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Repair procedure index for the Type 44 Audi 200 quattro 20-valve
Repair Procedure Index 
Last update May 22, 2002
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Scott Mockry has a site dedicated to the Type 44 Audi (5000/100/200).  Scott is a talented Audi mechanic and has put up detailed troubleshooting techniques, details on how/why things work, information on performance upgrades (including his ECU mods; none for the '91 200q yet, though), lists of technical literature/magazine reviews of Audis, and web site links of interest.   The whole site is worth exploring if you own an Audi.

Scott has a series of  pages of particular interest to owners of the 200q20v:  pulling and interpreting stored fault codes; the wiring for the motronic computer; troubleshooting the 20v engine; and stock versus modified ECU chips (performance graphs).  I've presented the links for each below, followed by my information (repair procedures and BTDT info).

I've put the descriptions of the various engine components on their own page, and added a page about the safety features of the '91 200 quattro 20v.

SJM Auto-Technik
The link to his main page is here:  http://www.sjmautotechnik.com

Here's a good starter page when you're having problems with the 200q20v: http://www.sjmautotechnik.com/20vboost.html

Last update on Dec. 18, 1998.

Part Numbers and related info

Parts and Pieces                                                                                                       (1/28/2000)
    Common parts, approximate pricing

Differences between early/late 20-valve 5-cylinder engines           (1/28/2000)
 

Recalls and Technical Bulletins

Audi has established a web repository of technical service bulletins, recall campaign notices, and service circulars.  They did not back-date the web site to provide older information, so most of this information is for later model cars.

Audi Electronic Technical Service Bulletins                  (12/1/99)
    Oil seals; oiling prior to installation (pdf file)
Campaign Circulars                                                                     (12/1/99)
    Airbag Recall Code KF (pdf file)
Service Circulars                                                                           (12/1/99)
 

Repair Info (BTDT posts), organized by Bentley repair index groups

Please note that this information is not meant to duplicate or replace information prepared by Robert Bentley, Inc. in their repair manuals for the '91 200q20v.
I've organized this information by Bentley/Audi subgroups, and included page references to the Bentley info where appropriate (and as I've the time to complete it!).
A lot of the Bentley subgroups do not have supplemental info, as it is not needed, or is beyond the scope of a normal home mechanic, or just hasn't been written up by someone yet.  I've also left out the information specific to the other models in the Bentley manual (such as front drive, or 100 models, or automatics).  If you find this info usefull, try to add to it!

(1/29/2000)   Please note that these pages will need to be reorganized to match the following index.  As that's a lot of work, it will be ongoing... for a while.  Let me know if this is a better way of organization than the old index (which is at the bottom of this page).

If you don't find the info you want here, try a search of this web site.

Add/read comments on the contents of this page.

Volume 1

Owner Information

1     Vehicle Care
24    Do-it-yourself Service
34    Gas Station Information
37    Technical Data
40    Maintenance/Lubrication Schedule
           Oil        (9/30/99)

Repair Groups

00    General
10    Engine - Assembly
            Engine Image (Big)(Smaller version)
           Motor Mounts and Suspension Bushings
           Changing Motor Mounts
           Bypass valve for turbo (throttle overrun cutoff valve)
           Carbon Canister Frequency Valve
           Timing Belt
           Mass Air Flow Sensor
           Oxygen Sensor (Lambda sensor)
           Plug Wires, Spark Plugs, Oil Filter, Air Filter
           Exhaust manifold stud replacement
           Fuel Pump
           Pressure Transducer in the ECU
           Waste Gate Frequency Valve
           Upgrades to ECU, turbo, manifold, etc.
13    Engine - Crankshaft/Crankcase
15    Engine - Cylinder Head/Valve Drive
17    Engine - Lubrication System
           Rear Engine Seal
           Oil Pan and Oil Starvation
           Oil Pan Drain Bolt
19    Engine - Cooling System
           After run fan and electric coolant pump
           Radiator cooling fan function                     (12/1/99)
           Flushing the coolant
           Replacing the radiator                                  (12/1/99)
           Fan bearing replacement                             (12/1/99)
20    Fuel Supply
21    Turbocharger
24    Fuel Injection - AFC System (20-valve turbo)
            Fuel Injectors                                                    (7/24/2001)
                Injector o-rings/sizes and sources
                Removing injectors to flow test and clean
D2    Diagnostics, Fault Memory (Engine Management)
           Motronic ECU and fault codes
26    Exhaust System/Emission Controls
           Exhaust
27    Electrical - Battery, Alternator, Starter, Cruise Control
           Alternator/Battery Splice
           Alternator Belt Tensioning
           Diagnosing and rebuilding alternators
           Starter replacement procedure
28    Ignition System

