Contents Section: Procedures All sections

Maintenance Information Audi 100 C4

Procedures 7 illustrations ~2411 words

VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN Code ID Explanation. Scheme 2

Scheme 2: VIN Code ID Explanation

SEVERE & NORMAL SERVICE DEFINITIONS

Note. Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions:

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating conditions:

Normal Service

  1. Driven More Than 10 Miles Daily
  2. No Operating Conditions From Severe Service Schedule

Severe Service (Unique Driving Conditions)

  1. Short Trips In Freezing Temperatures
  2. Towing Or Heavily Loaded
  3. Continuous Mountain Driving
  4. Severe Dust Conditions
  5. Hot Weather, Stop-And-Go Driving
  6. Extensive Idling Conditions (Taxi Or Delivery Type Service)

CAMSHAFT TIMING BELT

Replace camshaft timing belt at 90,000 mile intervals.

CAUTION:Failure to replace a faulty camshaft timing belt may result in serious engine damage.

The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some manufacturers do not recommend belt replacement at a specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt failure may cause extensive damage to internal engine components on most engines, although some designs do not allow piston-to-valve contact. These designs are often called "Free Wheeling".

Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt inspection and/or replacement at 50,000-60,000 miles. Most service interval schedules in this manual reflect these changes.

Belts or components should be inspected and replaced if any of the following conditions exist:

  1. Cracks Or Tears In Belt Surface
  2. Missing, Damaged, Cracked Or Rounded Teeth
  3. Oil Contamination
  4. Damaged Or Faulty Tensioners
  5. Incorrect Tension Adjustment

BRAKE FLUID SERVICE

Replace brake fluid every 2 years regardless of mileage.

CAUTION:DO NOT add or mix DOT 5 silicone type brake fluid with brake fluid in vehicle as severe component corrosion could result and may lead to brake system failure.

Scheme 3

Scheme 3: SERVICE POINT LOCATIONS

Scheme 4

Scheme 4

SERVICE LABOR TIMES

Note. For 1990 and newer vehicles, labor times are provided, where available, within appropriate SERVICE INTERVAL table in SCHEDULED SERVICES article.

LUBRICATION SPECIFICATIONS

Note. Audi does not recommend the use of oil additives as it may adversely affect the warranty. Always use Audi Hydraulic Oil G002000 when adding or replacing power steering fluid. DO NOT use ATF in the power steering system.

TIRE SIZE & INFLATION SPECIFICATIONS

Tire specifications are imprinted on the tire sidewall. All models use tire size 205/60 15VR. The required cold tire inflation pressures are listed on a sticker on the inside of fuel filler door and must never exceed the maximum value molded on the tire side wall. Before replacing original tires on vehicle with all season or radial snow tires, consult an Audi dealer for technical information on the required specifications. Snow tires should be mounted on all four wheels on FWD vehicles, and must be mounted on all four wheels for vehicles with 4WD. Snow chains may be used on the front wheels only. The compact spare tire is intended for temporary use only; it is limited to 50 mph (80 km/h) and must be inflated to 60 psi (4.22 kg/cm 2 ).

CAUTION:DO NOT mix tires of different design such as steel belted radials with radial bias belted or bias ply tires. Mixing tire types will adversely affect road handling and may lead to loss of vehicle control. DO NOT use spare tire on any other wheel or any other tire on the compact spare wheel. DO NOT use snow chains on the compact spare.

WHEEL RIM & BOLT SPECIFICATIONS

The original wheel rims on the vehicle comply with all applicable Federal Motor Vehicle Safety Standards. Before replacing original wheel rims, consult an Audi dealer for technical information regarding wheel rims and bolt specifications. Tighten all wheel nuts to 80 ft. lbs. (108 N.m). Always tighten wheel lug nuts in a crisscross pattern.

BATTERY SPECIFICATIONS

CAUTION:When battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See appropriate COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section below.

Battery is located under the rear seat. Under normal operating conditions, battery delivered with vehicle is maintenance-free. However, at high outside temperature it is advisable to check battery fluid level at regular intervals through the transparent battery housing. Fluid level should always be between the MIN and MAX marks in each cell. Battery specifications are listed on the battery housing. Replacement battery must meet all requirements and dimensions as specified on original battery.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG SYSTEM

Note. See the AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT Section.

