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AUDI AVANT RS2 Service Repair Manual 1994-1995

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Basic Information Identification Make: Audi Model: RS2 Avant Generation: B4 (Type 89) Production Years Covered: 1994-1995 Introduction Market Position Vehicle Class: High-Performance Compact Executive Wagon Segment: Ultra-Performance Station Wagon Competitive Analysis Competitors Era: Ford Sierra RS Cosworth Wagon (limited production), Porsche 911 Turbo (distinct category but similar performance goals) Key Features Distinctiveness: Collaboration with Porsche, homologation special for racing, potent drivetrain, practical wagon body. Manual Value Proposition Benefit 1: Empowers DIY repairs, reducing labor costs significantly. Benefit 2: Provides access to factory-level diagnostic and repair procedures. Benefit 3: Ensures correct and efficient maintenance for optimal vehicle longevity and performance. Manual Details Coverage Areas Primary Coverage: Service, Repair, Maintenance Scope: Complete Vehicle Page Count Estimated Pages: High (Detailed, often 1000+ pages for comprehensive manuals) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English (Likely, given context; original was German) Format Format: PDF Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Transmission Drivetrain: All-Wheel Drive (Quattro) System, Drive Shafts, Axles, Differentials Chassis: Suspension (Front & Rear), Steering System, Brakes (ABS), Wheels & Tires Electrical: Engine Control Unit (ECU), Ignition System, Lighting, Instrumentation, Power Accessories, Audio System, Security System Body: Body Panels, Doors, Windows, Glass, Interior Trim, Seats, Exterior Trim Procedures Included Maintenance: Scheduled Service, Oil Changes, Filter Replacements, Fluid Checks, Belt Inspection/Replacement Diagnostics: Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Component Testing Repair: Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Electrical Component Repair, Body Panel Repair Disassembly Assembly: Step-by-step instructions with exploded views for all major components Specifications: Torque values, clearances, fluid capacities, electrical diagrams Technical Depth Depth: Comprehensive, covering all aspects from basic maintenance to complete engine/transmission rebuilds and complex diagnostics. Manual Specifications File Format Quality: High-Resolution PDF, PC & MAC Compatible Searchability: Likely searchable text (depending on PDF creation) Print Quality Printability: Printable pages for workshop use Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Engine Specifications Primary Engine Engine Code: ADU Configuration: Inline 5-Cylinder Displacement: 2.2 Liters (2226 cc) Aspiration: Turbocharged and Intercooled Bore X Stroke: 81.0 mm x 86.4 mm Compression Ratio: 8.5:1 Horsepower: 310 PS (306 hp) @ 6500 rpm Torque: 410 Nm (302 lb-ft) @ 3000 rpm Fuel System Fuel Delivery: Bosch Motronic M2.3 Engine Management System with Multi-Point Fuel Injection Fuel Type: Unleaded Gasoline (RON 98 recommended) Cooling System Coolant Type: G12/G12+ Antifreeze (Audi/VW Specification) Lubrication System Oil Capacity: Approximately 5.0 Liters (5.3 US Quarts) Oil Type: API SG/SH, ACEA A2/A3, SAE 5W-40 or 0W-40 Synthetic Recommended Engine Management Ignition System: Distributorless Ignition System (DIS) Transmission Standard Transmission Type: 6-Speed Manual Transmission Model: Porsche Type 01E Gear Ratios: Refer to manual for specific ratios; designed for high performance. Optional Transmission Type: Not Available Features Drive System: Permanent All-Wheel Drive (Quattro) Differential: Torsen center differential, rear limited-slip differential (LSD) Fluid Specs Transmission Oil Type: API GL-4/GL-5 Synthetic Gear Oil (SAE 75W-90 or 75W-140) Transmission Oil Capacity: Approximately 2.5 Liters (2.6 US Quarts) Dimensions Exterior Body Style: 5-Door Station Wagon (Avant) Length: 4400 mm (173.2 inches) Width: 1700 mm (66.9 inches) Height: 1415 mm (55.7 inches) Wheelbase: 2610 mm (102.8 inches) Weights Curb Weight: Approximately 1590 kg (3505 lbs) Cargo Cargo Volume: Standard for B4 Avant, expandable with rear seats folded (refer to manual for exact figures). Safety