This comprehensive 44-page PDF file contains the official VAG Self-Study Program 485 (SSP 485), focused entirely on the development and mechanical function of the Audi 1.2-liter TFSI engine. Built as a core component of the EA111 engine family (and widely used in models like the Audi A1 and A3), this small-displacement, turbocharged engine was engineered under a strict “downsizing” philosophy. By replacing the older, heavier 1.6-liter MPI engines, Audi achieved a massive 15kg weight reduction while drastically improving fuel economy and low-end torque. This technical training manual is an indispensable resource for VAG technicians, diagnostic specialists, and mechanics looking to fully understand this incredibly common compact powerplant.
Please note: As a Self-Study Program, this document focuses on engineering design, structural layouts, and operational theory. It is not a step-by-step rebuild or workshop manual, though the foundational knowledge it provides is crucial for complex diagnostics.
This detailed technical training manual covers the following key engineering topics:
- Engine Mechanics and Ultra-Lightweight Design: A deep dive into the physical construction of the engine block. It meticulously details the transition to an open-deck die-cast aluminum cylinder block, the specialized piston design required to handle forced induction, and the lightweight timing chain drive system.
- The SOHC Valvetrain: Essential reading for understanding engine breathing. Unlike its larger EA111 siblings, the 1.2L TFSI utilizes a Single Overhead Camshaft (SOHC) with a 2-valve-per-cylinder arrangement (8 valves total), driven by a low-friction roller chain. The manual fully explains the mechanics of this simplified, friction-reducing design.
- Advanced Split-Cooling System: A complete breakdown of how the engine manages heat. It maps out the dual-circuit cooling system, which uses two thermostats to separate the cooling of the cylinder block from the cylinder head, ensuring the block reaches its higher operating temperature faster to reduce internal friction.
- Air Supply and Turbocharging: An overview of the forced induction system, detailing the electrically actuated wastegate on the turbocharger and the water-cooled charge air cooler integrated directly into the plastic intake manifold (which features its own dedicated low-temperature cooling loop).
- Fuel System and Engine Management: A comprehensive look at the high-pressure direct fuel injection system, the ignition coil architecture, and the sensors utilized by the Simos 10 engine management system.
Whether you are trying to map the flow of the complex dual cooling circuits, diagnosing a fault with the electrically actuated turbocharger wastegate, or preparing to service the SOHC timing chain, SSP 485 is the definitive technical resource.
CONTENTS
- Introduction
- Specifications
- Engine mechanicals
- Weight reduction measures
- Cylinder block
- Cranktrain
- Chain drive
- Cylinder head
- Positive crankcase ventilation
- Vacuum supply
- Oil supply
- Oil circuit
- Oil filter
- Air supply
- Overview
- Charge air circuit
- Charge pressure actuator V465 with charge pressure actuator position sensor G581
- Charge pressure control function
- Cooling system
- Overview
- Charge air cooling system
- Engine cooling system
- Thermal management
- Active coolant pump
- Fuel system
- System overview
- Injectors N30 – N33
- Engine management
- Overview of the Simos 10 system on the Audi A3
- Engine control unit J623
- Operating modes
- Ignition system
- Service
- Special tools
- Scope of maintenance
- Annex
- Glossary
- Test your knowledge
- Summary
- Self Study Programmes
Language: English
Format: PDF
Pages: 40
Self Study Program 485 – Audi 1.2l TFSI engine PDF free online