The SRS has no user-servicable parts. Always have servicing done by an authorized dealer.

WARNING:To avoid injury from accidental air bag deployment, read and carefully follow all warnings and service precautions. See appropriate AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT section.
CAUTION:Disconnect negative battery cable before servicing any air bag system, steering column or passenger side dash component. After any repair, turn ignition key to the ON position from passenger's side of vehicle in case of accidental air bag inflation

ANTI-LOCK BRAKE SYSTEM (ABS)

CAUTION:Never mix different diameter tires. On loose or uneven surfaces, the ABS system may require longer stopping distances than conventional brake systems. Exercise caution when removing mud or snow from the wheels so as not to damage the ABS wiring or speed sensors.

AIR CONDITIONING SERVICING

WARNING:Avoid breathing R-134a refrigerant and PAG lubricant vapors, exposure may irritate eyes, nose and throat. To remove R-134a from system use R-134a recycling equipment that meets SAE J2210 specifications. If accidental system discharge occurs, ventilate work area before resuming service.
WARNING:R-134a service equipment or vehicle A/C systems SHOULD NOT be pressure tested or leak tested with compressed air. Some mixtures of air/R134a have shown to be combustible at elevated pressures. These mixtures are dangerous and may cause fire and/or explosions. See the appropriate A/C SYSTEM GENERAL SERVICING article in the AIR CONDITIONING & HEAT section.

BATTERY WARNING

WARNING:When battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See appropriate COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section below.

REPLACING BLOWN FUSES

Before replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BRAKE PAD WEAR INDICATOR

Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

Continued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and vehicle.

COOLANT (PROPYLENE-GLYCOL FORMULATIONS)

CAUTION:To avoid possible damage to vehicle use only ethylene-glycol based coolants with a mixture ratio from 44-68% anti-freeze. DO NOT use 100% anti-freeze as it will cause the formation of cooling system deposits. This results in coolant temperatures of over 300° F (149°C) which can melt plastics. 100% anti-freeze has a freeze point of only -8° F (-22°C).
CAUTION:Propylene-Glycol Mixtures has a smaller temperature range than Ethylene-Glycol. The temperature range (freeze-boil) of a 50/50 Anti-Freeze/Water Mix is as follows: Propylene-Glycol -26° F (-32°C) - 257° F (125°C) Ethylene-Glycol -35° F (-37°C) - 263° F (128°C)
CAUTION:Propylene-Glycol/Ethylene-Glycol Mixtures can cause the destabilization of various corrosion inhibitors. Also Propylene-Glycol/Ethylene-Glycol has a different specific gravity than Ethylene-Glycol coolant, which will result in inaccurate freeze point calculations.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

WARNING:Many solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not. Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.

ENGINE OIL

CAUTION:Never use non-detergent or straight mineral oil.

FUEL SYSTEM SERVICE

WARNING:Relieve fuel system pressure prior to servicing any fuel system component (fuel injection models).

HALOGEN BULBS

WARNING:Halogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

RADIATOR CAP

CAUTION:Always disconnect the fan motor when working near the radiator fan. The fan is temperature controlled and could start at any time even when the ignition key is in the OFF position. DO NOT loosen or remove radiator cap when cooling system is hot.

RADIATOR FAN

WARNING:Keep hands away from radiator fan. Fan is controlled by a thermostatic switch which may come on or run for up to 15 minutes even after engine is turned off.

WARRANTY INFORMATION

CAUTION:Always refer to customer's copy of warranty information for specific model application and/or coverage limitations.

BASIC NEW CAR LIMITED WARRANTY

Everything is covered for 3 years 50,000 miles, whichever occurs first, provided the vehicle is maintained and used in accordance with the instructions for care and use in the Audi Owner's Manual. Warranty begins on the date vehicle is delivered or put in use, whichever occurs first. Covers the cost to all parts and labor needed to repair or adjust any item (except tires) on the vehicle that have been proven defective in material or workmanship under normal use. If a tire is defective, a credit will be given towards the purchase of new tire. The amount of credit is equal to the percentage of original tread depth remaining, multiplied by the suggested retail price of an equivalent new tire.

