Audi B3 1986-1991 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Audi Model: B3 Model Generations: Audi 80/90 (B3) Production Years: 1986-1991 Codes Chassis Code: Type 89 👋 Introduction Market Position Vehicle Segment: Compact executive car, sedan, coupe, and avant (wagon) body styles. Brand Positioning: Audi's entry into a more premium segment compared to some rivals, focusing on build quality and Quattro all-wheel drive. Competitive Analysis Key Competitors: BMW 3 Series (E30), Mercedes-Benz 190E (W201), Volvo 240, various Japanese premium sedans. Key Features Design: Aerodynamic styling, clean lines, galvanized body shell for corrosion resistance. Powertrain: Introduction of Audi's 2.3L 5-cylinder engine and the renowned Quattro all-wheel-drive system across more models. Safety: Improved safety cage structure, option for ABS (Anti-lock Braking System). 📋 Manual Details Coverage Areas Covered Years: 1986, 1987, 1988, 1989, 1990, 1991 Page Count Estimated Page Count: Detailed (specific count not provided in product data, but implies comprehensive coverage). Manual Type Type: Workshop Service Repair Manual Language Language: English (implied by product description, though originating from German market). Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair procedures, overhaul for various engine options (e.g., 1.6L, 1.8L, 2.0L, 2.3L 5-cylinder). Fuel System: Carburetor and fuel injection systems, fuel pumps, lines, injectors, pressure regulation. Ignition System: Ignition timing, spark plugs, coils, distributors, electronic ignition control. Cooling System: Radiator, thermostat, water pump, cooling fans, coolant specifications, flush procedures. Exhaust System: Exhaust manifolds, catalytic converters (if applicable), mufflers, pipes, emission controls. Transmission Manual: Clutch operation, gearbox overhaul, gear selection mechanisms, fluid specifications. Transmission Automatic: Hydraulic control, torque converter, planetary gear sets, ATF specifications, shift linkage adjustment. Drivetrain: Front-wheel drive components, driveshafts, CV joints, differentials. Suspension Front: MacPherson struts, control arms, ball joints, bushings, wheel alignment specifications. Suspension Rear: Torsion beam, trailing arms, shock absorbers, bushings, wheel alignment. Steering System: Steering rack, tie rod ends, power steering pump, fluid, column. Brakes Front: Ventilated disc brakes, calipers, pads, rotors, brake fluid specifications. Brakes Rear: Drum or disc brakes (model dependent), shoes, drums, rotors, parking brake mechanism. Electrical System: Battery, alternator, starter, lighting, fuses, relays, wiring diagrams. Body Electrical: Wipers, washers, horn, power windows, central locking, instrument cluster. HVAC: Heating, ventilation, air conditioning system components, refrigerant, diagnosis. Body And Frame: Body panel removal/installation, structural components, doors, windows, seals. Interior: Seat removal/installation, dashboard, trim panels, headliner. Procedures Included Preventive Maintenance: Oil changes, filter replacements, spark plug tuning, fluid checks, belt inspections. Scheduled Maintenance: Detailed intervals for all major service points. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults. Engine Repair: Overhaul procedures, piston ring replacement, valve adjustments, head gasket replacement. Transmission Repair: Gearbox rebuilds, clutch replacement, automatic transmission service. Brake Repair: Pad and rotor replacement, caliper service, bleeding procedures, parking brake adjustment. Suspension And Steering Repair: Component replacement, alignment procedures, power steering system service. Electrical Diagnostics: Use of multimeters, oscilloscope basics, circuit tracing with wiring diagrams. Bodywork Repair: Panel alignment, dent repair, rust prevention, window and seal replacement. Technical Depth Depth: Comprehensive, suitable for professional mechanics and advanced DIYers. Covers diagnosis, repair, and overhaul. Diagnostic Charts: Includes detailed diagnostic flowcharts for various symptoms. Specifications: Detailed torque specifications, clearances, fluid capacities, and electrical resistance values. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable for efficient information retrieval. Print Quality Quality: Digital PDF, allowing for high-resolution printing of individual pages. Binding Type Type: Not applicable (digital format). Paper Type Type: Not applicable (digital format). ⚙️ Engine Specifications Primary Engine Engine Codes Common: JN (1.6L), YN (1.8L), PM (1.8L), RP (1.8L), SK (2.0L), NG (2.3L 5-cyl). Displacement Common: 1.6L, 1.8L, 2.0L, 2.3L (inline-4 and inline-5 configurations). Performance Horsepower Range: Approximately 75 hp to 137 hp depending on engine variant. Torque Range: Approximately 120 Nm to 194 Nm depending on engine variant. Fuel System Fuel Delivery: Carburetor (early models, e.g., Pierburg 2E) and Bosch K-Jetronic or KE-Jetronic fuel injection. Fuel Type: Unleaded gasoline (RON 91+). Engine Construction Block Material: Cast iron. Cylinder Head Material: Aluminum alloy. 🔧 Transmission Standard Type Standard: 5-speed manual transaxle. Optional Type Optional: 3-speed or 4-speed automatic transaxle (e.g., Audi C-series). Features Quattro AWD: Available on select models, featuring a viscous coupling ( Haldex type) or Torsen differential (later models) for permanent all-wheel drive. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 or 80W-90 (verify specific viscosity based on temperature). Automatic Transmission Fluid: G052 162 A1 or equivalent Dexron II (verify specific type). 📐 Dimensions Exterior Body Styles: 2-door coupe, 4-door sedan, 5-door Avant (wagon). Length Sedan Approx: 4340 mm (170.9 in) Width Approx: 1690 mm (66.5 in) Height Sedan Approx: 1370 mm (53.9 in) Weights Curb Weight Range: Approx. 1050 kg to 1300 kg (2315 lbs to 2866 lbs) depending on body style and drivetrain. Gross Vehicle Weight Rating: Varies by model, typically around 1600 kg (3527 lbs). 🛡️ Safety Features Ratings Crash Test Results:...

