Manual Coverage
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Systems Covered
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Engine Mechanical:
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Engine overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing system (belts/chains), lubrication, cooling.
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Engine Management:
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Fuel injection systems (K-Jetronic, KE-Jetronic, Digifant), ignition systems, emissions control, sensors, actuators, ECU diagnosis.
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Transmission Manual:
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Clutch, gearbox overhaul, shift linkage, internal components, fluid specifications.
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Transmission Automatic:
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Torque converter, gearbox overhaul, valve body, control systems, fluid specifications, cooling.
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Drivetrain:
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Front-wheel drive axle shafts, CV joints, differentials, Quattro all-wheel drive system (if applicable to specific models covered).
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Suspension:
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Front suspension (MacPherson struts, control arms), rear suspension (independent trailing arms/beam axle depending on model), shock absorbers, springs, bushings, wheel alignment specifications.
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Steering:
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Power steering system, steering rack, pump, hoses, steering column, alignment.
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Brakes:
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Hydraulic system, brake master cylinder, calipers, pads, rotors, rear drums/discs, parking brake, ABS (if equipped), bleeding procedures, specifications.
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Electrical System:
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Battery, charging system (alternator, regulator), starting system (starter motor), lighting, fuses, relays, wiring diagrams for all systems.
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Body And Interior:
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Body panel removal/installation, door mechanisms, upholstery, dashboard, HVAC system, glass replacement, seals.
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Heating Ventilation Air Conditioning:
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HVAC system diagnosis, refrigerant, components (compressor, evaporator, condenser), blower motor, controls.
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Safety Systems:
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Seat belts, airbag systems (if equipped), general safety component checks.
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Procedures Included
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Maintenance:
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Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt tensioning.
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Troubleshooting:
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Systematic diagnostic procedures, common faults and their causes, symptom-based troubleshooting guides.
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Repair:
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Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission swaps, brake system overhauls.
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Diagnosis:
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Methods for diagnosing electrical faults, engine performance issues, transmission problems, and other mechanical failures.
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Technical Specifications:
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Torque values, clearances, fluid capacities, wiring diagrams, component data.
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Technical Depth
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Depth:
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Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring schematics.
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Engine Specifications
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Primary Engine
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Engine Options:
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Inline-5 cylinder petrol engines, V6 petrol engines, Turbocharged variants, Diesel engines (some markets).
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Common Engine Codes:
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WX, WT (2.2L Turbo I5), NP, NG, NF, NC, AAN (2.3L I5), PM (2.0L I4 diesel), AA, RT, 3B (2.6L V6, 2.8L V6).
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Performance
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Horsepower Range:
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80 hp (diesel) to 220 hp (20V Turbo)
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Torque Range:
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130 Nm to 350 Nm (Turbo)
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Fuel System
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Fuel Delivery:
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Mechanical Fuel Injection (K-Jetronic), Electronic Fuel Injection (KE-Jetronic, Digifant).
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Fuel Type:
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Unleaded Petrol (Octane rating as per manual), Diesel
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Engine Build
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Cylinder Arrangement:
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Inline-5, V6
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Displacement Range:
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1.9L to 2.8L
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 10,000-15,000 km or 12 months, whichever comes first (refer to specific model year in manual).
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Timing Belt Replacement:
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Recommended every 60,000-100,000 km or 5-7 years for petrol engines, critical for engine longevity.
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Fluid Specifications
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Engine Oil:
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Refer to manual for specific viscosity (e.g., 5W-40, 10W-40, 15W-50) and API/ACEA specifications depending on engine type and climate.
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Coolant:
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Ethylene glycol-based antifreeze coolant, typically mixed 50/50 with distilled water. Specific type varies by Audi specification.
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Brake Fluid:
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DOT 3 or DOT 4 brake fluid as specified in the manual.
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Transmission Fluid Manual:
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GL-4 or GL-5 gear oil (specific viscosity required, e.g., 75W-90 or 80W-90).
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Transmission Fluid Automatic:
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Dexron II or equivalent automatic transmission fluid (ATF) as per ZF specification.
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Known Issues
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Common Electrical Faults:
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Corroded ground points, failing relays, aged wiring insulation, faulty door lock actuators, issues with central locking systems.
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Engine Issues:
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Worn valve stem seals leading to oil consumption, timing belt tensioner failure, K-Jetronic fuel distributor issues, vacuum leaks.
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Suspension Wear:
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Worn control arm bushings, ball joints, and tie rod ends leading to steering looseness and uneven tire wear.
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Cooling System:
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Leaking radiator, coolant hoses, and water pump; heater core failure (common in older vehicles).
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Common Repairs
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Fuel System Maintenance:
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Cleaning or replacement of fuel injectors, fuel pumps, and fuel filters; recalibration of K-Jetronic systems.
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