake booster, ABS (Anti-lock Braking System) operation and diagnostics (if equipped). |
| Electrical System: | 12V DC system, battery, alternator, starter motor, lighting system (headlights, taillights, interior), fuses, relays, wiring harnesses. |
| Body And Interior: | Body panels, doors, hood, trunk lid, interior trim, seats, dashboard, HVAC system (heating, ventilation, air conditioning). |
| Fuel System: | Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors. |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements, spark plug replacement, fluid level checks and top-ups, belt inspection and replacement. |
| Engine Repair: | Engine rebuild procedures, valve adjustments, head gasket replacement, timing belt/chain replacement, piston and rod installation. |
| Transmission Service: | Transmission fluid and filter changes, clutch replacement, automatic transmission overhaul, repair of common transmission faults. |
| Brake Service: | Brake pad and rotor replacement, caliper servicing, brake bleeding, master cylinder replacement, ABS component testing. |
| Suspension And Steering Repair: | Strut replacement, control arm bushing replacement, ball joint replacement, tie rod end replacement, power steering pump and rack repair. |
| Electrical Diagnostics: | Troubleshooting electrical faults, testing circuits, component replacement (alternator, starter, ignition coil), wiring diagram interpretation. |
| Bodywork And Collision Repair: | Panel alignment, rust repair techniques, door and latch adjustment, glass replacement. |
| HVAC Service: | Refrigerant handling (R12 or R134a depending on region/conversion), compressor replacement, blower motor replacement, heater core service. |
| Troubleshooting Guides: | Diagnostic tables for common symptoms, fault codes (if applicable), and step-by-step troubleshooting sequences. |
| Technical Depth | |
| Depth Level: | Comprehensive (from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics). |
| Diagnostic Capability: | Covers component testing, wiring diagrams, and diagnostic procedures for engine management and ABS systems. |
| Precision Details: | Includes torque specifications, clearances, timing marks, and alignment procedures. |
| Manual Specifications | |
| File Format | |
| File Type: | |
| Searchability: | Likely text-searchable PDF (depending on the source scan quality). |
| Print Quality | |
| Printability: | Designed to be printed for workshop use. |
| Binding Type | |
| Binding: | N/A (Digital PDF format) |
| Paper Type | |
| Paper Type: | N/A (Digital PDF format) |
| Completeness | |
| Completeness: | Full workshop manual coverage, not a condensed version. |
| Engine Specifications | |
| Primary Engine | |
| Engine Type 1986 Common: | Inline-5 Cylinder |
| Displacement Common: | 2.2 Liters (2144 cc) |
| Engine Code Common: | JN, KU, KG (Gasoline) |
| Fuel Delivery: | Bosch CIS-E (Continuous Injection System - Electronic) |
| Horsepower Common: | 115-137 hp (depending on variant and tuning) |
| Torque Common: | 126-140 lb-ft (depending on variant) |
| Performance | |
| Top Speed Approx: | 115-125 mph (185-200 km/h) |
| 0 60 Mph Approx: | 9.5 - 11.5 seconds |
| Fuel System | |
| Fuel Type: | Unleaded Gasoline (RON 91/95 recommended) |
| Fuel Tank Capacity: | Approximately 70 Liters (18.5 US Gallons) |
| Engine Variants Covered | |
| Available Engines: | Naturally aspirated 5-cylinder gasoline (2.0L, 2.2L), Turbocharged 5-cylinder gasoline (2.2L Turbo), 5-cylinder diesel (2.0L, 2.4L TDI). |
| Transmission | |
| Standard | |
| Standard Transmission Type: | 5-speed Manual Transaxle |
| Optional | |
| Optional Transmission Type: | 4-speed Automatic Transaxle (e.g., ZF 4HP-22) |
| Features | |
| Drivetrain: | Front-Wheel Drive (FWD) or Permanent All-Wheel Drive (quattro) |
| Manual Transmission Fluid: | GL-4 Gear Oil (e.g., SAE 75W-90 or SAE 80W-90) |
| Automatic Transmission Fluid: | Dexron II or equivalent (check specific ZF specifications) |
| Dimensions | |
| Exterior | |
| Wheelbase: | Approx. 2610 mm (102.8 inches) |
| Length Sedan: | Approx. 4755 mm (187.2 inches) |
| Width: | Approx. 1770 mm (69.7 inches) |
| Height Sedan: | Approx. 1420 mm (55.9 inches) |
| Cargo | |
| Trunk Capacity Sedan: | Approx. 570 Liters (20.1 cubic feet) |
| Weights | |
| Curb Weight Approx FWD: | 1250 - 1350 kg (2755 - 2976 lbs) |
| Curb Weight Approx Quattro: | 1350 - 1450 kg (2976 - 3197 lbs) |
| Safety Features | |
| Ratings | |
