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...