Features Ratings Crash Test Data: N/A (ERA of limited standardized testing, but built to robust Audi standards of the time) Active Features ABS: Bosch ABS System Braking System: Performance Brakes (Front: 304mm Ventilated Discs, Rear: 269mm Solid Discs) - Potentially Porsche spec Passive Features Airbags: Driver Airbag (Standard) Seatbelts: Three-point Inertia-Reel Seatbelts Construction Chassis Construction: Unitary Body with Integrated Safety Cage Technology Features Infotainment Audio System: Factory Audi Gamma or Concert stereo system (optional upgrade available). Speakers: Multiple speaker setup, often with amplifier (specifics vary by trim/options). Driver Assistance Cruise Control: Standard Traction Control: Not explicitly named as ESP/TCS, but the potent Quattro system and ABS provide significant stability. Connectivity Original Features: Limited by era; no factory Bluetooth or navigation systems. Aftermarket upgrades common. Maintenance Service Intervals Oil Change Interval: Every 10,000 - 15,000 km (6,000 - 9,000 miles) or annually, whichever comes first. Synthetic oil recommended. Timing Belt Replacement: Every 60,000 - 90,000 km (37,000 - 56,000 miles) or 5 years. Critical for this engine. Spark Plug Replacement: Refer to manual, typically 30,000 - 60,000 km depending on plug type. Fluid Specifications Brake Fluid Type: DOT 4 Power Steering Fluid Type: G 002 000 (Pentosin CHF 11 S) or equivalent Known Issues Engine Components: Turbocharger wear, coil pack failure, potential for head gasket issues if overheated. Electrical: Wiring harness degradation, sensor failures (MAF, O2, Crank/Cam sensors), ABS sensor faults. Suspension Chassis: Worn suspension bushings, strut mount failure, driveshaft U-joint wear. Body Exterior: Rust in common Audi areas (wheel arches, sills),...
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AUDI AVANT RS2 Service Repair Manual 1994-1995
Basic Information
Identification
Make: Audi
Model: RS2 Avant
Generation: B4 (Type 89)
Production Years Covered: 1994-1995
Introduction
Market Position
Vehicle Class: High-Performance Compact Executive Wagon
Segment: Ultra-Performance Station Wagon
Competitive Analysis
Competitors Era: Ford Sierra RS Cosworth Wagon (limited production), Porsche 911 Turbo (distinct category but similar performance goals)
Key Features
Distinctiveness: Collaboration with Porsche, homologation special for racing, potent drivetrain, practical wagon body.
Manual Value Proposition
Benefit 1: Empowers DIY repairs, reducing labor costs significantly.
Benefit 2: Provides access to factory-level diagnostic and repair procedures.
Benefit 3: Ensures correct and efficient maintenance for optimal vehicle longevity and performance.
Manual Details
Coverage Areas
Primary Coverage: Service, Repair, Maintenance
Scope: Complete Vehicle
Page Count
Estimated Pages: High (Detailed, often 1000+ pages for comprehensive manuals)
Manual Type
Type: Factory Service Manual / Workshop Manual
Language
Language: English (Likely, given context; original was German)
Format
Format: PDF
Manual Coverage
Systems Covered
Powertrain: Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Transmission
Drivetrain: All-Wheel Drive (Quattro) System, Drive Shafts, Axles, Differentials
Chassis: Suspension (Front & Rear), Steering System, Brakes (ABS), Wheels & Tires
Electrical: Engine Control Unit (ECU), Ignition System, Lighting, Instrumentation, Power Accessories, Audio System, Security System
Body: Body Panels, Doors, Windows, Glass, Interior Trim, Seats, Exterior Trim
Procedures Included
Maintenance: Scheduled Service, Oil Changes, Filter Replacements, Fluid Checks, Belt Inspection/Replacement
Diagnostics: Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Component Testing
Repair: Engine Rebuild, Transmission Overhaul, Suspension Component Replacement, Brake System Repair, Electrical Component Repair, Body Panel Repair
Disassembly Assembly: Step-by-step instructions with exploded views for all major components
Specifications: Torque values, clearances, fluid capacities, electrical diagrams
Technical Depth
Depth: Comprehensive, covering all aspects from basic maintenance to complete engine/transmission rebuilds and complex diagnostics.