PERFORATION WARRANTY

Covers any repair or replacement of body-sheet metal parts that is perforated due to corrosion as a result of defects in workmanship or material. Warranty begins on date vehicle is delivered or first put in use, whichever occurs first and lasts for 10 years regardless of mileage.

EMISSION CONTROL SYSTEM WARRANTY (EXCEPT CALIFORNIA)

Manufacturer warrants its emission components in vehicle to be free of defects in material and workmanship and that vehicle is designed, built and equipped to conform at time of sale to all applicable Federal standards for emission control system. Warranty begins on the date vehicle is delivered or first put in use and is effective for 5 years or 50,000 miles, whichever occurs first.

EMISSION PERFORMANCE WARRANTY (EXCEPT CALIFORNIA)

Vehicle is warranted to comply to all applicable emissions standards as judged by an EPA-approved State Inspection and Maintenance Test for 24 months or 24,000 miles, whichever occurs first. Listed below are the primary components affecting vehicle's emission control system. The components listed are covered for 5 years or 50,000 miles, whichever occurs first. Warranty begins on date vehicle is delivered or first put in use, whichever occurs first.

  1. Activated Charcoal Filter
  2. Air Flow Sensor Assembly
  3. Altitude Compensator
  4. Catalytic Converter
  5. Coasting Fuel Cut-Off Valve And Control Unit
  6. Electronic Control Unit And Power Supply Relay
  7. Electronic Feedback Controls, Sensors, Switches And Valves
  8. Evaporative Purge Control Valve
  9. Exhaust Gas Recirculation System
  10. Exhaust Manifold And Gaskets
  11. Exhaust Pipe-To-Catalytic Converter
  12. Expansion Tank
  13. Filler Neck Restrictor
  14. Frequency Valve
  15. Fuel Distributor Assembly And Associated Controls
  16. Fuel Filler Cap And Gaskets
  17. Fuel Injectors, Fuel Injectors Line And Gaskets
  18. Fuel Tank
  19. Gravity Check Valve
  20. Idle Stabilizer And Control Unit
  21. Knock Sensor And Control Unit
  22. Crankcase Breather
  23. Spark Advance Unit And Associated Parts
  24. Turbocharger And Wastegate
  25. Emission-Related Hoses, Gaskets, Clamps And Accessories

EMISSION CONTROL SYSTEMS WARRANTY (CALIFORNIA)

Emission control system in vehicle is warranted to be free of defects in material and workmanship, and that vehicle is designed, built and equipped to conform at time of sales to applicable requirements of the California Air Resources Board (CARB). Warranty period is for 3 years/50,000 miles. Warranty begins on date vehicle is delivered or put in use, whichever occurs first.

EMISSION PERFORMANCE WARRANTY (CALIFORNIA)

Warrants vehicle to comply to all applicable emission standards as judged by the EPA and CARB approved emissions test. Should the vehicle fails to comply to the required emissions standards, manufacturer will make any repairs or replacements necessary for the vehicle to pass the required emissions test, provided the vehicle is maintained and used in accordance with the instructions for care and use in the Audi Owner's Manual. The warranty period is 3 years/50,000 miles and begins on date vehicle is delivered or put in use, whichever occurs first.

The following emissions system components are covered under the California Emission Warranties for 7 years or 70,000 miles whichever occurs first. If another part fails due to the failure of a warranted component, both parts will be covered.

  1. Air Flow Sensor Assembly
  2. Catalytic Converter
  3. Electronic Control Unit
  4. Exhaust Manifold
  5. Fuel Distributor Assembly And Associated Controls
  6. Idle Stabilizer Control Unit
  7. Ignition Distributor
  8. Intake Manifold
  9. Intercooler
  10. Knock Sensor Control Unit
  11. Throttle Valve Housing
  12. Turbocharger
  13. Wastegate

FUSE PANEL LOCATIONS

The fuses are arranged in one centralized unit. The fuse/relay box is located in the engine compartment and is protected by a cover.

