Home Audi Repair Audi 100/200: 1989-91

Audi 100, 200: 1989-1991 Official Factory Repair Manual

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A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

A

ABS
see Anti-Lock Brake System
Airbag
see Body Accessories-Interior
Air filter

see Owner Information
Alignment
see Wheels, Tires, Wheel Alignment
Alternator
see Engine Electrical-Battery, Alternator, Starter, Cruise Control
Anti-freeze

see Engine-Cooling System
Anti-Lock Brake System

-Brake lines removing/installing 45.5
--Combination relay removing/installing 45.6
-Electronic control unit removing/installing 45.6
-Front wheel speed sensors removing/installing 45.7
-General repair notes cautions/warnings 45.2, 45.13
-Hydraulic modulator
2 wheel drive 45.3
all wheel drive (Quattro) 45.4
pressure testing 45.5
removing/installing 45.5
--Rear axle components removing/installing 45.9
-Rear speed sensors disconnecting 45.10
-Rear wiring harness retainer installing 45.12
-Rear wheel speed sensor rotor pressing in 45.12
-Troubleshooting
ABS 2-LED test procedure 45.14
Anti-theft alarm

see Instruments
Air Conditioner

-A/C components
engine compartment, locating 87.10
interior, locating 87.19
-A/C compressor
clutch, air gap 87.34
clutch, removing/installing 87.34
drive belt, adjusting 87.17
removing/installing 87.32
-A/C control head removing/installing 87.20
removing/installing (100E) 87.37
-A/C cooling output checking 87.41
-A/C flap door positions checking 87.29
-A/C high pressure cut-out switch removing/installing 87.16
-A/C programmer removing/installing 87.21
--A/C refrigerant high pressure switch removing/installing 87.17
A/C refrigerant low pressure switch removing/installing 87.16
-A/C refrigerant system cautions/warnings 87.2
checking 87.41 components 87.5
discharging 87.4 repairing/replacing 87.3
troubleshooting 87.43 -A/C thermostat
removing/installing 87.14 -Accumulator
removing/installing 87.7 -Air outlets
removing/installing 87.26 -Air vanes
removing/installing 87.25 -Cables
attaching 87.38
removing/installing 87.37 -Covers
removing/installing 87.25 -Evaporator
assembling/disassembling 87.9
removing/installing 87.8 -Feedback potentiometer
adjusting 87.12
-Footwell/defrost flap door cable
removing/installing 87.37 -Fresh air blower
control unit 87.14
removing/installing 87.13
-Fresh air recirculation flap removing/installing 87.13
-Heater core sealing 87.31
-Heater/evaporator box
air ducts 87.36 assembly/disassembly 87.30 removing/installing 87.18
-High pressure relief valve identifying 87.8
-Inside temperature sensor (in dome light housing)
removing/installing 87.21
-Inside temperature sensor (in instrument panel) removing/installing 87.20
-Instrument panel air ducts locations 87.22
removing 87.24
-0-rings identifying 87.15
-Outside temperature switch checking 87.38
-Rear air outlet removinglinstalling 87.26
Restrictor
removinglinstalling 87.7
-Temperature flap servo motor removing/installing 87. 12
-Temperature regulating flap cable removingInstalling 87.37
-Two way valve checking 87.40
-Vacuum hose routing checking 87.27, 87.39
-Vacuum servos
checking positions 87.27, 87.39
removing/installing 87.23
Air Conditioner-Fault Memory

Diagnosis
-A/C compressor
does not run in AUTO, BI-LEV
or DEF modes D8-120
runs in ECON and OFF modes D8-130
-A/C control head
always dark D8-80
illumination cannot be regulated D8-90
memory display, checking D8-10
memory loss, checking D8-1 10
-A/C cooling performance checking D8-330
-A/C fresh air blower
always runs in OFF mode D8-160
does not run in AUTO, BI-LEV or ECON modes D8-170
speed cannot be regulated D8-180
-A/C high pressure switches (F118, F23) checking D8-230
-A/C refrigerant low pressure switch (F73) checking D8-260
-Digital climate control
quick-check D8-70
-Electrical system voltage display checking D8-250
-Electronic thermoswitch F76 (multi-function temperature sensor) checking D8-290
-Engine coolant temperature sensor (G62) checking D8-310
-Errors in area of climate control regulation D8-220
-Fault memory
cannot be initiated D8-100
-Idle speed increase (A/C ON)
checking D8-320
Inside temperature sensors (G56, G86) checking D8-300
-Kick-down function (1991 m.y.)
checking D8-280
Kick-down switch, F46 (through 1990 m.y.) checking D8-270
Memory channel error display D8-30
-Memory display
channels 1-22 D8-20 channel 7, checking D8-40
channel 17, checking D8-50
channel 18, checking D8-60
Outside temperature
cannot be displayed D8-100
-Outside temperature sensors (G57, G17) checking D8-240
-Radiator cooling fan
does not run at 1st speed in AUTO, BI-LEV
and DEF modes D8-140
always runs at 1st speed in ECON and
OFF modes D8-150
RPM increase (compressor ON) checking D8-320
Temperature regulating flap servo motor, V68 (with feedback potentiometer) checking D8-210
identification D8-200
-Vacuum units/flap positions checking D8-190
Auto-check system see Lights-Interior
Automatic shiftlock

see Automatic Transmission-Controls, Assembly
Automatic Transmission-Case, Gears, Shafts
3-speed 087

-ATF pump disassembling/assembling 38.22
-Direct/reverse clutch
checking 38.27 disassembling/assembling 38.25
drum bushing, removing/installing 38.26
drum, identification 38.27
end play, adjusting 38.26
-Direct/reverse/forward clutches
dimension 38.15
drive shell, modification 38.16
installing 38.13
push rod, length 38.18
-1st/reverse gear clutch checking 38.13
-Direct/reverse gear apply shell installing 38.13
measuring 38.12
-1st/reverse gear piston installing 38.12
-Forward clutch
checking operation 38.24
disassembling/assembling 38.23
drum, dimension 38.24
end play, adjusting 38.24
-Forward planetary gear set modification 38.16
-Governor
identification 38.5
removing/installing 38.5
-One-way clutch
cage segments, assembling 38.21
disassembling/assembling 38.20
springs and rollers, installing 38.21
-One-way clutch/locking key installing 38.14
-Parking lock disassembling/assembling 38.36
-Pump shaft length 38.3
-Reverse planetary gear set installing 38.14
modification 38.16
ring gear, installing 38.15
-Ring gear disassembling/assembling 38.19
-2nd gear brake band checking 38.14
adjusting 38.15
--2nd gear brake band piston cover 38.18
disassembling/assembling 38.17
installing 38.13
push rod, identification 38.15
removing 38.12
-Transmission
assembly 38.2 assembling/disassembling 38.10
installing on stand 38.3
studs, length 38.4
-Transmission/final drive
end play, adjusting 38.6 shim, determining 38.7
-Turbine shaft
length 38.3
rings, checking 38.3
seal, removing/installing 38.4
-Valve body
ball valve locations 38.31
disassembly/assembly 38.32
identification 38.31
removing/installing 38.28
spring table 38.35
transfer plate/separation plate 37.30
4-speed 097

-ATF pump assembly 38.54
replacing 38.42
-Clutch/brake system corresponding
selector lever positions 38.38
installed positions 38.37
--Clutch freeplay (K1, K2) adjusting 38.50
checking 38.51
-Drlveshaft, small
bolt for, replacing 38.44
-1st to 3rd gear clutch (K1) assembly 38.58
disassembling/assembling 38.60
-One-way clutch
assembly 38.55 circllp 38.43
disassembling/assembling 38.56
installing 38.43
-Parking lock
assembly 38.72
disassembling/assembling 38.74
-Planet carrier adjusting 38.45
checking 38.46
-Reverse brake (B1) adjusting 38.47
checking 38.48
-Reverse clutch (K2)
assembly 38.62
circlip for spring support 38.63
installing w/support tube 38.43
-2nd/4th gear brake (B2) adjusting 38.52
checking 38.53 replacing plates 38.42
-3rd/4th gear clutch (K3) assembly 38.64
circlip for spring support 38.66
installing 38.43
-Transmission
assembly 38.39
disassembling/assembling 38.42
-Valve body
assembly 38.68
disassembling/assembling 38.71
identifying 38.70
Automatic Transmission-Controls, Assembly
-Identification identification chart 00.2
general information 00.3
08700.3
09700.4
3-speed 087

--Accelerator operating mechanism
bearing bracket 37.16
pedal operation, adjusting 37.17
pull rod, installing 37.16
push rod length 37.18
repairing 37.15
-Final drive
lubricant capacity 37.3
repair instructions 37.5
--Selector lever/cable
(Shiftlock II, from VIN 44 KN 006 505) assembly 37.8
checking function 37.11
lever housing 37.10
lever switch 37.10
solenoid switch 37.10
troubleshooting 37.12
-Stall speed checking 37.25
-Technical data chart 37.4
-Transmission
checking 37.23
control, repairing 37.20
identification 37.2
lubricant capacity 37.3
removing/installing 37.21
repair instructions 37.5
4-speed 097

