This comprehensive PDF file contains the official VAG eSelf-Study Program (released as SSP 607 in Europe and 920223 in North America) focused entirely on the development and mechanical function of the first-generation Audi 4.0-liter V8 TFSI twin-turbo engine (EA824 series). Developed to deliver massive power while maintaining surprising fuel economy, this highly compact V8 produces between 420 hp (in the S6/S7) and up to 520 hp (in the S8), with 650 Nm of torque available almost immediately from idle. This technical training manual is an absolute must-have for VAG technicians, specialized mechanics, and high-performance tuners looking to fully understand the incredibly complex forced induction and thermal management systems of this flagship engine.
Please note: As an eSelf-Study Program, this document focuses heavily on engineering design, structural layouts, and operational theory. It is not a step-by-step workshop or repair manual, though the foundational knowledge it provides is crucial for complex diagnostics on the EA824 platform.
This detailed technical training manual covers the following key engineering topics:
- Engine Architecture and the “Hot V”: A deep dive into the completely redesigned engine block. It details the lightweight cast aluminum-silicon alloy crankcase and the unique cylinder head design where the exhaust ports are located on the inside of the V8, while the intakes are on the outside.
- Twin-Scroll Turbocharging: Essential reading for understanding the engine’s massive low-end torque. It meticulously maps out the design of the two twin-scroll turbochargers and the indirect charge air cooler, which are packed tightly into the inner V of the engine to minimize exhaust gas travel distance and virtually eliminate turbo lag.
- Cylinder on Demand (COD): The key to the engine’s efficiency. The manual thoroughly explains the complex mechanical and electronic actuation required to seamlessly deactivate four cylinders (two on each bank) during low to intermediate load conditions, significantly reducing fuel consumption without sacrificing drivability.
- Valvetrain and Fuel System: A complete breakdown of the chain-driven double overhead camshafts (DOHC), the variable valve timing system, and the 120-bar FSI direct fuel injection system. It also details the charge movement flaps in the intake ports used to improve combustion.
- Active Engine Mounts and Noise Cancellation: An overview of the ancillary systems required to maintain refinement when the engine is operating in 4-cylinder mode, including the active noise cancellation system and the active electromagnetic engine mounts that counter vibration.
Whether you are trying to understand the exact flow path of the twin-scroll turbos, diagnosing an issue with the Cylinder on Demand actuators, or preparing to modify an S6, this SSP is the definitive technical resource for the 4.0T EA824.
CONTENTS
- Introduction
- Eight Cylinder Engines at Audi
- Brief Technical Description
- Variants
- Audi S6 and S7 (C7 series)
- Audi A8 and S8 (D4 series)
- Engine Mechanical
- Cylinder Block
- Bed Plate
- Oil Module in the Inner V
- Crankshaft Assembly
- Crankcase Breather and Ventilation
- Coarse Oil Separation
- Fine Oil Separation
- Introduction of Cleaned Blow-By Gases
- Crankcase Ventilation (PCV)
- Evaporative Emission System
- Cylinder Heads
- Chain Drive
- Accessory Drive
- Oil Supply
- Oil Supply
- Operation of Volumetric Flow Control
- Oil Pressure Regulation
- Oil Cooling
- Oil Filter
- Oil Consumers
- Oil Pressure Monitoring
- Switchable Piston Cooling Jets
- Cooling System
- Engine Cooling Circuit and Cooling Module
- Map Controlled Engine Cooling Thermostat F265
- Transmission Fluid Heating/Cooling
- System 2 in Audi A8
- Turbocharger Cooling and Lubrication
- Charge Air Cooling
- Heater Circuit
- Air Supply and Charging
- Twin-Scroll Turbocharger
- Twin-Scroll Design
- Air Supply Schematic
- Charge Pressure Regulation
- Cylinder Deactivation (Cylinder on Demand)
- Allocation of Camshaft Actuators (AVS)
- Active Engine Mounts
- Purpose of the Engine Mount
- Active Noise Cancelation (ANC)
- ANC Deactivation
- Fuel System
- Exhaust System
- Exhaust Flaps
- Secondary Air System
- Engine Management
- Engine Management MED 17.1.1
- Engine Compartment Temperature Management
- Special Tools and Fixtures
- Knowledge Assessment
Language: English
Format: PDF
Pages: 96
Self Study Program 920223 – The Audi 4.0L V8 TFSI Engine with Twin Turbochargers
