This comprehensive 60-page PDF file contains the official VAG eSelf-Study Program (released as SSP 661 in Europe and 920273 in North America) focused entirely on the design and function of the Audi 2.5-liter 5-cylinder TFSI engine (EA855 EVO series). Famous for its incredible power potential and its unmistakable 1-2-4-5-3 firing order sound, the “EVO” generation of this legendary powerplant marked a massive leap forward from its predecessor. Audi engineers managed to shed 26 kilograms of weight while significantly increasing horsepower (400hp from the factory), making it a dominant force in the TT RS and RS3. This technical training manual is an absolute must-have for VAG technicians, specialized mechanics, and high-performance tuners.
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 and tuning.
This detailed technical training manual covers the following key engineering topics:
- Engine Mechanics and Lightweight Design: A deep dive into the completely redesigned engine block. It meticulously details the transition from an iron block to a “deep skirt” aluminum alloy crankcase with plasma-coated cylinder walls, the integration of a magnesium upper oil pan, and the hollow-bored crankshaft.
- Cylinder Head and Valvetrain: Essential details for understanding the engine’s breathing. It explains the operation of the Audi Valvelift System (AVS), which is strategically utilized on the exhaust camshaft to spool the turbocharger faster and improve low-end torque.
- Air Supply and Turbocharging: A complete breakdown of the forced induction system. It maps out the air routing and details the specific design of the large, single turbocharger.
- Fuel System (Dual Injection): A major upgrade for the EVO series. The manual thoroughly explains the integration of both high-pressure Direct Injection (FSI) and low-pressure Multi-Point Injection (MPI) into the intake manifold. This dual system drastically reduces particulate emissions and prevents carbon buildup on the intake valves.
- Intelligent Thermal Management (ITM) and Lubrication: A comprehensive overview of how the engine handles massive heat output. It explains the complex, electronically controlled cooling circuit that manages the cylinder head and block temperatures independently, as well as the map-controlled oil pump.
Whether you are trying to understand the exact actuation of the AVS system, diagnosing a fault in the dual-injection fueling map, or preparing to build a high-horsepower DAZA motor, this SSP is the definitive technical resource.
CONTENTS
- Introduction
- Engine description and special features
- Specifications
- Engine mechanicals
- Cylinder block
- Timing case (cover for timing chains)
- Oil pan top and bottom sections
- Crankshaft drive
- Pistons and connecting rods
- Cylinder head
- Audi valvelift system (AVS)
- Timing assembly
- Accessory belt drive
- Positive crankcase ventilation
- Oil supply
- Overview
- Oil pump
- Oil filter housing / oil cooler
- Oil flow
- Cooling system
- Overview
- Innovative Thermal Management (ITM)
- Sensors in the coolant circulation system
- Actuators in the coolant circuit
- Air supply and turbocharging
- Overview
- Intake manifold
- Turbocharging
- Exhaust system
- Overview
- Catalytic converter module
- Switchable exhaust valves
- Fuel system
- Overview
- Fuel injectors
- Intermediate Shaft Speed Sensor G265
- Combustion process
- Operating modes
- Engine management
- System overview
- Inspection and maintenance
- Service information and operations
- Special tools and workshop equipment
- Appendix
- Glossary
- Self-Study programs
- Knowledge assessment
Language: English
Format: PDF
Pages: 61
Self Study Program 920273 – The Audi 2.5l TFSI Engine EA855 EVO Series