-ATF cooler assembly 37.38
checking/filling 37.40
capacity 37.27
filter, removing 37.41
-Lubricant capacities chart 37.27
-Selector level/cable adjusting 37.31
assembly 37.30
lever housing 37.32
lever switch, checking 37.31
lever switch, installing 37.33
lever switch, locking 37.32
shift lock, checking 37.34
solenoid switch 37.32
--Shift points checking 37.43
-Stall speed checking 37.42
-Technical data
chart 37.28
-Transmission
identification 37.25
removing/installing 37.35
Automatic Transmission-Fault Memory Diagnosis

-Automatic transmission 097
diagnosis D3-15
electronic components D3-20
self-diagnosis/safety functions D3-10
troubleshooting using electrical test steps D3-100
-Tester VAG 1551
connecting D3-30 fault chart D3-50
fault memory, reading D3-40
individual measuring values, reading D3-90
measuring value block
early version D3-75
late version D3-80
returning to basic setting D3-70
ATF (automatic transmission fluid)

see Automatic Transmission-Controls, Assembly and Owner Information

B

Battery
see Engine Electrical-Starter, Alternator, Battery, Cruise Control
Body
-Acid rain repairing 50.13
-Body panels identification 00.12
-Body refinishing identifying 50.2
-Body repair dimensions 50.2
-Brilliant black ALD 626 Y9B painting 50.12
-Front fender installing 50.4 removing 50.3
-Front wheel house liner removing/installing50.3
-Galvanized body panels refinishing 50.10 welding 50.9
-Lower front panel
installing 50.8
removing 50.5
-Pearl effect paint
painting 50.11
Body Accessories-Exterior
-Outside mirror glass
replacing (early 1989 m.y.) 66.8
replacing (late 1989 m.y.) 66.8a
-Rear license plate panel
removing/installing 66.5 -Rear spoiler
assembly, Wagon 66.9
removing/installing, Wagon 66.10
-Roof rails installing 66.7 removing 66.6
-Roof trim molding
assembly 66.2
installing 66.4
removing 66.3
-Window slot moldings removing/installing 66.11
Body Accessories-Interior
-Accessories
floor mats
installing 68.12
removing 68.13
-Adjustable B-pillar belt
assembly 68.9a mounting 68.8
removing/installing 68.9b
retaining clips 68.9b
-Airbag system components 68.28
when to replace 68.29 date sticker, replacing 68.38
energy reserve
installed position 68.31 safety measures 68.29
steering wheel/airbag
removing/installing 68.32
testing 68.35
triggering unit
installed position 68.31
voltage supply connector
installed position 68.31
voltage transformer
installed position 68.31
-Airbag unit
disposal 68.30, 68.34
removing/installing 68.32
-Automatic seat belt tensioning assembly 68,14
cable guide bracket 68,23
cable identification 68.27
checking 68,15 removing/installing 68.16
retaining bracket
left 68.25
right 68.26
-Computer memory saver installing 68.30a
-Illuminated vanity mirrors repairing 68.36
-Inside rear view mirror installing 68.2
-Rear seat combination belt assembly 68.10
removing/installing 68.11
-Seat belt stop button replacing 68.8
-Seat belt system inspection 68.3
-Spiral spring
checking 68.33
removing/installing 68.32
-Steering column switches removing/installing 68.31
-Tether anchoring, child seat restraint
Sedan (rear seat) 68.39
Wagon (Canada only) 68.9
-Webbing defects
examples 68.6
Body-Front Doors
-Central door locking troubleshooting 57.9
-Door
assembly 57.7
-Door check strap rivet
removing/installing 57.3
-Door handle
assembly
left front 57.18
right front 57.16
trim, removing 57.17, 57.19
-Door lock
assembly 57.15
-Door shell
assembly 57.2
-Door window
adjusting 57.6
-Heated front door lock cylinders
assembly 57.20
troubleshooting 57.21
-Inner door panel adjusting 57.8
assembly 57.5a
-Key code location 57.17
-Lock clip installing
left front door 57.19
right front door 57.17
Position spring installing, right front door 57.17
Protective cover removing/installing 57.3
-Trim molding removing/installing 57.3
-Window slot seal
installing 57.5
removing 57.4
Body-Rear Doors
-Articulated lever assembly 58.5
Door handle assembly 58.3
-Door lock assembly 58.2
-Pull rod adjusting 58.4
Body-Seats
-Power seat
assembly 72.2
backrest, assembly 72.3
sending units 72.15
-Power seat with memory troubleshooting 72.4
Body-Seat Upholstery
-Alcantara trim
cleaning 74.22
-Heated seat elements
1989 m.y.
cloth upholstery, replacing 74.2
leather seat, installing 74.4
leather seat, removing 74.3
from 1990 m.y. removing/installing 74.
Brake fluid
see Brake-Hydraulic Components and Owner Information
Brake- Hydraulic Components
-Hydraulic servo assembly 47.23
checking 47.32
clevis, adjusting 47.30
identifying 47.26
installing 47.30
removing 47.28
troubleshooting 47.36
-Pressure accumulator
assembly 47.24
checking 47.25
check valve, checking 47.27
damper hose, installing 47.25
pressure relief valve, checking 47.34
All Wheel Drive
-Brake pressure regulator checking/adjusting 47.5
-Brake system bleeding 47.7
-Front double piston caliper assembly 47.14
pistons, removing/installing 47.15
piston seals, removing 47.15
-Rear caliper
assembly 47.20
bleeding 47.22
piston, removing/installing 47.21
piston seal, removing 47.21
Front Wheel Drive
-Brake fluid changing 47.4
-Brake master cylinder assembly 47.2
-Brake pressure regulator checking 47.3
-Brake system bleeding 47.4 checking 47.3
-Front caliper (100) assembly 47.8, 47.11, 47.14
piston
removing/installing 47.9, 47.12, 47.15
piston seal, removing 47.9, 47.12, 47.15
-Rear caliper
assembly 47.17
bleeding 47.19
piston, removing/installing 47.18
piston seal, removing 47.18
Brake-Mechanical Components
Calipers, Girling

-Front brake caliper brake pads
installing 46.4
removing 46.3
cautions/warnings 46.2
Calipers, Teves
-Front brake caliper brake pads
installing 46.7
removing 46.6
cautions 46.5
Front wheel drive
-Parking brake adjusting/checking 46.19
-Rear brake assembly cautions/warnings 46.11
checking brake pad thickness 46.12
removinglinstalling brake pads 46.12
100/100 Quattro
-Parking brake
assembly 46.18 adjusting/checking 46.20
-Rear brake
assembly/caution 46.15
brake pads, replacing 46.16
checking rear brake basic setting 46.17
200/200 Quattro
-Front brakes double piston caliper brake pads
installing 46.10
removing 46.9
cautions 46.8
200 Quattro 20V
-Alloy pedal bracket assembly/caution 46.21
-Brake noise
eliminating 46.23
---Clutch master cylinder clevis adjusting 46.22
-Front brake assembly 46.10a
pads, replacing 46.10b
changes 46.10d
-Steering wheel shimmy during braking
-eliminating (200T/200Q) 46.27
-Technical data
chart 46.1a
Bumpers -Bumper cover
replacing 63.5
-Front bumper
assembly 63.3
removing/installing 63.4
-Rear bumper
removing/installing 63.4

C

Carbon deposits
see Engine Cylinder Heads/Valve Drive
Catalytic converter
see Exhaust System/Emission Controls
Cautions and Warnings
also see individual systems and components
-Cautions and Warnings x, xi
-Wiring diagrams 3, 4
Central locking
see Body-Front Doors
CIS-E III
see Continuous Injection System
CIS turbo
see Continuous Injection System
Clutch
100 models
5-speed 01A

-Clutch assembly 30.7
removing/installing 30.8
Clutch
100 models
-Clutch release
assembly 30.5
-Diaphragm spring ends
checking 30.8
-Disc
replacing 30.11
-Hydraulic clutch components
assembly 30.4
-Master cylinder
clevis and adjusting 30.3
Pedals
assembly 30.2
-Pressure plate
replacing 30.12
-Troubleshooting
chart 30.13
5-speed 012
-Clutch
assembly 30.9
removing/installing 30.10
-Clutch release assembly 30.6
-Diaphragm spring ends checking 30.11
-Disc
checking runout 30.10
replacing 30.11
-Pressure plate
checking distortion 30.10
replacing 30.12
-Troubleshooting
chart 30.13
200 models- All Wheel Drive