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Sku: 461603

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Tags: 1986 1987 1988 1989 1990 1991 Audi B3 Car

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Model Generations:

Audi 80/90 (B3)

Production Years:

1986-1991

Codes

Chassis Code:

Type 89

👋 Introduction

Market Position

Vehicle Segment:

Compact executive car, sedan, coupe, and avant (wagon) body styles.

Brand Positioning:

Audi's entry into a more premium segment compared to some rivals, focusing on build quality and Quattro all-wheel drive.

Competitive Analysis

Key Competitors:

BMW 3 Series (E30), Mercedes-Benz 190E (W201), Volvo 240, various Japanese premium sedans.

Key Features

Design:

Aerodynamic styling, clean lines, galvanized body shell for corrosion resistance.

Powertrain:

Introduction of Audi's 2.3L 5-cylinder engine and the renowned Quattro all-wheel-drive system across more models.

Safety:

Improved safety cage structure, option for ABS (Anti-lock Braking System).

📋 Manual Details

Coverage Areas

Covered Years:

1986, 1987, 1988, 1989, 1990, 1991

Page Count

Estimated Page Count:

Detailed (specific count not provided in product data, but implies comprehensive coverage).

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English (implied by product description, though originating from German market).

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair procedures, overhaul for various engine options (e.g., 1.6L, 1.8L, 2.0L, 2.3L 5-cylinder).

Fuel System:

Carburetor and fuel injection systems, fuel pumps, lines, injectors, pressure regulation.

Ignition System:

Ignition timing, spark plugs, coils, distributors, electronic ignition control.

Cooling System:

Radiator, thermostat, water pump, cooling fans, coolant specifications, flush procedures.

Exhaust System:

Exhaust manifolds, catalytic converters (if applicable), mufflers, pipes, emission controls.

Transmission Manual:

Clutch operation, gearbox overhaul, gear selection mechanisms, fluid specifications.

Transmission Automatic:

Hydraulic control, torque converter, planetary gear sets, ATF specifications, shift linkage adjustment.

Drivetrain:

Front-wheel drive components, driveshafts, CV joints, differentials.

Suspension Front:

MacPherson struts, control arms, ball joints, bushings, wheel alignment specifications.

Suspension Rear:

Torsion beam, trailing arms, shock absorbers, bushings, wheel alignment.

Steering System:

Steering rack, tie rod ends, power steering pump, fluid, column.

Brakes Front:

Ventilated disc brakes, calipers, pads, rotors, brake fluid specifications.

Brakes Rear:

Drum or disc brakes (model dependent), shoes, drums, rotors, parking brake mechanism.

Electrical System:

Battery, alternator, starter, lighting, fuses, relays, wiring diagrams.

Body Electrical:

Wipers, washers, horn, power windows, central locking, instrument cluster.

HVAC:

Heating, ventilation, air conditioning system components, refrigerant, diagnosis.

Body And Frame:

Body panel removal/installation, structural components, doors, windows, seals.

Interior:

Seat removal/installation, dashboard, trim panels, headliner.

Procedures Included

Preventive Maintenance:

Oil changes, filter replacements, spark plug tuning, fluid checks, belt inspections.

Scheduled Maintenance:

Detailed intervals for all major service points.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults.

Engine Repair:

Overhaul procedures, piston ring replacement, valve adjustments, head gasket replacement.

Transmission Repair:

Gearbox rebuilds, clutch replacement, automatic transmission service.

Brake Repair:

Pad and rotor replacement, caliper service, bleeding procedures, parking brake adjustment.

Suspension And Steering Repair:

Component replacement, alignment procedures, power steering system service.

Electrical Diagnostics:

Use of multimeters, oscilloscope basics, circuit tracing with wiring diagrams.

Bodywork Repair:

Panel alignment, dent repair, rust prevention, window and seal replacement.

Technical Depth

Depth:

Comprehensive, suitable for professional mechanics and advanced DIYers. Covers diagnosis, repair, and overhaul.

