Haynes Audi 100 & 200 Owners Workshop Manual 1850104360, 9781850104360

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AUDI 1OONZ00 | Oct ’82 to ’87 (100) o Feb ’84 to ’87 (200) 1781 cco 1921 cco 1994 cc |2144 cco 2226 cc }

|

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Before leaving the Library readers must return the books to one of the attendants at the issue desk, or they will be held responsible for them. Readers are required to take care of the books. Writing or drawing with pen or pencil on any part of a book, or turning down the leaves, or cutting or mutilating them, will be treated as serious damage. q CoNnVERSATION IN THE REFERENCE DEPARTMENT IS ANNOYING TO STUDENTS, AND IS NOT PERMITTED.

Audi wners | orkshop anual John Models

S Mead

covered

Audi*@00; ‘Base’, CC, CS & CD including Avant Aud? 200; E and Turbo 1781 cc, 1921 cc, 1994 cc, 2144 cc & 2226 cc Does not cover Quattro or Diesel engine versions ABCDE

(907-11N2)

Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ

Group England

Haynes Publications, 861 Lawrence Drive Newbury Park California 91320 USA

Inc

FGHIJ KLMN:

EDINBURGH CITY LIBRARIES

Acknowledgements Thanks are due to the Champion Sparking Plug Company Limited who supplied the illustrations showing the spark plug conditions. Certain other illustrations are the copyright of Volkswagenwerk AG, and are used with their permission. Thanks are also due to Mr John Day of JP and S Day, South Lee Garage, South Molton, Devon for the loan of the project car, to Swallowdale Motors, Seaton, Devon for technical assistance, to Sykes-Pickavant Limited who provided some of the workshop tools, and all those people at Sparkford who assisted in the production of this manual. TE

RR

© Haynes Publishing Group 1986, 1988 fi

A book in the Haynes Owners Workshop _

OO

os

Marual Series

rr

Printed by J. H. Haynes & Co. Ltd, Sparkford, Nr Yeovil, Somerset BA22 7JJ, England SL

All rights reserved. No part of this book may be reprodu ced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ee ISBN 1 85010 436 0 _

British Library Cataloguing in Publication Data Mead, John S. 7950Audi 100 and 200 owners workshop manual,

1. Cars. Maintenance & repair — Amateurs’ manuals

|. Title 629.28'722 ISBN 1-85010-436-0

——— SS, Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the inform ation given.

Contents Introductory pages

About this manual

5

Introduction to the Audi 100, 200 and 5000 General dimensions, weights and capacities Jacking, towing and wheel changing Buying spare parts and vehicle identification numbers Use of English General repair procedures Tools and working facilities Safety first!

5 7 9 11 12 13 14 16

Routine maintenance

17

Recommended lubricants and fluids Conversion factors Fault diagnosis

22 23 24

Chapter 1 Engine

28

Chapter 2 Cooling system

80

Chapter 3 Fuel, exhaust and emission control systems

89

Chapter 4 Ignition system

131

Chapter 5

Clutch

150

Chapter 6 Manual gearbox

121

Chapter 7 Automatic transmission

209

Chapter 8 Driveshafts

218

Chapter 9

Braking system

226

Chapter 10 Suspension and steering

256

Chapter 11 Bodywork

281

Chapter 12 Electrical system

306

Chapter 13 Supplement: Revisions and information on later models

387

Index

40 o>)

Audi 100 CD - UK

Audi 100 Avant

CD - UK

About

this manual

Its aim

The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

/ts arrangement

The manual is divided into thirteen Chapters, each covering a into logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections on paragraphs (or sub-sections), with decimal numbers following etc. 5.3 5.2, 5.1, eg in, are they Section the from

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related

groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own

individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Introduction to the Audi 100, 200 and 5000 with the 200 The ‘new’ Audi 100 was announced in October 1982 version, version becoming available in early 1984. The North American the Audi 5000, was launched in 1983. ive design and All models feature startling new advances in automot attention to us meticulo the being these among technology, foremost 0.30 for the Audi aerodynamic shape. With a drag coefficient (Cd) of the most 100, these cars are of a design which is amongst class. their in efficient y aerodynamicall offer a In addition to aerodynamic excellence, all models nt features. comprehensive package of standard and optional equipme

The model range is extensive and offers a choice of trim, Saloon or Estate (Avant) body styles, four or five-cylinder engines, and four or five-speed gearbox or automatic transmission. Full instrumentation is provided, together with electric windows, central locking, on-board computer, extensive audio system, and power steering, according to model. UK models are available with carburettor, fuel injection or fuel injection with turbocharger engines. North American models are available with fuel injection or fuel injection with turbocharger engines.

