3-cylinder common rail engine (1.2 l, EA189)

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  2
• 2.1 Safety measures when working on fuel supply
  2
• 2.2 Safety measures when working on vehicles with a start/stop system
  3
• 2.4 Safety precautions when working on the cooling system
  3
• 2.5 Safety precautions when working on the SCR system
  3
• 2.6 Safety precautions when working on exhaust system
  4
• 3 General repair notes
  6
• 3.1 Rules for cleanliness
  6
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing engine
  7
• 1.2 Securing engine on engine and gearbox support
  15
• 1.3 Installing engine
  17
• 2 Assembly mountings
  20
• 2.1 Assembly overview - assembly mountings
  20
• 2.2 Supporting engine in installation position
  22
• 3 Engine cover panel
  24
• Crankshaft group
  25
• 1 Cylinder block (pulley end)
  25
• 1.5 Removing and installing poly V-belt (vehicles with idler roller)
  29
• 1.6 Removing and installing poly V-belt (vehicles with tensioning element)
  30
• 1.7 Removing and installing tensioner for poly V-belt
  32
• 1.8 Removing and installing vibration damper
  33
• 1.9 Ancillary bracket
  34
• 1.10 Removing and installing sealing flange on pulley end
  36
• 2 Cylinder block, gearbox end
  40
• 2.1 Assembly overview - cylinder block, gearbox end
  40
• 2.2 Removing and installing flywheel
  41
• 2.3 Removing and installing sealing flange on gearbox side
  42
• 3 Crankshaft
  51
• 3.1 Assembly overview - crankshaft
  51
• 3.2 Crankshaft dimensions
  52
• 3.3 Measuring axial clearance of crankshaft
  52
• 3.4 Measuring radial clearance of crankshaft
  53
• 4 Pistons and conrods
  54
• 4.1 Assembly overview - pistons and conrods
  54
• 4.2 Removing and installing pistons
  56
• 4.3 Measuring piston projection at “TDC”
  57
• 4.4 Checking pistons and cylinder bores
  58
• 4.5 Separating new conrods
  60
• 4.6 Measuring radial clearance of conrods
  60
• Cylinder head, valve gear
  62
• 1 Cylinder head
  62
• 1.1 Assembly overview - cylinder head cover
  62
• 1.2 Removing and installing cylinder head cover
  63
• 1.3 Assembly overview - cylinder head
  66
• 1.4 Removing and installing cylinder head
  68
• 1.5 Removing and installing vacuum pump
  80
• 1.6 Checking compression
  81
• 2 Toothed belt drive
  83
• 2.1 Assembly overview - toothed belt drive
  83
• 2.2 Removing, installing and tensioning toothed belts
  88
• 3 Valve gear
  97
• 3.1 Assembly overview - valve gear
  97
• 3.2 Measuring axial clearance of camshaft
  98
• 3.3 Measuring radial clearance of camshafts
  99
• 3.4 Inlet and exhaust valves
  100
• 3.5 Removing and installing camshafts
  109
• 3.6 Checking hydraulic compensation elements
  115
• 3.7 Removing and installing camshaft oil seal
  116
• Lubrication
  118
• 1 Sump
  118
• 1.1 Assembly overview - sump
  118
• 1.2 Removing and installing oil level and oil temperature sender G266
  120
• 1.3 Removing and installing sump
  121
• 1.4 Engine oil:
  125
• 2 Engine oil cooler
  126
• 2.1 Removing and installing engine oil cooler
  126
• 2.2 Checking engine oil cooler for leaks
  128
• 3 Oil filter, oil pressure switch
  131
• 3.1 Assembly overview - oil filter bracket and engine oil cooler
  131
• 3.2 Removing and installing oil filter bracket with engine oil cooler
  132
• 3.3 Checking oil pressure and oil pressure switch
  135
• 3.4 Removing and installing oil pressure switch F1
  137
• 4 Oil circuit
  138
• 4.1 Removing and installing oil supply line and oil return (turbocharger support)
  138
• 4.2 Oil spray jet
  141
• 5 Balancer shaft module
  142
• 5.1 Assembly overview - balancer shaft module
  142
• 5.2 Removing and installing balance shaft module
  143
• Cooling
  146
• 1 Cooling system/coolant
  146
• 1.1 Coolant hose connection diagram
  146
• 1.2 Checking cooling system for leaks
  147
• 1.3 Draining and adding coolant
  149
• 1.4 Cooling system - fitting locations