Diagnostic Charts:

Includes detailed diagnostic flowcharts for various symptoms.

Specifications:

Detailed torque specifications, clearances, fluid capacities, and electrical resistance values.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable for efficient information retrieval.

Print Quality

Quality:

Digital PDF, allowing for high-resolution printing of individual pages.

Binding Type

Type:

Not applicable (digital format).

Paper Type

Type:

Not applicable (digital format).

⚙️ Engine Specifications

Primary Engine

Engine Codes Common:

JN (1.6L), YN (1.8L), PM (1.8L), RP (1.8L), SK (2.0L), NG (2.3L 5-cyl).

Displacement Common:

1.6L, 1.8L, 2.0L, 2.3L (inline-4 and inline-5 configurations).

Performance

Horsepower Range:

Approximately 75 hp to 137 hp depending on engine variant.

Torque Range:

Approximately 120 Nm to 194 Nm depending on engine variant.

Fuel System

Fuel Delivery:

Carburetor (early models, e.g., Pierburg 2E) and Bosch K-Jetronic or KE-Jetronic fuel injection.

Fuel Type:

Unleaded gasoline (RON 91+).

Engine Construction

Block Material:

Cast iron.

Cylinder Head Material:

Aluminum alloy.

🔧 Transmission

Standard

Type Standard:

5-speed manual transaxle.

Optional

Type Optional:

3-speed or 4-speed automatic transaxle (e.g., Audi C-series).

Features

Quattro AWD:

Available on select models, featuring a viscous coupling ( Haldex type) or Torsen differential (later models) for permanent all-wheel drive.

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90 (verify specific viscosity based on temperature).

Automatic Transmission Fluid:

G052 162 A1 or equivalent Dexron II (verify specific type).

📐 Dimensions

Exterior

Body Styles:

2-door coupe, 4-door sedan, 5-door Avant (wagon).

Length Sedan Approx:

4340 mm (170.9 in)

Width Approx:

1690 mm (66.5 in)

Height Sedan Approx:

1370 mm (53.9 in)

Weights

Curb Weight Range:

Approx. 1050 kg to 1300 kg (2315 lbs to 2866 lbs) depending on body style and drivetrain.

Gross Vehicle Weight Rating:

Varies by model, typically around 1600 kg (3527 lbs).

🛡️ Safety Features

Ratings

Crash Test Results:

Euro NCAP not established for this era. Early models focused on passive safety cage construction.

Active Features

Optional on most models, standard on some higher trims or later production years.

Passive Features

Airbags:

Driver airbag optional, passenger airbag generally not available on this generation.

Seatbelts:

3-point front and rear seatbelts.

Body Structure:

Designed with energy-absorbing crumple zones and a rigid passenger safety cell.

💡 Technology Features

Infotainment

Radio Options:

Factory AM/FM radio with cassette player, optional amplifier systems.

Speaker Systems:

Typically 4 to 6 speakers depending on trim level.

Driver Assistance

Cruise Control:

Optional on higher trims.

Connectivity

Early Features:

No integrated smartphone connectivity, basic on-board computer on some higher-spec models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000-15,000 km or 6-12 months, using synthetic or semi-synthetic oil.

Timing Belt Replacement:

Crucial: 60,000-90,000 km or 4-5 years depending on engine and climate. Interference engine design makes failure catastrophic.

Brake Fluid Flush:

Every 2 years or 40,000 km.

Coolant Flush:

Every 2-4 years or 40,000-80,000 km.

Fluid Specifications

Engine Oil Viscosity:

Commonly 10W-40, 10W-50, or 5W-40 synthetic, depending on climate and specific engine. Refer to manual for exact specs.

Coolant Type:

G11 (blue/green ethylene glycol based) or equivalent.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Common Wear Items:

Suspension bushings, wheel bearings, fuel pumps, ignition components, radiator hoses, door seals.

Electrical Gremlins:

Can be prone to minor electrical issues, particularly with grounds and aging wiring harnesses.

Corrosion:

While galvanized, areas like wheel arches, sills, and around windows can be susceptible to rust if paint is chipped.

Fuel Injection Issues:

K-Jetronic systems can require careful tuning and maintenance of fuel pressure regulators and air flow meters.

📚 Vehicle History

Brand Heritage

Audi Legacy:

Audi, part of the Volkswagen Group, has a history dating back to the early 20th century with a focus on engineering and automotive innovation.

Model Evolution

Predecessor:

Audi 80/90 (B2).

Successor:

Audi 80/A4 (B4/B5).

Production

Manufacturing Locations:

Primarily Ingolstadt, Germany. Also produced in various other VW Group facilities.

Significance:

Marked a significant design and engineering step for Audi, introducing sleeker aerodynamics and a more modern platform.

🏆 Awards & Recognition

Recognitions

General Reputation:

The Audi B3 generation was well-received for its build quality, driving dynamics, and sophisticated design, contributing to Audi's growing reputation in the premium segment.