This comprehensive 40-page PDF file contains the official VAG Self-Study Program 639 (SSP 639), focused entirely on the development and mechanical function of the Audi 1.0-liter 3-cylinder TFSI engine. Developed under the EA211 series architecture (and famously shared with the VW Polo and Golf), this engine marked the first time Audi offered a 3-cylinder petrol engine in their modern lineup. Serving as the entry-level powerplant for the 2015 Audi A1, it completely replaced the older 1.2-liter 4-cylinder EA111 engine, offering more power (70 kW / 95 BHP) and meeting strict EU6 emission standards while weighing 15 kg less. This technical training manual is an absolute must-have for VAG technicians, diagnostic specialists, and mechanics maintaining modern compact Audis.
Please note: As a Self-Study Program, this document focuses heavily on engineering design, structural layouts, and operational theory. It is not a step-by-step rebuild or workshop manual, though the theoretical knowledge it provides is crucial for complex diagnostics.
This detailed technical training manual covers the following key engineering topics:
- Engine Mechanics and Refinement: A deep dive into the physical construction of the die-cast aluminum open-deck cylinder block. It meticulously explains how Audi achieved smooth operation without the use of a heavy, friction-inducing balance shaft. It details the precise balancing of the forged connecting rods and aluminum pistons, as well as the unique vibration damper and specifically drilled flywheel.
- Cylinder Head and Thermal Management: Essential reading for understanding the engine’s rapid warm-up phase. It details the aluminum cylinder head with its integrated exhaust manifold, the DOHC 12-valve layout, and the “maintenance-free” toothed timing belt drive (housed in an integral module).
- Lubrication System: A complete breakdown of the engine oil circuit. It thoroughly explains the continuously variable oil pressure control system, detailing how the crankshaft-driven vane-type oil pump adjusts pressure (up to 3.3 bar) based on engine load, RPM, and temperature.
- Air Supply and Turbocharging: An overview of the forced induction system, detailing the compact plastic intake manifold, the liquid-cooled charge air cooler (integrated with the engine coolant), and the turbocharger equipped with an electronically controlled bypass flap (wastegate).
- Fuel System and Management: A comprehensive look at the Bosch Motronic ME 17.5.21 engine management system, detailing the high-pressure direct fuel injection system (which operates between 120 and 250 bar using 5-hole injectors).
Whether you are trying to understand the continuously variable oil pump, diagnosing a fault with the electronic turbo bypass flap, or simply want to appreciate how Audi engineered a smooth 3-cylinder without a balance shaft, SSP 639 is the definitive technical resource.
CONTENTS
- Introduction
- Brief technical description
- Specifications
- Engine mechanicals
- Modular design
- Crankcase ventilation, activated charcoal system
- Engine block and oil pan
- Crankshaft drive
- Belt-drive system
- Cylinder head
- Valvegear module
- Oil supply
- Introduction
- Oil circuit
- Oil pump
- Oil pressure control
- Cooling system
- Introduction
- Coolant circulation
- System overview
- Thermostat
- Coolant pump
- Air supply and turbocharging
- Overview
- Exhaust turbocharger
- Charge pressure actuator V465
- Fuel system
- System overview
- Ignition
- Engine management system
- System overview (2015 model Audi A1)
- Lambda control
- Service
- Special tools and workshop equipment
- Maintenance operations
- Appendix
- Glossary
- Self study programmes
Language: English
Format: PDF
Pages: 36
Self Study Program 639 – Audi 1.0l 3-cylinder TFSI engine EA211 series PDF free online