CAUTION:Use extreme care when trouble-shooting electrical system. Relay locations are subject to change and may vary from vehicle to vehicle depending on options. If in doubt, consult an Audi dealer before replacing any relay.

Scheme 5

Scheme 5: FUSE PANEL IDENTIFICATION (1989)

Fuse & Circuit Breaker Identification

  1. 1 - Blank (Audi 200 before 11/88 & Audi 100) 15 Amp (Audi 200 starting on 11/88) Rear Foglights
  2. 2 - 15 Amp Emergency Flasher
  3. 3 - 25 Amp Horns, Brakelights
  4. 4 - 15 Amp Luggage Compartment Light, Cigarette Lighter, Interior Lights,
  5. 5 - Blank
  6. 6 - 5 Amp Right Taillights & Side Marker Lights
  7. 7 - 5 Amp Left Taillights & Side Marker Lights
  8. 8 - 10 Amp Right High Beam Headlight
  9. 9 - 10 Amp Left High Beam Headlight
  10. 10 - 10 Amp Right Low Beam Headlight
  11. 11 - 10 Amp Left Low Beam Headlight
  12. 12 - 15 Amp Automatic Transmission, Back-Up & Interior Lights
  13. 13 - 15 Amp Fuel Pump
  14. 14 - 5 Amp License Plate Lights, Glove Box Light, Engine Compartment Light, Center Console
  15. 15 - 25 Amp Wiper/Washers
  16. 16 - 30 Amp Rear Defogger (Sedan)
  17. 17 - 30 Amp Blower Motor, A/C
  18. 18 - 5 Amp Rear Window Wiper
  19. 19 - 10 Amp Central Locking System, Fuel/Ignition Injection Control Unit
  20. 20 - 30 Amp Heated Seats
  21. 21 - Blank (Audi 100) 25 Amp (Audi 200) Injector Coolant Fan Relay, Turbo Coolant Pump
  22. 22 - Blank
  23. 23 - Blank
  24. 24 - Blank
  25. 25 - Blank (Audi 100) 30 Amp (Audi 200) Memory Seats
  26. 26 - 5 Amp (Audi 100 Before 11/88) Speedometer, Power Mirrors Blank (Audi 100 Starting On 11/88) 5 Amp (Audi 200) Speedometer, Power Mirrors, Memory Seats
  27. 27 - 10 Amp Ignition Control Unit
  28. 28 - 15 Amp (Audi 100) Ignition Control Unit 15 Amp (Audi 200) OXS Control Unit
  29. 29 - Blank (Audi 200 before 11/88 & Audi 100) Rear Foglight Jumper Plug (Audi 200 starting on 11/88)
  30. 30 - Relay Radiator Coolant Fan (2nd stage)
  31. 31 - Relay Radiator Coolant Fan (After Run Control Unit)
  32. 32 - Blank
  33. 33 - Relay Load Reduction
  34. 34 - Blank
  35. 35 - Relay Horn
  36. 36 - Relay Anti-Theft
  37. 37 - Relay Wash/Wipe Intermittent
  38. 38 - Relay Fuel Pump
  39. 39 - Relay Air Conditioning