Clutch
removing/installing 30-80
-Clutch hydraulic system components 30-40
-Clutch linkage installing 30-60
repairing 30-50
-Foot pedals and clutch controls repairing
steel pedal bracket 30-10
alloy pedal bracket 30-30
-Overcenter spring
removing/installing 30-20
200 models- Front wheel drive
Clutch release mechanism assembly 30.2
-Diaphragm spring ends checking 30.7
-Disc
checking 30.8
-Hydraulic components assembly 30.4 Pedals
assembly 30.5
-Pressure plate assembly 30.3
checking 30.7 installing 30.7
-Return spring removing/installing 30.6
Cruise control

see Engine Electrical-Starter, Alternator. Battery, Cruise Control
Constant velocity (CV) joints
see Front Wheel Suspension-Shafts and Axle
Continuous Injection System
All with engine code MC

-Boost pressure indicator
checking 25.39
-Cold start valve (control function)
checking 25.36
-control pressure regulator
checking 25.20
-Coolant temperature sensor
checking 25.38 -Dashpot (throttle body)
checking and adjusting 25.27 -Deceleration fuel cut off
checking 25.28
component layout 25.6 operation 25.8
-Fuel injectors checking 25.13
injection quantity
comparative measurement 25.18
inserts, leak testing 25.16
-Fuel injection system component layout 25.2
-Fuel pressure checking control pressure warm and
cold, checking 25.2
system pressure, checking 25.22
residual pressure, checking 25.23
-Idle and full throttle switches
full throttle switch, checking 25.25
idle switch
adjusting 25.26
checking 25.24
voltage supply, checking 24.24
-Idle stabilization system component layout 25.45
-Intake air preheating system
component layout 25.10
control box, installing (Canada only) 25.11
thermostat, adjusting (Canada only) 25.11
-Intake air temperature sensor checking 25.41
removing and installing 25.42
-Oxygen sensor system
checking 25.31
control, checking 25.32
frequency valve, checking 25.35
heater, checking 25.33
removing/installing 25.34
-Rules of cleanliness chart 25.9
-Safety guidelines chart 25.9
-Tachometer signal
checking 25.40
-Technical data
chart 25.12
-Temperature safety switch
checking 25.44
-Wastegate frequency valve
checking 25.43
Engine code MC w/one knock sensor
-Carbon canister shut-off valve
checking 25.50
-Control unit output signals
fuel pump relay
signal, checking 25.49
-Engine settings
idle speed, checking/adjusting 25.53
CO value (OXS duty cycle)
adjusting 25.55
checking 25.53
preparations for checking/adjusting 25.51
-Engine control system
layout 25.46
-Idle stabilization system
NC load compensation, checking 25.59
checking 25.57
temperature sensor, checking 25.58
-Rules of cleanliness
chart 25.48
-Safety guidelines
chart 25.48
Engine code MC w/two knock sensors
-Carbon canister frequency valve
checking 25.67
-Carbon canister shut-off valve checking 25.65
-Engine settings
idle speed, checking/adjusting 25.70
CO value (OXS duty cycle)
adjusting 25.71
checking 25.70 preparations for checking/adjusting 25.68
-Fuel pump relay control function
checking 25.63
-Engine control system
layout 25.60
-Idle stabilization system
checking 25.73
troubleshooting 25.75
chart 25.76 -Rules for cleanliness
chart 25.62 -Safety guidelines
chart 25.62
Engine Code NF, CIS-E III
-Acceleration enrichment checking 25.114
-A/C compressor clutch ON/OFF signal checking 25.88
-Altitude sensor checking 25.91
-Air flow sensor plate assembly
control plunger
free play, adjusting 25.97
free play, checking 25.95
removing/installing 25.96
rest position, checking/adjusting 25.93
sensor plate
lever/control plunger, checking 25.93.
lever, centering 25.94
lever, basic adjustment 25.95
stop screw sealing ring, replacing 25.96
-Carbon canister shut-off solenoid
checking 25.84
-CIS-E III system components 25.78
component layout 25.77
control unit locations 25.82
-Cold start valve
operation, checking 25.113
power, checking 25.111
-Coolant temperature sensor checking 25.90
-Deceleration fuel shut-off checking 25.117
-Differential pressure regulator control checking 25.123
-Engine settings
checking 25.128
CO value, adjusting 25.130
ignition timing, checking/adjusting 25.134
-Fuel Injectors checking/cleaning 25.122a
-Fuel pressure, checking differential pressure
part 1, checking 25.120
part II, checking 25.121
injector pressure
specifications 25.122
pressure tester
VW 1318, connecting 25.119
Continuous Injection System)
residual pressure, checking 25.122
system pressure 25.119 - Fuel pump relay control
checking 25.87
-Idle and full throttle switches
checking/adjusting
(Automatic trans. 097) 25.109a
full throttle switch, checking 25.108
idle switch, checking 25.108a
voltage supply, checking 25.107
-Idle stabilization system
shift mode signal, checking 25.89
value power, checking 25.85 -Injection quantity
comparative measurement 25.125
-Oxygen sensor
control system, checking 25.103
heating, checking 25.104
removing/installing 25.105
-Potentiometer
adjusting 25.101
checking 25.98
-Rules of cleanliness
chart 25.83
-Safety guidelines
chart 25.83
-Technical data
chart 25.118 -Throttle potentiometer
(w/ 097 Automatic trans.)
checking/adjusting 25.102a
-Throttle valve
basic adjustment 25.106
dashpot, adjusting 25.111
Coolant
see Engine-Cooling System
CV joints
see Front Wheel Suspension-Shafts and Axle and Rear Wheel Suspension Shafts and Axle

D

Differential-Automatic Transmission
3-speed 087

-Adjusting ring removing/installing 39.6
-Axle flange oil seal removing/installing 39.2, 39.7
-Backlash
checking 39.26
measuring tools, locating 39.27
-Component exchange guide 39.28
-Differential
bearings 39.15 disassembling/assembling 39.14
-Differential and pinion removing/installing 39.6
-Final drive
assembly 39.4
cover, removing 39.13
cover oil seals, removing 39.8
-Governor needle bearing/oil seal removing/installing 39.7
-Pinion
adjusting 39.18
measuring 39.24
turning torque, checking 39.24
-Pinion/cover/oil seal bearings 39.9
bushing 39.11 installing 39.6
-Ring gear
adjusting 39.25 removing/installing 39.15
-Ring gear/pinion adjusting 39.17
-Shims
S4 determining 39.21
S4 available shims 39.23
S3 available shims 39.22
-Speedometer gear removing/installing 39.16
disassembling 39.13
-Torque converter oil seal removing/installing 39.8
-Transmission
overview and applications 39.31
-Transmission/final drive oil seal removing/installing 39.32
4-speed 097
-Axle flange oil seal removing/installing
(transmission installed) 39.33
installing (transmission removed) 39.38
-Differential
assembly 39.35, 39.49
disassembling/assembling 39.53
-Final drive
adjustment overview 39.55
bearing positions 39.53
shim positions 39.53, 39.62
-Output gear
adjusting 39.56
assembly 39.39
bearing turning torque 39.59
removing/installing 39.41
-Pinion
adjusting 39.60
assembly 39.43
identifying 39.60
removing/installing 39.45
-Pinion shaft
adjusting 39.63
drive gear bearing turning torque 39.66
-Ring gear
adjusting 39.60, 39.72
backlash
checking 39.78
determining 39.75
identifying 39.60
Differential-Manual Transmission 100 models
5-speed 012

