Audi 100 Workshop Service And Repair Manual 1987

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🏷️ Basic Information Identification Make: Audi Model: 100 Year: 1987 Generation Generation: Third Generation (Type 44/4C) Codes Chassis Code: Type 44/4C 👋 Introduction Market Position Market Position: The Audi 100 (Type 44) was positioned as a premium executive car, competing with established luxury marques. It emphasized advanced engineering, sophisticated styling, and a comfortable driving experience. The 1987 model year falls within the latter half of the Type 44's production, representing a mature and refined iteration of the platform. Premium Segment Offering: Audi positioned the 100 as a direct competitor to established European luxury sedans, offering a blend of performance, comfort, and advanced engineering. Competitive Analysis Competitive Analysis: Key competitors for the 1987 Audi 100 included the Mercedes-Benz E-Class (W124), BMW 5 Series (E28/E34), Volvo 240/740, and to some extent, larger American sedans. The Audi 100 differentiated itself with its aerodynamic design, front-wheel drive or optional Quattro all-wheel drive system, and a focus on user comfort and safety features. Key Features Key Features: Aerodynamic 'cW' design, front-wheel drive standard, optional permanent all-wheel drive (Quattro), spacious interior, sophisticated build quality, available with various inline-five engines, advanced (for its time) safety features. Aerodynamic Design: The Type 44 was celebrated for its exceptionally low drag coefficient (cW), contributing to fuel efficiency and reduced wind noise. 📋 Manual Details Coverage Areas Coverage Areas: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Fuel System, Cooling System, Exhaust System, Bodywork, Interior, HVAC, Diagnostics, Maintenance Diagnostics And Troubleshooting: Extensive coverage on diagnosing and resolving common and uncommon faults across all vehicle systems. Page Count Page Count: Estimated 1000+ 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 Systems: Internal combustion engine (ICE) overhauls, cylinder head service, piston and connecting rod assembly, crankshaft and bearing service, timing belt/chain replacement, lubrication system, fuel injection systems (CIS-Jetronic, KE-Jetronic depending on variant), ignition system, emission control systems Transmission Drivetrain Systems: Manual and Automatic transmission overhaul and repair, clutch service, driveshaft and CV joint inspection and replacement, differential service, AWD (Quattro) system components Suspension Steering Systems: Front and rear suspension component inspection and replacement (struts, shocks, control arms, bushings), power steering system service, steering rack and column repair, wheel alignment specifications Brake Systems: Front and rear brake component service (discs, pads, calipers, wheel cylinders), hydraulic system bleeding, parking brake adjustment, ABS system troubleshooting (if equipped) Electrical Systems: Wiring diagrams, fuse box layouts, relay functions, starter motor, alternator, battery service, lighting systems, power windows, central locking, instrument cluster diagnostics, ECU troubleshooting Fuel Cooling Exhaust Systems: Fuel tank and pump service, fuel filter replacement, cooling system flush and fill, radiator and water pump replacement, thermostat service, exhaust manifold and system repair, catalytic converter information Bodywork Interior HVAC: Body panel removal and installation, door and latch mechanisms, glass replacement, interior trim panel removal, HVAC system diagnosis and repair, heater core replacement, A/C system servicing Emission Control Systems: Information on emission control devices, their function, and troubleshooting, including catalytic converters, oxygen sensors (if equipped), and secondary air injection systems. Wheel Alignment Specifications: Precise specifications for camber, caster, and toe angles for both front and rear suspensions. Procedures Included Maintenance Procedures: Routine maintenance (oil changes, filter replacements), spark plug replacement, air filter servicing, fluid level checks and top-offs, brake fluid replacement, coolant flushes Repair Procedures: Detailed step-by-step repair instructions for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, suspension component replacement, and electrical system troubleshooting. Troubleshooting Diagnostics: Systematic diagnostic procedures for identifying and resolving common and uncommon faults, fault code interpretation (if applicable), wiring diagram analysis for electrical issues. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, including engine control, lighting, accessories, and safety systems, crucial for troubleshooting electrical faults. Torque Specifications: Detailed torque specifications for all critical fasteners, including engine components, suspension parts, and bodywork, ensuring proper assembly and preventing damage. Body Repair Procedures: Guidance on body panel alignment, rust prevention, and repair techniques, along with specifications for welding and sealing. Diagnostic Trouble Codes: Information on how to retrieve and interpret diagnostic trouble codes (DTCs) for engine management and other electronic systems, if applicable to the specific model year and engine. Technical Depth Technical Depth: Comprehensive: Covers everything from basic scheduled maintenance to full engine and transmission rebuilds, including detailed torque specifications, special tool requirements, and diagnostic procedures. Special Tools Required: The manual will detail the specific Audi special tools required for certain repair procedures, such as engine timing tools, suspension alignment tools, and fuel system diagnostic equipment. Schematics And Diagrams: Includes detailed mechanical schematics, system diagrams, and cutaway views to illustrate component function and assembly. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans ensuring clarity of text and diagrams Binding Type Binding Type: N/A...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Generation

