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. 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: PDF 📖 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: PDF 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...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Model Generation:

Third Generation (Type 443/444)

Model Year:

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.