-Adjustment overview adjustments, table of 39.77
differential, removing 39.78
pinion, determining position 39.78
-Backlash
adjusting 39.89
average, calculating 39.89
checking 39.91
-Differential
housing assembly 39.70
gears, installing 39.74
bearing inner race
large, removing 39.73
small, removing 39.72
bearing outer race
large, removing 39.73
small, removing/installing 39.72
bearing preload, adjusting 39.87
turning torque, measuring 39.88
-Drive flange
oil seals, removing/installing 39.68
shaft circlip, replacing 39.69
-Gear carrier housing replacing 39.85
-Ring gear and pinion adjusting
general notes 39.75
overview 39.78 p
inion
adjusting 39.80
bearing preload, checking 39.81
preload, adjusting 39.80
ring gear
adjusting 39.87
removing 39.73
Shims
positions 39.79
thickness, determining
S total (S1 + S2) 39.88
S total (S3 + S4) 39.80
S1 39.91
S2 39.90
S3 39.83
S4 39.84
5-speed 01 A, Front final drive
-Adjustment overview adjustments, table of 39.24
differential, removing 39.25
pinion installation position,
determining 39.25
sequence 39.26
-Backlash
adjusting 39.35
determination of average 39.37
-Differential
assembly 39.20
large bearing inner and
outer races, removing 39.22
pinion/side
gears, installing 39.22
small bearing inner and
outer races, removing 39.21
-Drive flange
oil seal, replacing 39.3
shaft circlip, replacing 39.3a
-Driveshaft
adjusting 39.6
assembly 39.5
center position, determining 39.7
center universal joints, lubricating 39.7
removing/installing 39.6
-Driveshaft flange oil seal replacing 39.4
-Gear carrier housing replacing 39.32
-Ring gear and pinion adjusting
general instructions 39.23
overview 39.24
pinion
adjusting 39.27
pinion and hollow shaft bearing pre-load
checking 39.28
turning torque, measuring 39.29
ring gear adjusting 39.33
removing 39.21
-Shims
thickness, determining
S total (S1 + S2) 39.34
S total (S3 + S4) 39.27
S1 39.38
S2 39.37 S339.30
S4 39.31
-Speedometer gear
replacing 39.3a
5-speed 01A, Rear final drive
-Adjustment overview
adjustments, table of 39.54
differential, removing 39.55
pinion position, determining 39.55
ring gear/pinion, adjusting 39.55
-Axle flange
adjusting 39.41
installing 39.39
-Backlash
adjusting 39.63
average, determining 39.64
-Differential
assembly 39.48
bearing
inner races, installing 39.50
inner races, removing 39.49
outer races, removing/installing 39.52
pinion gears
adjusting 39.51
installing 39.50
turning torque, measuring 39.63
-Differential flange oil seal left side, replacing 39.14
right side, replacing 39.13
-Driveshaft flange
assembly 39.9
bearing/oil seal, replacing 39.10
-Final drive housing, rear breather, installing 39.40
differential assembly 39.39 layout 39.8
magnet, installing 39.40 pinion shaft assembly 39.42
removing/installing 39.16
technical data 39.2
-Ring gear and pinion adjusting
general instructions 39.53
pinion
adjusting 39.57
bearing, removing/installing 39.45
bearing outer races, removing 39.44
large bearing outer race, installing 39.45
nut, loosening 39.43 nut, tightening 39.47
removing 39.44
small bearing outer race. installing 39 46
turning torque, measuring 39.47
ring gear adjusting 39.62 installing 39.50
removing 39 49
-Shims
positions 39.56
thickness, determining
S total (S1 + S2) 39.63
S1 39.65
S2 39.67
S3 39.60
200 models-Front wheel drive
5-speed 016

-Backlash adjusting 39.15
-Differential
assembly 39.2
housing, disassembling 39.3
-Differential bearings
installing 39.3
outer race, removing/installing 39.6
removing 39.2
-Differential pinion/side gears checking 39.6
installing/adjusting 39.3
-Pinion
adjusting 39.7, 39.10
-Ring gear
adjusting 39.7, 39.14
installing 39.3
removing 39.2
-Shims
thickness, determining S1 39.17
S2 39.16
S3 39.11
S4 39.13
-Turning torque measuring 39.15
200 models-Quattro
5-speed 016, Front final drive

-Axle flange oil seal (transmission installer replacing 39-10
-Backlash adjusting 39-130
-Differential
assembly 39-50
disassembling/assembling 39-60
-Differential bearings
pre load, adjusting 39-130
removing/installing 39-60
-Differential pinion gears adjusting 39-60
-Driveshaft
adjusting 39-170
aligning 39-180
assembly 39-140
removing/installing 39-160
repairing 39-150
-Pinion
adjusting 39-120
-Pinion bearing pre load checking/adjusting 39-120
-Pinion gears installing 39-60
-Ring gear adjusting 39-130
installing 39-60
-Ring gear/pinion
adjusting 39-70, 39-100
adjustment overview 39-80
determining position 39-90
-Shims
positions 39-110
S total, determining
(S1 and S2) 39-130
(S3 and S4) 39-120
-Speedometer drive gear (transmission installed) replacing 39-20
5-speed 016, Rear final drive
-Axle flange adjusting 39-260
-Axle flange oil seal
Left/right side, replacing 39-220
-Backlash adjusting 39-380
-Clutch body
installing 39-250
adjustment shim thickness 39-250
-Differential
assembly 39-290
bearing, removing/installing 39-300
disassembling /assembling 39-300
gears, installing 39-300
-Drive flange/bearing bearing, removing 39-280
cover, removing 39-280
-Driveshaft flange oil seal/bearing replacing 39-210
-Pinion
adjusting 39-360
assembly 39-270
bearings, removing/installing 39-280
determining position 39-330
disassembling/ assembling 29-280
gears, adjusting 39-300
nut, loosening/tightening/securing 39-280
-Rear final drive
assembly 39-200, 39-240
housing, disassembling/assembling 39-250
removinglinstalling 39-230
-Ring gear
adjusting 39-370
removing/installing 39-300
-Ring gear/pinion
adjusting 39-310, 39-340
adjustment overview 39-320
-Shims
positions 39-350
S total (S1 and S2), determining 39-370
thickness, determining
S1 39-380
S2 39-380
S3 39-360
-Torsen differential assembly 39-190

E

Engine-Assembly
--Engine identification chart 00.12
engine code (NF, MC) 00.6
engine code (3B) 00.6
MC turbo engine 00.13
-Engine technical data charts
MC turbo engine, pre-Nov. 1988 00.14
MC turbo engine, post-Nov. 1988 00.15
NF CIS-E III engine 00.17
3B 20-valve turbo engine 00.16
Engine code MC
-Corrosion protection engine 10.27
installing 1 0.14
removing 1 0.2
tightening torques 10.14
-Transmission aligning 10.16
Engine code NF
-Corrosion protection engine 10.27
installing 10.25
removing 10.17
tightening torques 10.25
--Transmission aligning 10.26
Engine code 3B
-Corrosion protection engine 10.27
installing 10.33 removing 10.28
tightening torques 10.34
Engine-Cooling System
Engine code MC/NF

-Antifreeze hydrometer
checking 19. 5
-Coolant
assembly 19.2
checking 19.3
draining/refilling 19.4
expansion cap, checking 19.3
level, checking 19.5
mixture ratio 19.5
thermostat, checking 19.3
Engine code 3B
-Antifreeze hydrometer checking 19.5
-Coolant
checking 19.9
component layout 19.6
draining/refilling 19.10
expansion tank cap, checking 19.9
level, checking 19.11
mixture ratio 19.11
pump, checking 19.12
thermostat, checking 19.9
turbocharger thermoswitch, checking 19.
Engine-Crankcase, Crankshaft
Engine codes MC, NF

-A/C compressor belt adjusting 13.7
tension, checking 13.7
-Connecting rod bearing
bolt, identification 13.18
clearance, checking 13.18
side clearance, checking 13.18
-Crankshaft
assembly 13.8 dimensions 13.12
end play, checking 13.11
main bearing clearance, checking 13.11
oil seal
flywheel side 13.9
pulley side 13.10
-Cylinder bore 13.17
-Drive belt assembly 13.2
installing 13.5
-Drive plate
removing/installing (087) 13.13b
installing (097) 13.13c
-Engine assembly 13.3
-Flywheel
assembly 13.8
engine tester magnetic pick-up pins
checking 13.13
ignition timing reference sensor
installing 13.13
removing/installing 13.9 13.12
replacing (engine code MC) 13.11
-Idler pulley removing 13.4
-Oil pan removing/installing 13.4
-Pilot bearing removing/installing 13.9
-Pistons
assembly 13.14
circlip 13.16
clearance 13.16
dimensions 13.16
end gap 13.15
identification 13.16
installing 13.17
rings 13.15
-Power steering belt checking tension 13.7
-Vibration damper removing/installing 13.4
Engine code 3B
-Connecting rod
bearing clearance, checking 13.41
side clearance, checking 13.41
-Crankshaft assembly 13.28
checking 13.32
dimensions 13.33
oil seal
flywheel side 13.31
pulley side 13.31
-Cruise control removinglinstalling 13.26
-Cylinder bore 13.40
-Drive belt assembly 13.19
installing 13.24
-Engine
cylinder head, component layout 13.21
-Flywheel assembly 13.28
replacing 13.34
-Idler pulley removing 13.22
-Oil pan removing/installing 13.23
-Pilot bearing removing 13.30
-Pistons
assembly 13.36
checking/installing 13.39
dimensions 13.40
rings
checking 13.38
removing/installing 13.38
-Power steering belt
adjusting 13.27
-Vibration damper
removing/installing 13.22
Engine-Cylinder Head, Valve Drive
Engine code MC / NF