Audi 5000S Wagon

|—-USA

Audi 5000S - USA

General dimensions, weights and capacities Dimensions Overall length: PRCT OOM Pitre eee rere dete pbEtaes classsosbavcssesetlssbsseltscnasutavasevesstediecbases RUIN OO irre eeeliiacasssesesscrsccescsrsisssez=sansosidsccessdsancesivnssnstvesoasandonvbisconsesss tore cetant Vaden costees Ua ieredd cae dhsscdeoh sali tessheslanspeuasdtosesenss INU OOO Sree Overall Width v.cccccccccccccsccssctecsetsssssssstseseseseeeessesseesesensassatseseaeessesseneeneas

4792 4808 4894 1814

mm mm mm mm

(188.8 in) (189.4 in) (192.8 in) (71.5 in) (56.2 in) approximately

Overall height (UMIACEN) ......cccccesereseesesesesereseseeeeeneseeneseesisenetseeeeeeenes

1428 mm

Ground clearance (laden): Saloon MOAEIS ....c.ccccsssescsssesscssscseesssessesssesesssseseteneeassssesssesateeesseessassenensens AVANt MOAEIS .occccccesccsccscssescssecsescsssssscsssseneteeseesseesdeneessnestenessesessessenennenens Vehicles with self-levelling SUSPENSION 0.0... esses eee eteesteteenenens WhEEIDASE .occececcescecescesssssscsscsseccsscscssessssusecsessesseneudsseseasaisovensodeesssesassennseesnente FFON trACK veccccccsceccssscsscsssssssscscscssescsscesscsssssecsesesessessaassvenessasecececastenenseaelenenens Rear track ...cccccccccosssssssscscsssssscsssscsesssscssscsosseneseesssesesssasscensslecsenesenteeesenssenesebens Turning circle (between WallS) ........s:sscessesseeeeeseneenienestsseessenssesesenteneaneens

133 mm (5.2 in) 140 mm (5.5 in) 187 mm (7.3 in) 2687.5 mm (105.8 in) 1468 mm (57.8 in) 1469 mm (57.8 in) 11500 mm (453.1 in) approximately

Weights” Kerb weight: Saloon models:

1090 BB KW ENGINE ...cceessecsessesseesessecsecsesneniescssesseansnnsenedseneennssssessonsessesees 1090 tseeesentens nenneanseseess esseneensssnen sneenesseasees ssesessecsesse BE KW ONGINE ......cesesese 1145 TA KW ENGINE o..scccssessesssseesesessesnennesnessecssenessecsecseateenneansenseesenseesesnens 1250 BE KW ENGINE o....seesessessessesseeseesesneeseenesecnnesesesenneaneeneenesscssessensseneenatte 1210 uetees sssesssessessen csscusessensees eseasesseeseese seecsssnessecne ....csseessesse 100 KW @NGiMe 1250 101 KW ONIN .oceeseesscssscsssesesecnetecesesscesecsseneaseansssussneeteeneesstiaseeetnes 1300 134 KW ONGIMNE .o.cceeseseesssssscesseessenestesesecssansenennssncsseenesesesseneeeseseenees Avant models: 1130 BB KW @NGIME .oc.sesssessscsessseesecssecneennessecnsesnecsscnnecnscedsousccsscnseesssanseanennes 1140 BE KW ONGINE ......essssssssesessseneenessnsssssensssneenssnesssenscseatecseenecnnenssassensees 1290 BB KW ONGINE ...secseessessessecsessssesecssesseesscssesnscnnecnnessesenscesseseenesetaeetieeses 1260 ecnseenss ecsecnseennent ssnsessnesssen essessseenecss ecsecssecstecs ..ssessssssscs 100 KW @NGINE 1290 essiees sseenseneessen necneentesssns essssseenessss 101 KW @NGING wrcessscsseseessscsscessness Add 25 Add 15 kg (33 |b) for automatic transmission on five-cylinder engines.