Volume 2

Manual Transmission

30-00-1    Clutch
            30-1 to 30-40 Clutch slave cylinder
34-00-1    Controls, Assembly
35-00-1    Case, Gears, Shafts
           Rebuilding the transmission                                      (1/28/2000)
39-00-1    Differential
           The dreaded Torsen Differential
           Center Driveshaft
            Lubricate
            R&R
           Rear Differential Oil Seal Replacement
           Fixing the rear diff. switch

Other Repair Groups

40-1    Front Suspension - Shafts and Axle
           Front end clunk?  Look at these suggestions first:
           Suggestions for suspension upgrades
           How do these suspension thingys work, anyways?
            40.13  Replacing the front shocks  Diagram: 40.8a
            40.2  Subframe bushing replacement
            40.9  Wheel bearing replacement
42    Rear Suspension - Shafts and Axle
            42.23  Replacing the rear shocks  Diagram 42.28
44    Wheels, Tires, Wheel Alignment
           Alignment (DIY)
           Tires and Rims
            Rims page (under development)
                Stock BBS rims
                Steel rims for snows
                Wheels that fit over UFOs
                Partial list of wheels that DO NOT fit over UFOs
                Rim/tire distributors and manufacturer links
                Weights for various rims
45    ABS - Antilock Brake System
           ABS system diagram
46    Brake - Mechanical Components
           UFO/Internal Calipers
           Turning UFO rotors
           Brake upgrades
           Rear brakes
47    Brake - Hydraulic Components, Regulator, Booster
           Brake Fluid
           Brake bleeding
           Pentosin (hydraulic fluid)
           Bomb or brake booster
48    Steering
           Replacing the rack
           Rebuilding the steering pump
           Damper
           Hoses
           Pentosin
50    Body
55    Hoods/Lids
            55.3    Rear Lid (Trunk) Lock Repair
57    Doors - Front
           Front Door Lock Repair
58    Doors - Rear
60    Sunroof
           Sunroof liner re-gluing
63    Bumpers
64    Glass, Window Regulators
           Window Glass Tinting
           Fixing the blown bulb in the mirror control
           Fixing the blown bulb in the window switches
          Window is down, and won't go back up
        Window regulator cable repair
           Aligning the window frame to lessen wind noise
66    Body Accesories
           Exterior Mirror R&R, Type 44 '88-'91
           Mirror Replacement (Heated)
68    Body Accesories - Interior, Airbag
70    Trim - Interior
72    Seats
74    Body - Seat Upholstery
           Seat Heater element fix
           Dying the Leather Upholstery (again)
D8    Diagnostics, Fault Memory (Climate Control) 
           Error codes
87    Air Conditioner 
           Fresh air flap, or "it's foggy in here"
           Temperature sensors
           Temperature regulating flap 
           Heater blower fan and heater core                                        (5/22/2002)
           Compressor
           Fixing the A/C Clutch Suppression Diode

Volume 3

Repair Groups

90    Electrical System - Instruments
           Instrument Panel Removal Procedure, with bulb replacement         (3/4/2000)
           Fuel Guage fix
           Spedometer/Odometer
           Fixing the electronic spedometer                                                          (12/1/99)
           Changing the clock to 24-hour mode
           Adjusting the miles-to-empty readout on the trip computer    (11/23/99)
91    Electrical System - Radio, Telephone, Board Computer
           SCREECH!! SQUAWK!!!! BRAAAAP!!!!?  Loud popping noises from the rear speakers?  CAUTION: POSSIBLE FIRE HAZARD!!!
           Removing/reinstalling Bose rear speakers (sedan)
           Fire damaged 200q20v (with photos)
           Pictures of the amplified Bose rear speakers and integrated amps
           Letter to Audi requesting safety investigation
             Infinity Recall on Bose amplified speakers
           Intermittant pop (from A/C clutch engaging)

            Fixing the OK system check display

            Phone
92    Electrical System - Windshield Wiper and Washer
           Adding a programmable intermitant wiper relay
94    Electrical System - Exterior Lights
           Adding European Headlights
           Description here.
           Relays and wiring here.
           Installation here.
           Adding relays for your headlights
           Other Details
           Aiming the european headlights
           Disabling the Autocheck headlight monitor
96    Electrical System - Interior Lights
97    Electrical System - Wiring

Wiring Diagrams

3     General Information
29    Wiring Diagrams

------

Accessories                                                               (12/1/99)
    Valentine 1 remote mount
    Adding a boost gauge
    Adding an o2 gauge/duty cycle meter
    Adding a trailer hitch
    Wiring the trailer lights
    Front spoiler

Strutbrace (how to build Bernie Benz's custom brace for the front shocks).                   (11/24/99)

Old links below.  This is the same info as above, just in a different format.