-Camshaft
assembly 15.6
bearing caps 15.15
end play, checking 15.8
oil seal
installing 15.18
removing 15.16
radial clearance, checking 15.8
-Carbon deposits fuel quality 15.20
-Compression values checking 15.5
-Cylinder head assembly
engine code NF 15.3
engine code MC 15.4
bolts 15.5
cracks, checking 15.9
distortion, checking 15.9
gasket 15.5
machining 15.9
-Drive belts assembly 15.2
-Oil spray jet positioning 15.16
-Valves
assembly 15.7
dimension 15.11
exhaust valve, discarding 15.14
guides 15.10,15.13
hydraulic lifters 15.7
keepers 15.10
lapping 15.10 refacing 15.13
seats 15.12
stem seals 15.18
Engine code 3B
-Camshaft
assembly 15.25 bearing caps 15.27
end play, checking 15.27
-Camshaft oil seal
installing 15.32
removing 15.32 removing/installing 15.33
-Carbon deposits fuel quality 15.20
-Compression values checking 15.24
-Cylinder head
assembly 15.21 bolts 15.23
distortion, checking 15.23
-Valves
assembly 15.28
dimension 15.28
exhaust valve, discarding 15.30
guides 15.35
hydraulic lifters 15.31
keepers 15.37
seats 15.28 stem seals 15.31
Engine Electrical-Battery, Alternator, Starter, Cruise Control
-Alternator
exciter circuit, checking 27.12
exploded view 27.10
indicator light, troubleshooting 27.16
output, checking 27.11 v-belt tension
checking and adjusting 27.13. 27.14a
voltage regulator carbon brushes
replacing 27.15
-Battery
charging 27.5
checking and charging 27.2
condition, checking 27.4
jump starting 27.6
load test 27.7
removing/installing 27.3
troubleshooting 27.8
voltage test 27.7
-Cruise Control troubleshooting 27.23
-Starter
exploded view 27.18
removing/installing 27.22
troubleshooting 27.20
Engine-Lubrication System
-Assembly
engine code MC 17.4 engine code NF 17.3
engine code 3B 17.10,17.12
-Crankshaft oil seal
engine codes MC, NF 17.6
engine code 3B 17.18
-Drive belt
engine codes VC, NF 17.2
engine code 3B 17.10
-Lubrication system engine code 3B 17.14
-Oil capacity specification 17.8
-Oil pressure sender
checking, engine code 3B 17.19
-Oil pressure switch
checking, engine codes MC, NF 17.9
checking, engine code 3B 17.18
-Oil pump
engine codes MC, NF 17.2, 17.7
engine code 3B 17.16 vibration damper 17.5
-Relief valve
engine codes MC, BF 17.2
engine code 3B 17.10
Exhaust System/Emission Controls
-Evaporative system leakage
troubleshooting 26.11 -Exhaust system
installing 26.13
Engine code MC
-Exhaust system component layout 26.2
-Vacuum connections layout 26.5, 26.6
Engine code NF
-Exhaust gas recirculation system (EGR) checking 26.21
fault code, troubleshooting 26.28
functional check 26.26
-Exhaust system
component layout 26.4
vacuum connections 26.8, 26.1 Oa
Engine code 3B
-Exhaust manifold removing installing 26.16
-Exhaust system component layout 26.3
installing 26.14
leak checking 26.15
-Vacuum connections layout 26.7

F

Final drive
see Differential -Automatic Transmission or Differential-Manual Transmission
Front Wheel Suspension-Shafts and Axle
-Axle shaft
ABS components 40.6
assembly 40.18
-Coil spring assembly 40.8
-Constant velocity joints installing 40.20
removing 40.19
-Damping ring identifying 40.13
-Drive shaft/CV joint
revised for 097 transmission 40.21
-Rubber bushing
in control arm
removing/installing 40.3
in subframe
pressing in 40.5
pressing out 40.3
removing/installing 40.4
-Shock absorber assembly 40.8
removing/installing 40.13
-Speed sensor
ABS components 40.6
assembly 40.7
-Subframe assembly 40.2
-Suspension strut
assembly 40.7
20V 40.8a
disassembling 40.14
removing/installing 40.11
-Wheel bearing removing/installing 40.10
-Wheel bearing housing ABS components 40.6
-Wheel hub/wheel bearing removing/installing 40.9
Fuel Injection-AFC System
Engine code 3B

-Altitude sensor
checking 24-140
-Air mass sensor
checking 24-160
component layout 24-150
-Carbon canister frequency valve
checking 24-110
-Fuel injectors
checking 24-60
-Fuel injection system
component layout 24-10
-Fuel pressure
checking 24-40
-Fuel pump relay
checking 24-50
-Idle speed and CO content
Checking 24-70
-Idle switch
checking adjusting 24-120
-Oxygen sensor system
checking 24-90
-Safety precautions
rules of cleanliness 24-20
safety measures 24-20
-Technical data
chart 24-30
-Throttle potentiometer
checking /adjusting 24-130
-Vacuum connections
layout 24-170
-Wastegate frequency valve
checking 24-100
Fuel Supply
Engine codes MC, NF

-Fuel gauge sending unit
removing/installing 20.6
-Fuel pump
checking 20.7
check valve, checking and replacing 20.11
delivery rate, checking 20.9
electrical checking 20.13
-Fuel supply
component locations 20.15
-Fuel system component layout 20.2
removing and installing 20.41
-System precautions rules of cleanliness 20.4
safety precautions 20.5
Quattro
-Fuel tank
removing and installing 20.34
Engine code 3B
-Carbon canister vent system component layout 20.30
-Fuel filter
mounting position 20.18
-Fuel gauge sending unit removing /installing 20.19
-Fuel pump
checking 20.22
check valve, checking/replacing 20.24 component layout 20.17
relay checking 20.27
removing and installing 20.20
-Fuel supply
component layout 20.16
-Remote control VAG 1348/3A connecting 20.18
-Throttle cable checking/adjusting 20.32
component 20.31
--Throttle damper
checking and adjusting 20.33
Fuel tank
see Fuel Supply
Fuses
see Owner Information or Main Wiring Diagram for the specific model/model year,

G

Glass, Window Regulators
-Bonded rear window Wagon
installing 64.21
removing 64.18
-Power window regulators assembly
front door 64.31
rear door 64.32
control panel switches 64.36
individual windows do not operate 64.35
no window operates 64.33
rear safety switch, checking voltage 64.37
safety switch
checking continuity 64.41
removing/installing 64.40
thermo fuse, location 64.42
troubleshooting, general 64.33
window operating switches
checking 64.38
continuity, checking 64.41
removing/installing 64.40
window regulators
checking/replacing 64.39
-Rear window
installing 64.12
removing 64.10
resealing, Wagon 64.24
-Replacing
general information 64.2 installing 64.6
-Side windows installing 64.14
Wagon 64.27
removing 64.13
Wagon 64.25
sealing leaks, Wagon 64.30
-Window lifter pivot
repairing 64.54
-Window regulator assembly inspecting 64.43
-Window regulator drive replacing 64.55
-Window regulator motor disassembly 64.44
inspecting/cleaning 64,47
reassembly 64.48
replacing 64.50

H

Heating/ventilation
see Air Conditioner
Hoods/Lids
-Front hood cable
adjusting 55.1
-Gas-filled strut
discarding 55.2
removing 55.1
-Rear lid lock
assembly 55.3
Hydraulic fluid
see Steering

I

Idle speed
see Continuous Injection System or Fuel Injection-AFC System
Ignition System
Engine code MC

-Ignition wires/connectors, rotor arm checking 28.13
-Safety guidelines chart 28.3
Engine Code MC w/one Knock Sensor
-Engine RPM sensor
checking 28.5
-Hall sending unit
checking 28.7
-Ignition coil (with power stage)
checking 28.10
-Ignition distributor
basic adjustment 28.9
-Ignition timing reference sensor
checking 28.4
-Technical data
chart 28.2
Engine Code MC w/two knock sensors
-Engine speed sensor checking 28.17
-Hall sensor checking 28.19
-Ignition coil
checking 28.16
control function checking 28.15
-Ignition control unit removing /installing 28.15
supply voltage, checking 28.23
-Ignition distributor basic setting 28.21
-Ignition timing sensor checking 28.18
-Technical data
chart 28.14
Ignition-Fault Memory Diagnosis
Engine code MC w/one knock sensor

-Fault code
construction D2-30
troubleshooting chart D2-70
-Fault memory
activating
using US 1115 D2-20
using fuel pump relay D2-40
using VAG 1551 D2-60
-Output checks activating
using fuel pump relay D2-80
using VAG 1551 D2-90
-Self diagnosis
general information D2-10
-VAG 1551 diagnostic tester
connecting D2-50
Engine code MC w/two knock sensors
-Fault code
troubleshooting chart D2-140
-Fault code (California only starting 7/90) chart D2-200
-Fault memory activating
using US 1115 D2-1 10
using VAG 1551 D2-130
erasing using US1115 D2-160
-Fault memory (California only starting 7/90) checking/erasing D2-190
-Idle stabilization system (California only starting 7/90) checking D2-210
-Ignition system
(California only starting 7/90) electrical troubleshooting D2-220
-Output checks activating
using US 1115 D2-150
using VAG 1551 D2-180
general information D2-170
-Self diagnosis
general information D2-100
-VAG 1551 diagnostic tester general information D2-120
Engine code NF
-CIS-E III system electrical testing D2-325
-Fault code
activating, using diagnostic connectors and US 1115 D2-280
listing D2-320
troubleshooting chart D2-330
-Fault diagnosis
using instrument panel warning light D2-230
flow chart using instrument panel warning light D2-240
-Fault memory activating/interrogating
using VAG 1551 D2-300
erasing using 1551 D2-310
-Output checks
activation using VAG 1551 D2-370
fuel pressure regulator preparation D2-360
vehicles without diagnostic connectors D2-340
using VAG 1551 diagnostic tester D2-350
--Permanent memory erasing D2-250
-VAG 1551 diagnostic tester connecting D2-290
general information D2-260
-VAG 1598 test box description D2-270
Engine code 3B
-Diagnostic connectors for VAG 1551 checking D2-240
-Engine basic adjustment using VAG 1551 D2-430
-Engine ground connections checking D2-390
-Fault code
troubleshooting chart D2-480
-Fault memory
checking erasing D2-400
-Motronic control unit removing/installing D2-460
-Output checks diagnosis using VAG 1551 D2-410
-Self diagnosis technical data D2-380
-VAG 1551 diagnostic tester function 04
key to displays in channels 1 to 10 D2-440
troubleshooting table D2-450
-VAG 1598 text box
connecting to Motronic control unit D2-470
Injection, fuel
see Continuous Injection System or Fuel Injection- AFC System
Instruments
-Additional gauges
checking 90.13
-Anti-theft alarm components 90.15
troubleshooting 90.18
-Coolant temperature gauge checking 90.11
-Coolant warning lamp checking 90.12
-Instrument cluster components 90.3
control lamps 90.5
removing/installing 90.4
-Emergency flasher/turn signal relay locating 90.4
-Fuel gauge adjusting 90.10 checking 90.9
-Oil pressure gauge checking 90.14
-Speedometer sender checking 90.13
-Voltage stabilizer checking 90.8
-Voltmeter checking 90.14

