Manual Coverage
|
Systems Covered
|
Engine Mechanical:
|
Engine overhaul, disassembly, assembly, timing, lubrication, cooling, fuel injection systems (KE-Jetronic/Motronic), emission controls
|
Engine Electrical:
|
Ignition system, starter, alternator, engine control unit (ECU) diagnostics and wiring diagrams
|
Transmission Manual:
|
Manual gearbox overhaul, clutch, driveshafts, shifting mechanisms
|
Transmission Automatic:
|
Automatic transmission (e.g., ZF 4HP22) overhaul, hydraulic control, electronic control, torque converter
|
Brakes:
|
Hydraulic system, ABS (Anti-lock Braking System), disc brake overhaul, drum brake (rear), parking brake
|
Suspension:
|
Front and rear suspension components (struts, control arms, ball joints, bushings), wheel alignment specifications
|
Steering:
|
Power steering system, steering rack, steering column, tie rods
|
Electrical Body:
|
Lighting, power windows, central locking, wipers, horn, instrument panel, comfort systems, wiring diagrams for all circuits
|
Climate Control:
|
Heating, ventilation, air conditioning (HVAC) system operation, refrigerant, component testing
|
Body And Chassis:
|
Body panel removal/installation, door mechanisms, interior trim, glass replacement, chassis component repair
|
Procedures Included
|
Maintenance:
|
Routine maintenance (oil changes, filter replacements, spark plugs), fluid level checks, lubrication points
|
Troubleshooting:
|
Diagnostic procedures for common problems, fault code interpretation (if applicable), symptom-based troubleshooting guides
|
Repair:
|
Detailed step-by-step repair procedures for all major components and systems
|
Disassembly Assembly:
|
Comprehensive instructions for removing and reinstalling parts and components
|
Technical Specifications:
|
Torque specifications, clearances, tolerances, electrical resistance values
|
Illustrations Diagrams:
|
Extensive use of diagrams, schematics, and photographs to clarify procedures
|
Technical Depth
|
Depth Of Coverage:
|
Factory-level detail, suitable for professional technicians and advanced DIYers
|
Target Audience:
|
Professional technicians, experienced DIY mechanics
|
Engine Specifications
|
Primary Engine
|
Engine Options:
|
Various inline-5 cylinder petrol engines, 2.2L Turbocharged I5 (e.g., 200 Quattro), 2.3L Naturally Aspirated I5
|
Performance
|
Engine Power Output Example:
|
2.2L Turbo (e.g., 200 Quattro) ~165-200 hp (depending on market and tune)
|
Engine Torque Output Example:
|
2.2L Turbo (e.g., 200 Quattro) ~265 Nm (depending on market and tune)
|
Fuel System
|
Fuel Injection Type:
|
Bosch K-Jetronic (CIS), Bosch Motronic (ECU controlled)
|
Engine Code Example
|
Engine Codes:
|
e.g., MC, NF, KV, WT, 3B (for 200 Turbo Quattro)
|
Maintenance
|
Service Intervals
|
Oil Change Interval:
|
Typically 7,500-10,000 miles (12,000-15,000 km) or 12 months, whichever comes first (check manual for specifics)
|
Timing Belt Interval:
|
Around 60,000 miles (100,000 km) or 5 years (critical for interference engines)
|
Fluid Specifications
|
Engine Oil Specification:
|
e.g., API SG, SAE 5W-40 or 10W-40 (check manual for exact viscosity and API rating)
|
Coolant Specification:
|
G11 (blue) or equivalent ethylene glycol-based coolant
|
Brake Fluid Specification:
|
DOT 3 or DOT 4
|
Automatic Transmission Fluid:
|
e.g., ATF Dexron III or equivalent (check specific ZF fluid requirements)
|
Known Issues
|
Common Wear Items:
|
CV joints, suspension bushings, fuel accumulators (K-Jetronic), door seal degradation, early ABS sensor failures
|
Typical Electrical Gremlins:
|
Corroded connectors, failing relays, issues with door lock actuators and power window motors
|