Ib) Ib) Ib) Ib) Ib) Ib) Ib)

kg kg kg kg kg kg kg

(2403 (2403 (2524 (2756 (2668 (2756 (2866

kg kg kg kg kg kg

(2491 Ib) (2513 Ib) (2844 Ib) (2778 Ib) (2844 Ib) (55 /b) for automatic transmission on four-cylinder engines

General dimensions, weights and capacities

8'

Gross vehicle weight: Saloon models: d "onnc90e Fakayiestave Coke htA MACIi Ye|Ute ccerc-ren gonna ceocceea eecocoaco-b, o-pucsoeaceron-cecncasc

TRAKVNRONIGGPs eres ects ccssae sec ctertee sacs fereete cesses cc owes sure a Ceatuavarne? ccc scoteceecrcseceteecscmtcnvarrauseewareeottuaenencamrnnea SHIR Pomayineueeniccit MOOIRW HEN GING: srernccencoccrtr certs tr oncncsare ire, o.spiatecseasenresepasenetese ecass astevtusstrr creat terecchetan SepsunegaeceusucsvantPacuianes MO TEKVVRGIVGIMG cestateccctt euteesmlansuacee eee ekgtasechepaeatae stere TSE CIT cetets cee c otis. ccceassshaeo VSAM Avant models: B5randG6- KW. encimeyc.tecuess eters ene nee ta cgebeesres MaxitntimmirOo faa CK: Oa fee. cascccesatace tater rncnvesdatac Maximum towing weight (12% gradient): Saloon models: BGvand: GEAKW.GNGIMCS ser. cee-cakteccecoursectttetereestecaacecsspiesesse2ptecsevecrysets 74 kW engine: Mantialicearbox iscsi tecrcseteattcctts tasvseeecs-ss caterers seeeetictads ners PAT EOMMAUIOMAMSMMUSSION vcrcesncrcsesvsusucccvexstznusteces¥adteassissvecdseveenevases 85 kW engine:

Wai ClalbO GSO Xiesceessatv.cccrcsanosstteydevre coussaefisvotseat dosesstuvasesesanessses3 AULOMALIC CrANSIMISSLOM) ce. carats te ceidacetacc tay cadstovesunterssslepevseassecaters 100 kW engine: Wahi lal Oar OX? tateretercsves tot sccacteandert se usseat ete daas sv usvetatunvencagvestaes AUROMAL CatranSIMISSION) ....00.

fj oOon

Foglights and tail foglight

Fig. 12.40 Wiring diagram for 1983 1.9 litre Audi 100 models (continued)

Jofel woon

i

N

TZe Sz °

= 3z—zz—h =Tl

oS ars Fa me coe a |Cae a

Zs

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aed gr

wo |®

re) Ts .

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355 Key to Fig. 12.41 (for diagram see facing page) Designation’

ane ae RES

Ss COE

FORE

er Ye

in current track

B D E17

to starter, terminal 50 to ignition switch, terminal 50 Starter inhibitor switch and reversing

J60 J118 L19 M16

Automatic gearbox relay Relay for brake pad wear indicator Gearshift scale light Reversing light left

N

to coil, terminal 15

$12 We T2a

Fuse in fusebox Connector 2pin (behind dash) Connector 4pin (engine compartment right)

1 6

light switch

?

1 to3

ih S "5A

Y

A

fine 3 5 4

5

as

S isa

my, a

10 ra | oot

F

Earth point near handbrake

‘2

For colour code see key to Fig. 12.44

a

Ts

Teo {1\Ts Jaa

Key to Fig. 12.42 (for diagram see facing page)

6 Designation

Fog $19 T3 V37

Central locking switch (in driver's door) Fuse in fuse box Connector, 3pin (behind dash) Central locking motor (Bi-pressure pump)

1 to 3

AUFNEIN AUS:

_

Ts

Tc

0,5 swiro

J124 . To bulb monitoring device, rear S4, S12 Fuses in relay plate/fusebox T1 Connector, single (behind dashboard) 3c Connector, three point (behind dashboard) T4 Connector, four point (behind dashboard) T6 Connector, six point (behind dashboard) Connector, six point (behind dashboard) T6a

(3)

me vs

05

0,5

05

0,5

05

bl

ro/ge

ws

ws/bl

Control unit for automatic cruise control

ee

a Fe

6 Zito) 7 4to9 2 7

Ts

Ts

Ts

| i Ts 05 bliro

Ts

TL

a ws/bl |

:

P .

2

10

of Faz

© a of Fae

To main control unit for Auto-check system

V18

te

bliro

in current track Bp

To foglight and rear foglight switch Automatic cruise control switch Switch unit for cruise control Brake light switch Cruise control clutch pedal switch Automatic cruise control brake pedal switch

G38 ~—_ Cruise control induction sender J122

a

;

1 to 3

For colour code see key to Fig. 12.44

perc

=

b.

Earth point under rear seat

E23 E45 E46 E F36 F47

E

:

in current track

ot? 8

1,8

iGs

Nie |

|