L

Lifting vehicle
see Owner Information
Lights-Interior
-Auto-check code
checking 96.5
-Auto-check sensors location 96.6
-Auto-check system coding 96.4
operation 96.2
testing 96.8
troubleshooting 96.8
-Automatic transmission control unit removing/installing 96.19
-Selector lever display (from 1991) connector terminals, checking 96.17
connector terminal identification 96.17
removing/installing 96.16
Lights-Exterior
-Back-up light lens removing/installing 94.9
-Headlights
aiming 94.4
assembly 94.2
removing/installing 94.3
-Steering column switches
assembly 94.10
removing 94.11
-Steering lock housing/lock cylinder
removing/installing 94.11
-Taillight assembly
100 models 94.6
200 models 94.7
-Taillight housing
removing/installing 94.8
Locks
see Body-Front Doors and Body-Rear Doors

M

Manual Transmission-Case, Gears, Shafts
100 models
5-speed 01A

-Double taper roller bearing inner race
installing/removing 35.10 outer race
installing/removing 35.10
-Fifth gear installing/removing 35.4
-Fifth/reverse gear operating sleeve installing 35.16
-First/second gear operating sleeve installing 35.11
-First/second gear synchronizer hub installing 35.12
removing 35.11
-Fourth gear circlip 35.5
installing 35.13
removing 35.12
-Mainshaft
adjusting 35.6
assembly 35.2
circlips, location 35.5
installing 35.3
-Mainshaft needle bearing installing 35.3
removing 35.3, 35.5
-Pinion and hollow shaft assembly 35.8
circlips, location 35.15
-Synchronizer hub
removing 35.13
-Synchronizer ring
checking 35.4, 35.11
-Synchronizer spring
installing 35.3, 35.11
-Taper roller bearing inner race
circlip, determining 35.14
removing/installing 35.13
-Taper roller bearing outer race
removing 35.14 -Third gear
removing/installing 35.12
-Third/fourth gear operating sleeve
installing 35.4
-Transmission
modifications 35.16a
5-speed 012
-Double taper roller bearing inner race
installing 35.29
removing 35.28 outer race
installing/removing 35.28
-Fifth gear installing 35.21
removing 35.20
-Fifth/reverse gear operating sleeve installing 35.32
-First/second gear operating sleeve installing 35.30
-Fourth gear
circlip, installing 35.21
installing/removing 35.31
-Main shaft
adjusting 35.24
assembly 35.17
ball bearing, installing 35.19
circlips, locating/selecting 35.22
needle bearing
installing 35.19
removing 35.19, 35.21 plastic sleeve, installing 35.23
-Pinion and hollow shaft assembly 35.26
circlips, locating/selecting 35.34
-Synchronizer hub
removing 35.31
-Synchronizer ring checking 35.20, 35.29
-Synchronizer spring installing 35.20, 35.29
-Taper roller bearing inner race
circlip, determining 35.34
removing/installing 35.32
outer race
installing/removing 35.33
locking bushing, removing 35.33
-Third gear removingInstalling 35.33
-Third/fourth gear synchronizer hub
installing 35.23
-Third/fourth gear operating sleeve
installing 35.20
-Transmission
modifications 35.35
200 models-Front wheel drive
5-speed 016

-Drive flange oil seal installing 35.14
removing 35.14
-Final drive housing assembly 35.4, 35.14
-Gear carrier housing
assembling 35.9
assembly 35.2
disassembling 35.7
interlock pins/detent plungers 35.18
reverse lever 35.18
-Mainshaft
bearing inner/outer race 35.24
disassembling 35.20
4th gear 35.23
needle bearing 35.25
oil seal 35.14
synchronizer rings/hub 35.22
3rd gear 35.22
-Pinion shaft
assembly 35.26
bearing inner race 35.29
1st gear needle bearing 35.27
1st/2nd gear synchronizer 35.30
2nd gear synchronizer hub 35.31
synchronizer rings 35.30
3rd/4th gear 35.29
-Shim S4
determining thickness 35.19
200 models-Quattro
5-speed 016

-Bearings
differential, removing/installing 35-200
removing/installing 35-60
inner races
removing 35-130
installing 35-150
outer races
removing/installing 35-160
-Differential disassembly/assembly 35-180
-Differential gears installing 35-190
-Differential with lock
assembly 35-170
-Gear carrier housing disassembling/assembling 35-30
-Hollow shaft and gears
disassembly/assembly 35-100
-Input shaft
disassembling/assembling 35-40
-Input shaft and gear carrier
adjustment 35-70
disassembly/assembly 35-20
-Pinion
dimensions 35-120
-Pinion and hollow shaft adjustment 35-70
disassembly/assembly 35-20
-Synchronizer assembling 35-140
-Synchronizer and gears assembling 35.50
-Transmission
general layout 35.10
Manual Transmission-Controls, Assembly
-Identification
general information 00.3
identification chart 00.2
transmission type 012 00.5
transmission type 016 00.5
100 Models
5-speed 01 A

-Differential and final drive assembly 34.20
-Differential lock
assembly 34.5
hose layout 34.6
-Differential lock control unit
removing/installing 34.7
-Differential lock operating switch
removing 34.7
-Drive flange
ball bearing 34.21 removing 34.14, 34.22
removing circlip 34.15
sealing ring 34.15
-Fifth/reverse near interlock assembly 34.16
installed position 34.15
-Final drive cover
tapered roller bearing removing and
installing 34.15
-Final drive housing
assembly 34.12
-Gearshift assembly 34.3
-Gearshift linkage
adjusting 34.4
-Main shaft
assembly 34.17
ball bearing removing/installing 34.13
modification from 21 to 9 34.23a
-Multi-function sender installing 34.14
-Oil collector removing/installing 34.19
-Relay shaft bolts removing 34.18
-Selector shaft bushing removing 34.18
-Shift fork bearing removing/installing 34.19
-Shift rod bushing removing 34.14
-Shift mechanism installation position 34.18
-Technical data chart 34.2
-Torsen differential
cover cap, removing 34.21
installing 34.23
needle bearing removing/installing 34.22
removing/installing 34.21
Transmission assembly 34.10
disassembling/assembling 34.11
mounting in stand 34.13
removing/installing 34.8
-Transmission housing tapered roller bearing, removing/installing 34.16
5-speed 012
-Drive flange
circlip, removing/installing 34.36
removing 34.36 sealing ring 34.36
-Fifth/reverse gear interlock assembly 34.38
installed position 34.38
-Final drive cover tapered roller bearing
removing/installing 34.37
-Final drive housing assembly 34.31
-Gearshift assembly 34.26
-Gearshift linkage adjusting 34.27
-Main shaft
assembly 34.39
ball bearing, removing/installing 34.34
-Multi-function sender installing 34.35
-Oil collector removing/installing 34.42
-Relay shaft
bolts, removing 34.41 installing 34.41
-Selector shaft bushing removing 34.42
-Shift fork bearing removing/installing 34.42
-Shift rod bushing removing 34.35
-Shift mechanism installation position 34.41
-Speedometer drive replacing 34.37
-Technical data
chart 34.25
-Transmission
assembly 34.30 disassembling/assembling 34.33 layout 34.24
mounting in stand 34.34 removing/installing 34.28
-Transmission housing tapered roller bearing
removing/installing 34.38
200 models-Front wheel drive 5-speed 016
-Drive flange oil seals removing/installing 34.10
-Gearshift lever adjusting 34.6
-Gearshift linkage
assembly 34.4
adjusting 34.5
-Technical data chart 34.2, 34.2a
-Transmission installing 34.9
removing 34.8
200 models-Quattro 5-speed 016
-Differential removing/installing 34-230
-Differential lock controls assembly 34-120
hose installation 34-140
hose connection diagram 34-150
switch, removing/installing 34-190
-Differential lock pneumatic control unit removinglinstalling 34-170
-End cover/drive flange
components, removing/installing 34-360
disassembling/assembling 34-350
-Fifth/reverse gear
assembly 34-190
--Gear carrier
disassembling/assembling 34-240, 34-250, 34-310
removing/installing 34-220
-Gear carrier housing
disassembling/assembling 34-320
-Gear carrier/final drive housing
assembly 34-200
-Main shaft selector rods
disassembling/assembling 34-260
-Pinion shaft
removing/installing 34-210
--Rear final drive
assembly 34-130
-Shift controls
assembly 34-20
checking adjustment 34-100
repairing 34-30
-Shift lever
assembly 34-60
general information 34-70
-Shift linkage adjusting 34-110
-Shift rods
general information 34-50
push rods, removing/installing 34-90
removing/installing 34-80
repairing 34-40
-Shim S4
thickness, determining 34-340
overview 34-330
--Technical data
chart 34-10
--Transmission
assembling 34-280 disassembling 34-270
removing/installing 34-180
--Transmission housing components, installing 34-300
disassembling/assembling 34-290
Motronic
see Fuel Injection AFC System