  153
• 2 Coolant pump, regulation of cooling system
  157
• 2.1 Assembly overview - coolant pump and 4/2-way valve with thermostat
  157
• 2.2 Removing and installing 4/2-way valve with thermostat
  158
• 2.3 Removing and installing coolant pump
  162
• 3 Radiator, radiator fan
  165
• 3.1 Removing and installing radiator
  165
• 3.2 Assembly overview - with radiator fan V7
  167
• 3.3 Removing and installing cowling with radiator fan V7
  167
• Turbocharging/supercharging
  169
• 1 Turbocharger
  169
• 1.1 Assembly overview - turbocharger with attachments
  169
• 1.2 Removing and installing turbocharger
  171
• 2 Charge air system
  178
• 2.1 Assembly overview - charge air system
  178
• 2.2 Removing and installing charge air cooler
  179
• 2.3 Fitting charge air system hose connections
  180
• 2.4 Checking charge air system for leaks
  182
• Mixture preparation - injection
  185
• 1 Injection system
  185
• 1.1 Instructions for working on fuel system
  185
• 1.2 Schematic overview - fuel system
  186
• 1.3 Filling/bleeding fuel system
  188
• 1.4 Checking for leaks in the fuel system
  189
• 2 Vacuum system
  190
• 2.1 Vacuum hose connection diagram
  190
• 2.2 Checking vacuum system
  191
• 3 Injectors, fuel rail
  193
• 3.1 Assembly overview - injectors
  193
• 3.2 Adapting correction values for injectors
  195
• 3.3 Checking return flow rate of injectors with engine running
  195
• 3.4 Removing and installing injectors
  197
• 3.5 Removing and installing high-pressure lines
  202
• 3.6 Assembly overview - fuel rail
  206
• 3.7 Removing and installing fuel rail
  208
• 4 High-pressure pump
  213
• 4.1 Assembly overview - high-pressure pump
  213
• 4.2 Removing and installing high-pressure pump
  214
• 4.3 Checking vacuum at high-pressure fuel pump (venturi nozzle)
  219
• 5 Senders and sensors
  224
• 5.1 Removing and installing fuel pressure regulating valve N276
  224
• 5.2 Checking fuel pressure regulating valve N276
  226
• 5.3 Removing and installing fuel pressure sender G247
  228
• 5.4 Removing and installing pressure differential sender G 505
  229
• 6 Lambda probe
  232
• 6.1 Assembly overview - lambda probe and exhaust temperature sensors
  232
• 6.2 Removing and installing Lambda probe G39 with Lambda probe heater Z19
  232
• 7 Air filter
  234
• 7.1 Assembly overview - air filter
  234
• 7.2 Removing and installing air filter housing
  235
• 8 Intake manifold
  237
• 8.1 Assembly overview - intake manifold with attachments
  237
• 8.2 Removing and installing intake manifold
  237
• 9 Engine control unit
  241
• 9.1 Reading and deleting engine control unit event memory
  241
• 9.2 Adapting functions and components
  241
• 9.3 Removing and installing engine control unit with no ant-theft protection
  242
• 9.4 Removing and installing anti-theft engine control unit
  242
• Exhaust system
  244
• 1 Exhaust pipes and silencers
  244
• 1.1 Assembly overview - silencers
  244
• 1.2 Separating exhaust pipes from silencers
  244
• 1.3 Aligning exhaust system free of stress
  246
• 1.4 Installation position of clamp
  247
• 2 Emission control
  248
• 2.1 Assembly overview - particulate filter
  248
• 2.2 Removing and installing particulate filter
  253
• 3 Exhaust gas recirculation
  266
• 3.1 Assembly overview - exhaust gas recirculation
  266
• 3.2 Removing and installing exhaust gas recirculation cooler
  267
• 3.3 Checking changeover for exhaust gas recirculation cooler
  270
• 3.4 Checking exhaust gas recirculation cooler for leaks
  271
• 3.5 Cleaning exhaust gas recirculation system
  275
• Glow plug system
  281
• 1 Glow plug system
  281
• 1.1 Checking glow plug system
  281
• 1.2 Removing and installing ceramic glow pin plugs; carrying out resistor test
  281
• 1.3 Removing and installing Hall sender G40
  284
• 1.4 Removing and installing knock sensor G61
  286
• 1.5 Removing and installing engine speed sender G28
  287