Generation:

Third Generation (Type 44/4C)

Codes

Chassis Code:

Type 44/4C

👋 Introduction

Market Position

Market Position:

The Audi 100 (Type 44) was positioned as a premium executive car, competing with established luxury marques. It emphasized advanced engineering, sophisticated styling, and a comfortable driving experience. The 1987 model year falls within the latter half of the Type 44's production, representing a mature and refined iteration of the platform.

Premium Segment Offering:

Audi positioned the 100 as a direct competitor to established European luxury sedans, offering a blend of performance, comfort, and advanced engineering.

Competitive Analysis

Competitive Analysis:

Key competitors for the 1987 Audi 100 included the Mercedes-Benz E-Class (W124), BMW 5 Series (E28/E34), Volvo 240/740, and to some extent, larger American sedans. The Audi 100 differentiated itself with its aerodynamic design, front-wheel drive or optional Quattro all-wheel drive system, and a focus on user comfort and safety features.

Key Features

Key Features:

Aerodynamic 'cW' design, front-wheel drive standard, optional permanent all-wheel drive (Quattro), spacious interior, sophisticated build quality, available with various inline-five engines, advanced (for its time) safety features.

Aerodynamic Design:

The Type 44 was celebrated for its exceptionally low drag coefficient (cW), contributing to fuel efficiency and reduced wind noise.

📋 Manual Details

Coverage Areas

Coverage Areas:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, Fuel System, Cooling System, Exhaust System, Bodywork, Interior, HVAC, Diagnostics, Maintenance

Diagnostics And Troubleshooting:

Extensive coverage on diagnosing and resolving common and uncommon faults across all vehicle systems.

Page Count

Page Count:

Estimated 1000+ 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 Systems:

Internal combustion engine (ICE) overhauls, cylinder head service, piston and connecting rod assembly, crankshaft and bearing service, timing belt/chain replacement, lubrication system, fuel injection systems (CIS-Jetronic, KE-Jetronic depending on variant), ignition system, emission control systems

Transmission Drivetrain Systems:

Manual and Automatic transmission overhaul and repair, clutch service, driveshaft and CV joint inspection and replacement, differential service, AWD (Quattro) system components

Suspension Steering Systems:

Front and rear suspension component inspection and replacement (struts, shocks, control arms, bushings), power steering system service, steering rack and column repair, wheel alignment specifications

Brake Systems:

Front and rear brake component service (discs, pads, calipers, wheel cylinders), hydraulic system bleeding, parking brake adjustment, ABS system troubleshooting (if equipped)

Electrical Systems:

Wiring diagrams, fuse box layouts, relay functions, starter motor, alternator, battery service, lighting systems, power windows, central locking, instrument cluster diagnostics, ECU troubleshooting

Fuel Cooling Exhaust Systems:

Fuel tank and pump service, fuel filter replacement, cooling system flush and fill, radiator and water pump replacement, thermostat service, exhaust manifold and system repair, catalytic converter information

Bodywork Interior HVAC:

Body panel removal and installation, door and latch mechanisms, glass replacement, interior trim panel removal, HVAC system diagnosis and repair, heater core replacement, A/C system servicing

Emission Control Systems:

Information on emission control devices, their function, and troubleshooting, including catalytic converters, oxygen sensors (if equipped), and secondary air injection systems.

Wheel Alignment Specifications:

Precise specifications for camber, caster, and toe angles for both front and rear suspensions.