O

Oil
-Engine
see Engine--Lubrication System and
Owner Information
-Manual transmission
see Owner Information
Oil filter
see Engine-Lubrication System and Owner Information
Owner Information
-Do-it-yourself service changing a wheel 25
compact spare wheel 25 emergency starting 32
fuses 27
headlight adjustment 31 jack and tools 24
lifting vehicle 00.9, 33
location of servicing points 35
replacing bulbs 28
replacing the radio 31
-Gas station information emergency towing
with commercial towing truck 34
location of servicing points 36
towing anchorages 34
-Maintenance/lubrication schedules table 40
-Technical data capacities/dimensions 38
engine data/spark plugs 37
v-belts 37
vehicle identification 39
weights 39
-Vehicle care
additional accessories, modifications and
parts replacement 23
air cleaner 1 1
automatic transmission fluid 10
battery 16
brake fluid 13
cleaning products 2
cooling system 14
corrosion protection 4
difficult operating conditions 21
engine compartments 6
engine hood 6
engine oil 8
engine oil filter 10
exterior/interior 3
fuel supply 1
fuel tank 1
lubricants 8
maintenance 5
manual transmission oil 11
power steering / brake booster 12
tires/wheels 19
v-belt 15
windshield/rear window washer container 18
winter driving 22
wiper blades 18
Oxygen sensor (OXS)
see Continuous Injection System and Fuel Injection--AFC System

R

Radio, Telephone, Board Computer
Radio

-Bose speaker removing/installing 91.24
-CD changer controller removing/installing 91.27
-CD changer system
component layout 91. 26
components, removing/ installing 91. 27
electrical connectors
terminal identification 91.28
self-diagnosis 91.30
troubleshooting 91.32
-CD changer unit
cable, terminal identification 91.28
removing/installing 91.27
-CD frequency and loudness switches changing 91. 39
-CD magazine
emergency ejecting 91.39
CD remote control cable terminal identification 91.28
Delta Bose fixed coded radio
coding/reactivating 91. 20
unlocking 91.22
Delta Bose stereo system component layout 91. 23
-Eight-point radio connector terminal identification 91.29
-Four-point CD changer connector terminal identification 91.29
-Front antenna
checking 91.16
installation/connections 91.15
-Radio
connections 91.14
signal reception 91.13
-Rear antenna
checking 91.18 installation/connections 91.17
Telephone
-Antenna performance checking 91.55
-Cellular telephone
system components 91.44
-Cradle and antenna removing/installing 91. 47
-Electronic serial number (ESN) checking
(diagnostic test command 38#) 91.58
-Fast busy signal
when placing calls 91.67
-Fuse
checking 91.51
-Handset
identifying 91.41
-Hands-free microphone and speaker
removing/installing 91.45
-Hands-free system
checking 91.56
-Lockout counter
resetting
(diagnostic test command 32#) 91.57
-NoSvc light
stays on 91.66
-Roam characteristics
checking 91.43
-Security code
identifying
(diagnostic test command 55#) 91.60
-Static
on calls 91.71
-Telephone
does not operate in hands-free mode 91.69
does not respond to voice commands 91.72
does not switch ON 91.63
-Test mode
programming chart (55#) 91.62
-Transceiver
registering 91.49
removing/installing 91.48
-8-point modular connector on handset terminal identification 91.52
-25-point connector to transceiver terminal identification 91.53
Board Computer
-Airflow sensor potentiometer adjusting 91.9
removing/installing 91.9
-Average fuel consumption display checking 91.5
-Average speed display checking 91.5
-Board computer
code checking 91.3
controls checking 91.6
country code checking 91.4
functional testing 91.3
test notes 91.2
-Boost pressure display checking 91.6
-Boost pressure signal checking 91.10
-Fuel consumption factor
checking 91.5t
correcting 91.11
from start, checking 91.7
signal
CIS checking 91.8
CIS-E III, checking 91.7
test notes 91.2
-Fuel injection code checking 91.4
-Fuel shut-off signal checking 91.10
-Function selector switch checking 91.12
operating 91.2
-Range calibration
adjusting 91.11
checking 91.10
-Speed signal checking 91.7
Rear Wheel Suspension-Shafts and Axle
Front wheel drive
-ABS
components 42.10
-Grease cap removing 42.8
-Rear axle
assembly 42.2 removing/installing 42.3
repairing 42.6
-Rear axle bushings removing/installing 42.7
-Rear suspension strut removing/disassembling 42.11
-Rotor for ABS pressing on 42.9
-Shock absorber assembly 42.12
-Wheel bearing
adjusting 42.8
inner race, driving in 42.8
outer race, driving in 42.9
Quattro
-ABS
components 42.13
-Axle shaft
assembly 42.15
removing/installing 42.21 a
--Bushings removing/installing 42.18
-Crossmembers assembly 42.14
-Damper ring positioning 42.27
-Lower spring retainer positioning 42.27, 42.29
-Transverse link assembly 42.17 removing/installing 14.21
-Trapezoidal arm assembly 42.14
20V 42.17a removing/installing 42.22
-Wheel bearing
inner race, removing 42.20
pressing out/in 42.21
-Wheel bearing housing assembly 42.17
-Wheel hub
pressing out/in 42.20
-Rear suspension strut assembly 42.26
20V 42.28 disassembling/assembling 42.27
removinglinstalling 42.23
-Trapezoidal arm removing/installing 42.22
20V 42.25
-Wheel bearing housing removing/installing 42.24
Relays
see Owner Information or Main Wiring Diagram for the specific model/model year

S

Seat belts
see Body Accessories-Interior
Starter
see Engine Electrical-Starter, Alternator, Battery, Cruise Control
Steering
-Airbag system
components 48.37, 48.40
checking spiral spring 48.42
disposal 48.38a, 48.43
removinglinstalling 48.41
safety measures 48.38
testing 48.44
-High pressure hose replacing 48.9a
-Hydraulic fluid replacing 48.24
-Hydraulic oil reservoir repairing 48.21
-Hydraulic pump checking pressure 48.23
repairing 48.22, 48.28 resealing 48.30
v-belt, adjusting 48.23
-Steering column removing/installing 48.3
repairing 48.2
-Steering column switches
removing 48.7
-Steering damper
for Quattro 20V 48.8a
-Steering gear
adjusting 48.15
assembly 48.8
hydraulic lines, installing 48.9
repairing 48.10
-Steering lock housing/lock cylinder removing 48.6
-Steering (short rack) assembly adjusting 48.19
preparation/installing 48.16, 48.20
-Steering system
bleeding 48.25
checking for leaks 48.23
checking for restrictions 48.15
troubleshooting 48.26
-Tie rods
installing 48.8
-Airbag system
Struts
see Front Wheel Suspension Shafts and Axle
Sunroof
Electrical drive checking/adjusting 60.13
-Sealing gap
fine adjustment 60.13
-Sunroof
assembly 60.2, 60.7
disassembly 60.9
installing 60.10
removing 60.5
-Sunroof lid adjusting 60.12
assembly 60.3
installing 60.11
removing 60.4
-Sunroof motor adjusting 60.13
installing 60.14
removing 60.5
-Sunroof troubleshooting procedure 60.16
100E
-Cable drive
adjusting 60.35
assembly 60.25
gear removing 60.27
-Sunroof
assembly 60.23
assembling 60.29
disassembling 60.28
installing 60.32
removing 60.27
-Sunroof lid
adjusting 60.34
assembly 60.24
removing 60.26
sealing gap, fine adjustment 60.35
-Water drain hoses location 60.36
Suspension
see Front Wheel Suspension-Shafts and Axle and Rear