| Crash Test Era: | Pre-date standardized Euro NCAP and IIHS testing as we know it. Safety focused on structural integrity and passive restraints. |
| Active Features | |
| ABS Availability: | Optional on many models, standard on higher trims or specific engine/drivetrain configurations. ABS system was typically a Bosch 2-channel unit. |
| Passive Features | |
| Seat Belts: | Three-point inertia-reel seat belts front and rear. Pre-tensioners not common on this model. |
| Crumple Zones: | Designed with front and rear crumple zones for energy absorption in impacts. |
| Side Impact Protection: | Reinforced door beams for side impact protection. |
| Technology Features | |
| Infotainment | |
| Audio System: | Factory fitted radio cassette players (e.g., Grundig, Blaupunkt) with optional amplifiers and speaker upgrades. Some models may have early attempts at CD changers. |
| Driver Assistance | |
| Cruise Control: | Optional cruise control system available on many models. |
| Climate Control: | Manual or optional automatic climate control (Climatronic) available. |
| Connectivity | |
| Early Connectivity Features: | No modern connectivity like Bluetooth or USB. Communication systems were limited to basic radio/telephone integration (if factory fitted). |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 10,000 km (6,200 miles) or 12 months, whichever comes first (standard recommendation for the era). |
| Air Filter Replacement: | Every 20,000 km (12,400 miles) or 24 months. |
| Spark Plug Replacement: | Every 30,000 km (18,600 miles) for standard plugs, potentially longer for platinum plugs if fitted. |
| Timing Belt Replacement: | Every 60,000 km (37,000 miles) or 4-5 years for gasoline engines (critical maintenance item). |
| Fluid Specifications | |
| Engine Oil Spec: | API SF/SG or ACEA A2/A3, Viscosity SAE 10W-40 or 15W-50 recommended (check owner's manual for specific climate recommendations). |
| Coolant Spec: | Ethylene glycol based antifreeze, mixed 50/50 with distilled water for freeze protection and corrosion inhibition. |
| Brake Fluid Spec: | DOT 3 or DOT 4 brake fluid. |
| Known Issues | |
| Cis E Fuel Injection Quirks: | Deterioration of fuel distributor seals, air flow meter issues, incorrect mixture settings, vacuum leaks causing rough running. |
| Electrical Gremlins: | Corroded connectors, failing relays (especially fuel pump and starter relays), dashboard warning light issues, aging wiring insulation. |
| Cooling System Issues: | Leaking coolant pipes, radiator leaks, heater core leaks (especially problematic on the passenger side). |
| Suspension Wear: | Worn control arm bushings, strut top mounts, and ball joints leading to imprecise handling and noise. |
| Corrosion: | While galvanised, corrosion can still occur in wheel arches, sills, and around window seals, particularly in areas with heavy road salt use. |
| Vehicle History | |
| Brand Heritage | |
| Audi Heritage Post Wwii: | Audi's revival in the post-WWII era under Volkswagen Group, known for engineering innovation and premium positioning. |
| Model Evolution | |
| Audi 100 Evolution Type 44: | The Type 44 chassis replaced the Type 43. Introduced in 1982, it was a significant redesign, focusing on aerodynamics, comfort, and advanced technology for its time. The 1986 model is a mid-cycle refresh, with subtle styling and feature updates. |
| Key Innovations Type 44: | Introduction of the highly aerodynamic design, advanced galvanised steel unibody construction for corrosion resistance, and the widespread adoption of the sophisticated 5-cylinder engine and quattro AWD. |
| Production | |
| Production Period Type 44: | 1982-1991 |
| Manufacturing Locations: | Primarily Ingolstadt, Germany, with potential assembly in other VW Group facilities. |
| Awards & Recognition | |
| Recognitions | |
| Aerodynamic Awards: | The Type 44 Audi 100 was widely praised for its aerodynamic efficiency, achieving a low drag coefficient (Cd) for its time, which contributed to its quietness and fuel economy. It often featured in discussions about automotive aerodynamics. |
| Quattro Reputation: | The model benefited greatly from the growing reputation of Audi's quattro all-wheel-drive system, which was becoming synonymous with grip and performance, particularly in adverse conditions. |
| Certifications | |
| Build Quality Certification: | No specific external certifications, but the model was regarded for its durable chassis construction and advanced galvanization processes for its era, leading to good long-term rust resistance. |