4-cylinder common rail engine (2.0 l, EA189 Gen II)

Kapitelübersicht

• Technical data
  1
• 1 Technical data
  1
• 1.1 Engine number
  1
• 1.2 Engine data
  1
• 2 Safety information
  3
• 2.1 Safety regulations for working on fuel supply
  3
• 2.2 Safety measures when working on vehicles with a start/stop system
  3
• 2.4 Safety precautions when working on the cooling system
  4
• 2.5 Safety precautions when working on the SCR system
  4
• 2.6 Safety precautions when working on exhaust system
  5
• Removing and installing engine
  7
• 1 Removing and installing engine
  7
• 1.1 Removing and installing engine cover
  7
• 1.2 Removing engine
  7
• 1.3 Separating engine from gearbox
  14
• 1.4 Separating engine from dual clutch gearbox
  16
• 1.5 Securing engine to assembly stand
  18
• 1.6 Installing engine
  20
• 1.7 Assembly mountings
  22
• 1.8 Adjusting assembly mountings
  23
• Crankshaft group
  27
• 1 Dismantling and assembling engine
  27
• 1.1 Poly V-belt drive with tensioning element and air conditioner compressor
  27
• 1.2 Poly V-belt drive with tensioning roller and air conditioner compressor
  30
• 1.3 Poly V-belt drive without air conditioning compressor
  34
• 1.4 Removing and installing bracket for ancillaries
  35
• 1.5 Assembly overview - toothed belt drive
  36
• 1.6 Removing and installing engine bracket
  38
• 1.7 Assembly overview - crankcase
  42
• 2 Removing and installing sealing flange and flywheel
  44
• 2.1 Assembly overview - Sealing flange, belt pulley end
  44
• 2.2 Renewing crankshaft oil seal - pulley end
  45
• 2.3 Removing and installing sealing flange - pulley end
  47
• 2.4 Assembly overview - Dual-mass flywheel and sealing flange
  49
• 2.5 Removing and installing dual-mass flywheel
  51
• 2.6 Renewing crankshaft sealing flange - flywheel end
  52
• 2.7 Removing and installing engine speed sender G28
  59
• 3 Pistons and conrods
  61
• 3.1 Assembly overview - pistons and conrods
  61
• 3.2 Piston and cylinder dimensions
  64
• 3.3 Separating new conrods
  64
• 3.4 Bearing shells - installation position
  65
• 3.5 Piston and cylinder dimensions
  65
• 3.6 Checking piston projection at TDC
  65
• 3.7 Measuring radial clearance of conrods
  67
• 4 Crankshaft
  69
• 4.1 Assembly overview - crankshaft
  69
• 4.2 Crankshaft dimensions
  69
• 4.3 Renewing needle bearing in crankshaft
  70
• Cylinder head, valve gear
  72
• 1 Cylinder head
  72
• 1.1 Assembly overview - cylinder head cover
  72
• 1.2 Removing and installing cylinder head cover
  74
• 1.3 Removing, installing and tensioning toothed belt
  77
• 1.4 Assembly overview - cylinder head
  84
• 1.5 Removing and installing cylinder head
  86
• 1.6 Removing and installing vacuum pump
  95
• 1.7 Compression test
  96
• 2 Valve gear
  98
• 2.1 Assembly overview - valve gear
  98
• 2.2 Removing and installing camshafts
  101
• 2.3 Measuring axial clearance of camshaft
  108
• 2.4 Measuring radial clearance of camshafts
  109
• 2.5 Removing and installing camshaft oil seal
  109
• 2.6 Checking hydraulic compensation elements
  112
• 2.7 Renewing valve stem seals with cylinder head installed
  112
• 2.8 Renewing valve stem seals with cylinder head removed
  116
• 2.9 Valves
  119
• Lubrication
  121
• 1 Engine oil:
  121
• 1.1 Oil capacities
  121
• 1.2 Checking engine oil level
  121
• 2 Parts of lubrication system
  122
• 2.1 Assembly overview - oil pump, sump, balance shaft module
  122
• 2.2 Removing and installing oil level and oil temperature sender G266
  126
• 2.3 Removing and installing oil sump
  126
• 2.4 Removing and installing oil pump
  130
• 2.5 Removing balancer shaft module
  131
• 2.6 Installing a new balancer shaft module
  133
• 2.7 Installing a previously used balancer shaft module again
  135
• 3 Oil filter bracket and engine oil cooler
  137
• 3.1 Assembly overview - oil filter bracket and engine oil cooler
  137
• 3.2 Removing and installing oil filter bracket with engine oil cooler
  138
• 3.3 Removing and installing oil pressure switch F1
  141
• 3.4 Checking oil pressure switch F1
  142
• 3.5 Checking oil pressure
  143
• Cooling
  145
• 1 Parts of cooling system
  145
• 1.1 Assembly overview - parts of cooling system, body side
  145
• 1.2 Assembly overview - parts of cooling system, engine side
  147
• 1.3 Assembly overview - coolant pump and thermostat
  148
• 1.4 Coolant hose connection diagram
  149
• 2 Repairing cooling system
  150
• 2.2 Removing and installing radiator
  151
• 2.3 Removing and installing coolant pump
  152
• 2.4 Removing and installing 4/2-way valve with thermostat
  154
• 2.5 Draining and adding coolant
  159
• 2.6 Coolant pipes, coolant temperature sender
  163
• 2.7 Checking cooling system for leaks
  174
• Fuel supply system
  178
• 1 Safety regulations for working on fuel supply
  178
• 2 Rules for cleanliness
  179
• 3 Repair instructions if tank has been filled with incorrect fuel
  180
• 3.1 Step 1 (Engine was started with incorrect fuel)
  180
• 3.2 Step 2 (Engine was not started with incorrect fuel)