T

Thermostat
see Engine Cooling System
Tires
see Wheels, Tires, Wheel Alignment
Torque Converter
-Pilot needle bearing removing 32.6
-Torque converter assembly checking 32.2
draining 32.7
identification 32.2
-Torque converter bushing checking 32.2
removing/installing 32.3
-Torque converter drive plate removing/installing 32.5
-Torque converter oil seal removing/installing 32.4
4-speed 097
-Torque converter assembly draining 32.7
identifying 32.8
-Torque converter drive plate installing 32.5a
-Torque converter oil seal removing and installing 32.8
Towing
see also Owner Information
-Towing
emergency 00.10
long distance 00.11
Transmission, automatic
see Automatic Transmission-Case, Gears Shafts and Automatic Transmission Controls, Assembly
Transmission, manual
see Manual Transmission-Case, Gears, Shafts, Manual Transmission-Controls, Assembly
Tune-up
-Engine tune-up specification charts engine code MC 00.18
engine code NF 00.19
engine code 3B 00.20
Trim-Interior
-A/C control head removing/installing 70.14
-Bonded molded headliner
Wagon
installing 70.26
removing 70.25
-C-pillar trim Wagon
installing 70.23
removing 70.22
-Center console, rear assembly 70.10
-D-pillar trim , Wagon
installing 70.24
removing 70.23
-Front center console assembly 70.13
-Front console side panel assembly 70.11
-Front door
assembly 70.2
inner opening mechanism, removing/
installing 70.3
trim panel, assembly 70.4
-Gearshift lever boot removinglinstalling 70.12
-Glove compartment assembly 70.17
-Headliner installing 70.20
removing 70.18
-Instrument cluster removing/installing 70.16
Instrument panel
assembly 70.15
Locking button installation height 70.8
Pull rod
assembly 70.3, 70.6
Rear door assembly 70.5
inner opening mechanism removing/installing 70.6
trim panel, assembly 70.7, 70.9
-Roof frame trim removing/installing, Wagon 70.24
Steering column switch removing/installing 70.16
Storage tray
removing/installing 70.16
Roof frame trim removing/installing, Wagon 70.24
Turbocharger
Engine code MC

Secondary coolant pump checking 21.10
-Turbocharger
checking 21.5 component layout 21.2
cooling system layout 21.4
removing 21.11
-Wastegate
checking 21.5
frequency check valve 21.7
Engine code 3B
-Bypass valve checking 21.28
-Intercooler and crankcase ventilation component layout 21.16
removing and installing 21.22
-Turbocharger checking
using VAG 1379 21.25
using VAG 1397a 21.27 component layout 21.15
removing and installing 21.17
-Wastegate checking
using VAG 1397 21.25
using VAG 1397a 21.27

V

V-belts
see Owner Information or the specific component
Vehicle Identification
Type/model identification chart 00.2a
-Vehicle identification number (VIN) coding chart 00.8
location 00.7
Voltage regulator
see Engine Electrical-Starter, Alternator, Battery, Cruise Control

W

Warnings
also see individual systems and components
-Cautions and Warnings x, xi
-Wiring diagrams 3, 4
Wheels, Tires, Wheel Alignment
--Tires
rotating 44.11
-Vibrations eliminating 44.8
Front wheel drive
-Front camber adjusting 44.5
-Front toe adjusting 44.5
-Total toe/alignment of rear wheels determining 44.4
-Wheel alignment data 44.3
Quattro
-Front camber adjusting 44.5
-Front toe adjusting 44.5
-Rear camber adjusting 44.7
-Rear toe adjusting 44.7
-Wheel alignment data 44.6
data. 20V 44.6a
-Wheels/tires assembly, 20V 44.1a
Windshield Wiper and Washer
-Heated windshield washer nozzles installing 92.5
-Spray jets adjusting 92.6
-Windshield washer bottle installing 92.5
-Windshield wiper removing/installing 92.2
wiper blade, positioning 92.3
-Windshield wiper arm angle, adjusting 92.3
troubleshooting 92.4
Wiring
-Airbag control unit
locating 97.11a
-Auxiliary relay panel
relay identification 97.10
-Component locations, engine compartment
100 models 97.16
200 models 97.17
200 Quattro 20V Turbo 97.1
-Connector housing
removing 97.4
rubber insulating grommet, modifying 97.4
-Control units locating 97.11
-Fuse/relay panel assembly/disassembly 97.3
wiring connections 97.9
-Fuses location/identification 97.7
removing/installing 97.4
-Relays identification 97.8
Wiring Diagrams
General information

-Cautions and warnings 3
-Handling components and connectors 15
-How to read wiring diagrams 5
-Test equipment 9
computer memory saver 14
LED test light 9
multimeter or volt/ohm meters I test kits 13
-Troubleshooting 17
basic electricity 17
ground connections, checking 21
short circuit to ground, checking for 27
voltage, checking for 20
wiring and components, checking 23
Main wiring diagrams
1989

-100/100 Quattro (production up to Nov. 1988) 29
-100/100 Quattro (production from Nov. 1988) 83
-200/200 Quattro (production up to Nov. 1988) 139
-200/200 Quattro (production from Nov. 1988) 205
1990
-100/100 Quattro 275
-200/200 Quattro 331
1991
-1991 100/100 Quattro 399
-1991 200 (USA, Canada) 459
-1991 200 Quattro (Canada only) 459
-1991 200 Quattro 20V Turbo (USA only) 529
-1991 200 Quattro Wagon 20V Turbo
(USA only) 529
Wiring diagrams, Auxiliary
-Air conditioning, electronic climate control see the appropriate Main Wiring Diagram
-Air conditioning, manual 1989 100E 725
-Airbag, 100 models
1989 100/100 Quattro (production from Nov. 1988) 637
1990 100/100 Quattro 645
1991 100/100 Quattro 655
-Airbag, 200 models
(production from Nov. 1989)
see the appropriate Main Wiring Diagram
-Anti lock brake system (2 wheel drive) 1989 100/200
(production up to Nov. 1988) 597
1989 100 (production from Nov. 1988) 601
1989 200 (production from Nov. 1988) 605
1990-1991 100 601
1990-1991 200 609
-Anti-lock brake system (4 wheel drive)
1989 100 Quattro/200 Quattro
(production up to Nov. 1988) 613
1989 100 Quattro
(production from Nov. 1988) 619
1989 200 Quattro
(production from Nov. 1988) 625
1990-1991 100 Quattro 619
1990 200 Quattro 631
1991 200 Quattro (Canada) 631
1991 200 Quattro 20V Turbo (USA) 631
-Board computer
1989 100/100 Quattro
(production up to Nov. 1988) 665
1989-1991 100/100 Quattro
(production from Nov. 1988) 671
-Compact disc changer (6 disc)
1991 100/200 (sedan only) 676
-Cruise control (Automatic transmission)
1989 100/200
(production up to Nov. 1988) 679
1989 100
(production from Nov. 1988) 685
1989 200
(production from Nov. 1988) 691
1990 100 697
1990 200 703
-Daytime driving lights (Canada only)
1990-1991 100/100 Quattro 709
1990-1991 200/200 Quattro 709
-Differential locks
1989-1991 100 Quattro 715
1989-1990 200 Quattro 715
1991 200 Quattro (Canada) 715
1991 200 Quattro 20V Turbo (USA) 715
-Heated lock system
1989-1991 100/100 Quattro 719
1989-1990 200/200 Quattro 719
1991 200 719
1991 200 Quattro (Canada) 719
1991 200 Quattro 20V Turbo (USA) 719
--Heated seats with memory
1989-1991 100/100 Quattro 719
1989-1990 200/200 Quattro 719
1991 200 719
1991 200 Quattro (Canada) 719
1991 200 Quattro 20V Turbo (USA) 719
-Heated window spray jets
1989-1991 100/100 Quattro 719
1989-1990 200/200 Quattro 719
1991 200 719
1991 200 Quattro (Canada) 719
1991 200 Quattro 20V Turbo (USA) 719
-Manual transmission
1991 100/100 Quattro 731
1991 200 Quattro (Canada) 731
-Power mirrors
1989-1991 100/100 Quattro 743
-Power seat with memory
1989-1991 100/100 Quattro 743
-Power sunroof
1989-1991 100/100 Quattro 751
-Stereo radio 1989 100 Wagon
(production up to Nov. 1988) 755
1989 100 Wagon
(production from Nov. 1988) 759
1989 200 Wagon
(production up to Nov. 1988) 763
1989 200 Wagon
(production from Nov. 1988) 767
1990 200 Quattro Wagon 767
1990-1991 100 Wagon (Canada) 771
1991 200 Quattro Wagon 20V Turbo (USA) 767
-Telephone 1991 775
-Wagon, additional wiring 1989 100 Wagon
(production up to Nov. 1988) 778
1989 100 Wagon
(production from Nov. 1988) 782
1989 200 Wagon 787
1990-1991100 Wagon (Canada) 792
1990 200 Quattro Wagon 787
1991 200 Quattro Wagon 20V Turbo 787