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,...

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Sku: 461603

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Description

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