Scheme 6

Scheme 6: FUSE PANEL IDENTIFICATION (1990-93)
  1. 1 - 15 Amp Rear Foglights
  2. 2 - 15 Amp Emergency Flasher System
  3. 3 - 25 Amp Horn, Brakelights
  4. 4 - 15 Amp Clock, Cigarette Lighter, Climate Controls, Reading, Dome, Trunk & Vanity Mirror Lights, Trip Computer (If Equipped), Radio
  5. 5 - Blank
  6. 6 - 5 Amp Right Taillights, Parking & Sidemarker Lights
  7. 7 - 5 Amp Left Taillights, Parking & Sidemarker Lights
  8. 8 - 10 Amp Right High Beam Headlight, High Beam Indicator
  9. 9 - 10 Amp Left High Beam Headlight
  10. 10 - 10 Amp Right Low Beam Headlight
  11. 11 - 10 Amp Left Low Beam Headlight
  12. 12 - 15 Amp Differential Lock (Quattro Models), Back-Up Lights, Cruise Control, Heating System
  13. 13 - 15 Amp Fuel Pump
  14. 14 - 5 Amp License Plate, Instrument Cluster, Ashtray, Electronic Climate Control Panel Illumination, Engine Compartment & Glove Compartment Lights
  15. 15 - 25 Amp Wiper Motor, Turn Signals, A/C, Heated Washer Jets, Radiator Fan Thermoswitch
  16. 16 - 30 Amp Rear Window Defogger, Mirror Heating
  17. 17 - 30 Amp Electronic Climate Control System (Blower)
  18. 18 - 15 Amp Rear Wiper
  19. 19 - 10 Amp Central Locking & Anti-Theft Systems, Door Lock Heating
  20. 20 - 30 Amp Seat Heater
  21. 21 - 10 Amp Diagnostic
  22. 22 - Blank
  23. 23 - 5 Amp License Plate Light
  24. 24 - Blank
  25. 25 - 30 Amp Passenger Seat Adjuster, Seat Memory
  26. 26 - 5 Amp Instrument Cluster, Electric Mirrors, Auto-Check System, Trip Computer (If Equipped)
  27. 27 - 10 Amp Engine Timing I
  28. 28 - 15 Amp Engine Timing II
  29. 29 - Blank
  30. 29 - 10 Amp Heated Lambda Probe (1991 200 Quattro 20V)
  31. 30 - Blank 5 Amp Cruise Control (1991 100 Models)
  32. 31 - Spare Fuses

Scheme 7

Scheme 7: FUSE PANEL IDENTIFICATION (1994)
  1. 1 - 10 Amp High Beam Right, High Beam Indicator Light
  2. 2 - 10 Amp High Beam Left
  3. 3 - 10 Amp Low Beam Right
  4. 4 - 10 Amp Low Beam Left
  5. 5 - 5 Amp Right Tail, Parking & Sidemarker Lights, License Plate Light, Daytime Running Lights (Canada)
  6. 6 - 5 Amp Left Tail, Parking & Sidemarker Lights
  7. 7 - 5 Amp Illumination Of: Climate Control, Ashtray & Instrument Cluster
  8. 8 - 15 Amp Courtesy Lights, Clock, Seat & Mirror Memory Control Unit
  9. 9 - 10 Amp Brakelights
  10. 10 - 15 Amp Flashers
  11. 11 - 30 Amp Climate Control System (Blower)
  12. 12 - 30 Amp Rear Window Defog, Mirror Heating
  13. 13 - 25 Amp Wiper Motor, Turn signals, A/C Trans Fluid Temp Switch, Sliding/Prop-Up Roof
  14. 14 - 15 Amp Back-Up Lights, Cruise Control, Multiple Sensor, Washing Nozzle, Heating, A/T, Differential Lock (100 Quatro), Warning Lights, Inf. Remote Control
  15. 15 - 5 Amp Instrument Cluster, Electric Mirrors, Airbag Warning Lights
  16. 16 - 15 Amp Foglights, Rear Foglights
  17. 17 - 20 Amp Fuel Pump
  18. 18 - Not Used
  19. 19 - 25 Amp Diagnostic, Horn
  20. 20 - 5 Amp Cruise Control
  21. 21 - 15 Amp Anti-Lock Brakes (ABS)

Scheme 8

Scheme 8: AUXILIARY RELAY PANEL IDENTIFICATION

Relay & Control Unit Identification

  1. 1 - Blank
  2. 2 - Control Unit Seat Belt, Park Light & Radio Warning
  3. 3 - Control Unit Interior Light Delay
  4. 4 - Blank
  5. 5 - Control Unit Front Light
  6. 6 - Blank
  7. 7 - Relay Radiator Coolant Fan (3rd Stage)
  8. 8 - Relay ABS Combination Relay
  9. 9 - Blank - Audi 100 Relay - Audi 200 Intensive Washer
  10. 10 - Control Unit Power Window
  11. 11 - Control Unit Power Window
  12. 12 - Relay Rear Window Wiper/Washer
  13. 13 - Blank
  14. 14 - Circuit Breaker Windows
  15. 15 - Relay Driver Heated Seat
  16. 16 - Relay Passenger Heated Seat
  17. 17 - Blank