Accessories                                                               (12/1/99)
    Valentine 1 remote mount
    Adding a boost gauge
    Adding an o2 gauge/duty cycle meter
    Window Glass Tinting
    Adding a trailer hitch
    Wiring the trailer lights
    Front spoiler

Alarm

Body and Hardware page                            (9/30/99)
    Front Door Lock Repair
    Adding a programmable intermitant wiper relay
    Fixing the blown bulb in the mirror control
    Fixing the blown bulb in the window switches
    Exterior Mirror R&R, Type 44 '88-'91
    Mirror Replacement (Heated)
    Window regulator cable repair
    Aligning the window frame to lessen wind noise
    Fixing the rear diff. switch
    Seat Heater element fix
    Dying the Leather Upholstery (again)
    Adding European Headlights
           Description here.
           Relays and wiring here.
           Installation here.
           Adding relays for your headlights
           Other Details
           Aiming the european headlights
           Disabling the Autocheck headlight monitor
    Fixing the OK system check display
    Fixing the electronic spedometer                                                          (12/1/99)
    Changing the clock to 24-hour mode
    Adjusting the miles-to-empty readout on the trip computer    (11/23/99)
    Fuel Guage fix
    Spedometer/Odometer
    Sunroof liner re-gluing

Brakes, hydraulic clutch, brake booster                            (1/28/2000)
    UFO/Internal Calipers
    Turning UFO rotors
    Brake upgrades
    Rear brakes
    Brake bleeding
    Clutch slave cylinder
    Pentosin (hydraulic fluid)
    Bomb or brake booster
    ABS (anti-lock braking system)

Climate Control System                            (12/1/99)
    Fresh air flap, or "it's foggy in here"
    Temperature sensors
    Temperature regulating flap 
    Heater blower fan and heater core                                        (5/22/2002)
    Error codes
    Compressor
    Fixing the A/C Clutch Suppression Diode

Cooling System
    After run fan and electric coolant pump
    Radiator cooling fan function                     (12/1/99)
    Flushing the coolant
    Replacing the radiator                                  (12/1/99)
    Fan bearing replacement                             (12/1/99)

Electrical System                      (1/28/2000)
    Alternator/Battery Splice
    Alternator Belt Tensioning
    Diagnosing and rebuilding alternators

Engine                                                                                                  (9/23/99)
    Motronic ECU and fault codes
    Bypass valve for turbo (throttle overrun cutoff valve)
    Carbon Canister Frequency Valve
    Starter replacement procedure
    Rear Engine Seal
    Oil Pan and Oil Starvation
    Oil Pan Drain Bolt
    Timing Belt
    Mass Air Flow Sensor
    Oxygen Sensor (Lambda sensor)
    Plug Wires, Spark Plugs, Oil Filter, Air Filter
    Exhaust manifold stud replacement
    Fuel Pump
    Pressure Transducer in the ECU
    Waste Gate Frequency Valve
    Upgrades to ECU, turbo, manifold, etc.
    Engine Image (Big)(Smaller version)

Exhaust

Oil        (9/30/99)

Phone

Radio                                                                                (2/28/2000)
    SCREECH!! SQUAWK!!!! BRAAAAP!!!!?  Loud popping noises from the rear speakers?  CAUTION: POSSIBLE FIRE HAZARD!!!
    Removing/reinstalling Bose rear speakers (sedan)
    Fire damaged 200q20v (with photos)
    Pictures of the amplified Bose rear speakers and integrated amps
    Letter to Audi requesting safety investigation
         Infinity Recall on Bose amplified speakers
   Intermittant pop (from A/C clutch engaging)

Steering                            (9/23/99)
    Replacing the rack
    Rebuilding the steering pump
    Damper
    Hoses
    Pentosin

Suspension                                                                                         (11/24/99)
    Front end clunk?  Look at these suggestions first:
    Replacing the front shocks
    Replacing the rear shocks
    Subframe bushing replacement
    Wheel bearing replacement
    Suggestions for suspension upgrades
    How do these suspension thingys work, anyways?

Strutbrace (how to build Bernie Benz's custom brace for the front shocks).                   (11/24/99)

Tires and Rims                            (9/30/99)

Transmission and Driveline
    Center Driveshaft
        Lubricate
        R&R
    Rear Differential Oil Seal Replacement
    Motor Mounts and Suspension Bushings
        Changing Motor Mounts
    The dreaded Torsen Differential
    Rebuilding the transmission                                      (1/28/2000)
    Replacing transmission mounts
    Shift linkage adjustments
    Replacing the driveshaft tranny seals
    Transmission fluid replacement
    Transmission diagram
 

Troubleshooting section
Glossary of terms and abbrieviations

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Back to the Repair Index

Add/read comments on the contents of this page.
All rights to this info in this format are reserved; feel free to use it, but don't just copy it verbatim! Not responsible for screwups in typing etc. YMMV, etc. I haven't  tried many of these procedures, and some are adapted from procedures for other Audi models.

Please send me any comments, updated procedures, etc.  This page is a part of http://members.aol.com/c1j1miller/index.html

Chris Miller
 
 

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