Manual Specifications
File Format
Quality: High-Resolution PDF, PC & MAC Compatible
Searchability: Likely searchable text (depending on PDF creation)
Print Quality
Printability: Printable pages for workshop use
Binding Type
Binding: Not Applicable (Digital Download)
Paper Type
Paper Type: Not Applicable (Digital Download)
Engine Specifications
Primary Engine
Engine Code: ADU
Configuration: Inline 5-Cylinder
Displacement: 2.2 Liters (2226 cc)
Aspiration: Turbocharged and Intercooled
Bore X Stroke: 81.0 mm x 86.4 mm
Compression Ratio: 8.5:1
Horsepower: 310 PS (306 hp) @ 6500 rpm
Torque: 410 Nm (302 lb-ft) @ 3000 rpm
Fuel System
Fuel Delivery: Bosch Motronic M2.3 Engine Management System with Multi-Point Fuel Injection
Fuel Type: Unleaded Gasoline (RON 98 recommended)
Cooling System
Coolant Type: G12/G12+ Antifreeze (Audi/VW Specification)
Lubrication System
Oil Capacity: Approximately 5.0 Liters (5.3 US Quarts)
Oil Type: API SG/SH, ACEA A2/A3, SAE 5W-40 or 0W-40 Synthetic Recommended
Engine Management
Ignition System: Distributorless Ignition System (DIS)
Transmission
Standard
Transmission Type: 6-Speed Manual
Transmission Model: Porsche Type 01E
Gear Ratios: Refer to manual for specific ratios; designed for high performance.
Optional
Transmission Type: Not Available
Features
Drive System: Permanent All-Wheel Drive (Quattro)
Differential: Torsen center differential, rear limited-slip differential (LSD)
Fluid Specs
Transmission Oil Type: API GL-4/GL-5 Synthetic Gear Oil (SAE 75W-90 or 75W-140)
Transmission Oil Capacity: Approximately 2.5 Liters (2.6 US Quarts)
Dimensions
Exterior
Body Style: 5-Door Station Wagon (Avant)
Length: 4400 mm (173.2 inches)
Width: 1700 mm (66.9 inches)
Height: 1415 mm (55.7 inches)
Wheelbase: 2610 mm (102.8 inches)
Weights
Curb Weight: Approximately 1590 kg (3505 lbs)
Cargo
Cargo Volume: Standard for B4 Avant, expandable with rear seats folded (refer to manual for exact figures).
Safety Features
Ratings
Crash Test Data: N/A (ERA of limited standardized testing, but built to robust Audi standards of the time)
Active Features
ABS: Bosch ABS System
Braking System: Performance Brakes (Front: 304mm Ventilated Discs, Rear: 269mm Solid Discs) - Potentially Porsche spec
Passive Features
Airbags: Driver Airbag (Standard)
Seatbelts: Three-point Inertia-Reel Seatbelts
Construction
Chassis Construction: Unitary Body with Integrated Safety Cage
Technology Features
Infotainment
Audio System: Factory Audi Gamma or Concert stereo system (optional upgrade available).
Speakers: Multiple speaker setup, often with amplifier (specifics vary by trim/options).
Driver Assistance
Cruise Control: Standard
Traction Control: Not explicitly named as ESP/TCS, but the potent Quattro system and ABS provide significant stability.
Connectivity
Original Features: Limited by era; no factory Bluetooth or navigation systems. Aftermarket upgrades common.
Maintenance
Service Intervals
Oil Change Interval: Every 10,000 - 15,000 km (6,000 - 9,000 miles) or annually, whichever comes first. Synthetic oil recommended.
Timing Belt Replacement: Every 60,000 - 90,000 km (37,000 - 56,000 miles) or 5 years. Critical for this engine.
Spark Plug Replacement: Refer to manual, typically 30,000 - 60,000 km depending on plug type.
Fluid Specifications
Brake Fluid Type: DOT 4
Power Steering Fluid Type: G 002 000 (Pentosin CHF 11 S) or equivalent
Known Issues
Engine Components: Turbocharger wear, coil pack failure, potential for head gasket issues if overheated.
Electrical: Wiring harness degradation, sensor failures (MAF, O2, Crank/Cam sensors), ABS sensor faults.
Suspension Chassis: Worn suspension bushings, strut mount failure, driveshaft U-joint wear.
Body Exterior: Rust in common Audi areas (wheel arches, sills), seal degradation.
Preventative Maintenance
Cooling System: Regular coolant flushes and thermostat replacement are vital due to potential for overheating.
Vehicle History
Brand Heritage
Audi Performance Division: Audi Sport GmbH (formerly quattro GmbH)
Model Evolution
Origin: Homologation special based on Audi 80 Avant (B4 chassis).
Collaboration: Developed in collaboration with Porsche; many components sourced from Porsche.
Production
Production Period: 1994-1996
Production Numbers: Limited Production Run (Approx. 3000 units)
Manufacturing Location: Audi AG, Germany (with Porsche assembly involvement)
Motorsport Connection
Racing Homologation: Built to homologate the RS2 for touring car racing, specifically the German STW Championship.
Awards & Recognition
Recognitions
Automotive Press: Widely acclaimed by automotive press for its groundbreaking performance and practicality. Featured in numerous performance car lists.
Ratings
Performance Benchmark: Often cited as one of the fastest production station wagons of its time.
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