Procedures Included

Maintenance Procedures:

Routine maintenance (oil changes, filter replacements), spark plug replacement, air filter servicing, fluid level checks and top-offs, brake fluid replacement, coolant flushes

Repair Procedures:

Detailed step-by-step repair instructions for all major mechanical and electrical components, including engine rebuilds, transmission overhauls, suspension component replacement, and electrical system troubleshooting.

Troubleshooting Diagnostics:

Systematic diagnostic procedures for identifying and resolving common and uncommon faults, fault code interpretation (if applicable), wiring diagram analysis for electrical issues.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, including engine control, lighting, accessories, and safety systems, crucial for troubleshooting electrical faults.

Torque Specifications:

Detailed torque specifications for all critical fasteners, including engine components, suspension parts, and bodywork, ensuring proper assembly and preventing damage.

Body Repair Procedures:

Guidance on body panel alignment, rust prevention, and repair techniques, along with specifications for welding and sealing.

Diagnostic Trouble Codes:

Information on how to retrieve and interpret diagnostic trouble codes (DTCs) for engine management and other electronic systems, if applicable to the specific model year and engine.

Technical Depth

Technical Depth:

Comprehensive: Covers everything from basic scheduled maintenance to full engine and transmission rebuilds, including detailed torque specifications, special tool requirements, and diagnostic procedures.

Special Tools Required:

The manual will detail the specific Audi special tools required for certain repair procedures, such as engine timing tools, suspension alignment tools, and fuel system diagnostic equipment.

Schematics And Diagrams:

Includes detailed mechanical schematics, system diagrams, and cutaway views to illustrate component function and assembly.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution scans ensuring clarity of text and diagrams

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Variants:

Inline-five cylinder gasoline engines. Common variants include 2.0L (52 kW / 70 hp), 2.2L (74 kW / 100 hp), 2.2L 5E (85 kW / 115 hp), 2.2L 5V (turbocharged, 121 kW / 165 hp - Audi 100 Turbo/200). Diesel variants (e.g., 2.0L TD, 2.4L D) were also available.

Performance

Horsepower Range:

Approx. 70 hp to 165 hp (depending on engine variant)

Torque Range:

Approx. 133 Nm (98 lb-ft) to 250 Nm (184 lb-ft) (depending on engine variant)

Compression Ratio:

Varies by engine, typically 8.5:1 to 10.3:1 for gasoline engines.

Fuel System

Fuel System Types:

Bosch K-Jetronic (CIS) and KE-Jetronic (CIS-E) fuel injection for gasoline engines. Diesel engines typically used rotary injection pumps.

Fuel Type:

Unleaded gasoline (RON 95/98 recommended), Diesel fuel

Engine Management

Engine Management System:

Mechanical fuel injection control with electronic ignition timing (e.g., Motronic for some later variants or specific engine types).

Idle Speed Specifications:

Specific idle speed settings for each engine variant under warm operating conditions, crucial for proper engine operation.

Ignition Timing:

Detailed procedures and specifications for setting ignition timing, including static and dynamic timing methods.

🔧 Transmission

Standard

Standard Transmission:

5-speed manual transmission

Optional

Optional Transmission:

3-speed or 4-speed automatic transmission (e.g., ZF 4HP-22)

Features

Drivetrain Options:

Front-wheel drive (FWD), Permanent all-wheel drive (Quattro)

Transmission Fluid Type:

Manual: GL-4 gear oil (e.g., SAE 75W-90 or 80W-90). Automatic: ATF Dexron II or equivalent.

Gear Ratios:

Specific gear ratios for both manual and automatic transmissions, and final drive ratios for different models.

📐 Dimensions

Exterior

Length:

Approx. 4750 mm (187 in) (Sedan)

Width:

Approx. 1780 mm (70 in)

Height:

Approx. 1420 mm (56 in) (Sedan)

Wheelbase:

2610 mm (102.8 in)

Interior

Wheelbase:

Approx. 2610 mm (102.8 in)

Interior Dimensions:

Detailed measurements for passenger and cargo space, providing context for vehicle practicality.

Weights

Curb Weight Range:

Approx. 1300 kg - 1500 kg (2866 lbs - 3307 lbs) depending on engine and drivetrain

Gross Vehicle Weight Rating Gvwr:

Typically around 1850 kg - 2000 kg

🛡️ Safety Features

Ratings

Crash Test Ratings:

No standardized crash test ratings as per modern NHTSA/Euro NCAP exist for this era. However, the Type 44 platform was considered robust for its time.