  181
• 3.3 Step 3 (There are filings in fuel delivery unit and fuel tank)
  182
• 3.4 Step 4 (There are no filings in fuel delivery unit and fuel tank)
  182
• 3.5 Step 5 (There are filings in high-pressure pump)
  183
• 3.6 Step 6 (There are no filings in high-pressure pump)
  183
• 4 Parts of fuel supply system
  184
• 4.1 Assembly overview - fuel tank
  184
• 4.2 Assembly overview - fuel delivery unit, fuel gauge sender and suction jet pump
  185
• 4.3 Removing and installing fuel delivery unit
  186
• 4.4 Removing and installing fuel gauge sender G
  188
• 4.5 Emptying fuel tank
  189
• 4.6 Removing and installing fuel tank
  192
• 5 Repairing fuel supply
  194
• 5.1 Assembly overview - fuel filter
  194
• 5.2 Removing and installing fuel filter
  195
• 5.3 Checking fuel system pressurisation pump G6
  196
• 5.4 Assembly overview - accelerator mechanism
  200
• 5.5 Removing and installing accelerator pedal module
  201
• Turbocharging/supercharging
  204
• 1 Exhaust turbocharger
  204
• 1.1 Safety precautions
  204
• 1.2 Rules for cleanliness
  204
• 1.3 Assembly overview - turbocharger
  205
• 1.4 Removing and installing turbocharger
  207
• 1.5 Replacing vacuum unit with position sender for charge pressure positioner G581
  211
• 2 Charge air system
  217
• 2.1 Installing hose connections with plug-in connectors
  217
• 2.2 Installing hose connections with corrugated pipe connection
  218
• 2.3 Assembly overview - parts of charge air cooling
  218
• 2.4 Removing and installing charge air cooler
  219
• 2.5 Checking charge air system for leaks
  220
• 2.6 Vacuum hose connection diagram
  224
• 2.7 Checking vacuum system
  224
• Mixture preparation - injection
  228
• 1 Diesel direct injection system
  228
• 1.1 Safety precautions
  228
• 1.2 Rules for cleanliness
  228
• 1.3 System layout
  229
• 2 High-pressure pump
  231
• 2.1 Assembly overview - high-pressure pump
  231
• 2.2 Removing and installing high-pressure pump
  232
• 2.3 Filling/bleeding fuel system
  235
• 2.4 Checking for leaks in the fuel system
  236
• 3 Injectors
  237
• 3.1 Assembly overview - injectors
  237
• 3.2 Carrying out adaptation for injector delivery calibration
  240
• 3.3 Checking for injectors sticking open
  241
• 3.4 Removing and installing injectors
  242
• 3.5 Installing high-pressure lines
  246
• 3.6 Checking fuel pressure regulating valve N276
  247
• 3.7 Removing and installing fuel pressure regulating valve N276
  249
• 3.8 Removing and installing fuel pressure sender G247
  250
• 3.9 Removing and installing fuel rail
  252
• 4 Intake manifold
  256
• 4.1 Assembly overview - intake manifold with attachments
  256
• 4.2 Removing and installing throttle valve module J338
  257
• 4.3 Removing and installing intake manifold
  258
• 5 Air filter
  262
• 5.1 Assembly overview - air filter
  262
• 5.2 Removing and installing air filter housing
  263
• 5.3 Removing and installing air mass meter G70
  265
• 6 Lambda probe and pressure differential sender
  266
• 6.1 Removing and installing Lambda probe G39 with Lambda probe heater Z19
  266
• 6.2 Removing and installing pressure differential sender G505
  267
• 7 Engine (motor) control unit
  269
• 7.1 Removing and installing engine (motor) control unit J623
  269
• 7.2 Removing and installing anti-theft engine control unit J623
  270
• Exhaust system
  272
• 1 Front exhaust pipe with particulate filter
  272
• 1.1 Assembly overview - front exhaust pipe with particulate filter
  272
• 1.2 Removing and installing particulate filter
  274
• 2 Silencer
  282
• 2.1 Assembly overview - silencers
  282
• 2.2 Aligning exhaust system free of stress
  283
• 2.3 Installation position and specified torque of clamp
  283
• 3 Exhaust gas temperature regulation
  285
• 3.1 Assembly overview - exhaust gas temperature regulation
  285
• 3.2 Removing and installing exhaust gas temperature sender 1 G235
  286
• 3.3 Removing and installing exhaust gas temperature sender 3 G495
  287
• 3.4 Removing and installing exhaust gas temperature sender 4 G648
  289
• 4 SCR system (selective catalytic reduction)
  290
• 4.1 Assembly overview - reduction catalytic converter
  290
• 4.2 Assembly overview - tank for reducing agent
  292
• 4.3 Removing and installing heater element (heater cup)
  293
• 4.4 Removing and installing injector for reduction agent N474
  297
• 4.5 Draining reducing agent tank
  298
• 4.6 Removing and installing reducing agent tank
  300
• 5 Exhaust gas recirculation system
  304
• 5.1 Assembly overview - exhaust gas recirculation
  304
• 5.2 Checking changeover for exhaust gas recirculation cooler
  305
• 5.3 Removing and installing exhaust gas recirculation cooler
  305
• 5.4 Checking exhaust gas recirculation cooler for leaks
  308
• 5.5 Cleaning exhaust gas recirculation system
  312
• Glow plug system
  318
• 1 Checking glow plug system
  318
• 1.1 Removing and installing glow plugs
  318
• 1.2 Removing and installing automatic glow period control unit J179
  320