Active Features

Active Safety Features:

Optional Anti-lock Braking System (ABS) on higher trims and later models.

Passive Features

Passive Safety Features:

Seat belts (front and rear), reinforced safety cell, impact-absorbing steering column, padded interior surfaces, child safety locks (rear doors).

💡 Technology Features

Infotainment

Infotainment System:

Basic analog radio with cassette player. Optional premium sound systems. Manual tuning and controls.

Speaker Configuration:

Typically 4 to 8 speakers depending on trim level and optional sound systems.

Driver Assistance

Driver Assistance Features:

Limited by modern standards. ABS was optional. Cruise control was available on some models.

Connectivity

Connectivity Features:

No modern connectivity features like Bluetooth or USB. Basic antenna and speaker system.

Lighting

Lighting Technology:

Halogen headlights, incandescent turn signals and tail lights. Manual headlight aim adjustment.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 km (6,200 miles) or 12 months, whichever comes first, under normal driving conditions.

Timing Belt Replacement:

Recommended every 80,000 - 100,000 km (50,000 - 60,000 miles) or 5 years, due to the interference nature of some engine designs. Consult manual for specific engine.

Fluid Specifications

Engine Oil Specification:

API SF or SG, ACEA A2. Viscosity: 10W-40, 15W-40, or 20W-50 depending on ambient temperature (e.g., 10W-40 for moderate climates).

Coolant Specification:

Ethylene glycol-based antifreeze mixed with distilled water in a 50/50 ratio. G11 specification or equivalent.

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid

Power Steering Fluid:

Type specified by Audi, typically a CHF 11S or similar hydraulic fluid, though some older models might use ATF.

Manual Gearbox Oil Capacity:

Typically around 1.5 - 2.0 liters depending on transmission type.

Automatic Gearbox Oil Capacity:

Typically around 3.5 - 4.5 liters for a fluid change, more for a full overhaul.

Differential Fluid Specifications:

GL-5 gear oil for both front and rear differentials, especially important for Quattro models.

Known Issues

Common Issues:

Oil leaks (valve cover gaskets, oil pan seals), cooling system issues (leaking hoses, radiator, water pump), worn suspension bushings, fuel distributor leaks (K-Jetronic), catalytic converter failure, electrical gremlins (older wiring), seizing brake calipers, automatic transmission hard shifting.

Preventative Maintenance:

Regular inspection of fuel lines, vacuum hoses, and coolant hoses. Timely replacement of timing belt and tensioner. Cleaning of K-Jetronic system components. Checking for electrical connection corrosion.

Engine Mounts:

Wear and tear on engine mounts can lead to increased vibration and noise in the cabin.

Heater Control Valves:

Leaking or malfunctioning heater control valves can lead to poor cabin heating performance.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Audi has a long history dating back to the early 20th century, known for its engineering prowess and innovation. By the 1980s, Audi had established itself as a manufacturer of sophisticated and technologically advanced vehicles, particularly with its focus on front-wheel drive and the introduction of the Quattro all-wheel drive system.

Model Evolution

Model Evolution Audi 100 Type 44:

The Type 44 generation of the Audi 100 was introduced in 1982, replacing the Type 43. It was a radical departure with a highly aerodynamic design, earning it the nickname 'Aerodynamic Sedan'. The 1987 model year represents a facelifted version of the Type 44, with updated styling, interior refinements, and engine improvements. It was also offered as the more luxurious Audi 200, which featured more powerful engines, including turbocharged variants.

Facelift And Updates 1987:

The 1987 model year is part of the facelifted Type 44 series, featuring revised front and rear fascias, improved interior ergonomics, and potential updates to engine management and chassis components.

Production

Production Years:

Audi 100 (Type 44): 1982-1991

Manufacturing Locations:

Ingolstadt, Germany; Brussels, Belgium; Aurangabad, India (CKD assembly)

🏆 Awards & Recognition

Recognitions

Recognitions And Awards:

While specific awards for the 1987 model are not widely publicized, the Type 44 generation as a whole was recognized for its advanced aerodynamic design and engineering. It contributed to Audi's reputation for innovation in the automotive industry during the 1980s.