4-cylinder common rail engine (1.6 l, EA189)

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  3
• 2.1 Safety measures when working on fuel supply
  3
• 2.3 Safety measures when working on vehicles with a start/stop system
  4
• 2.4 Safety precautions when working on the cooling system
  4
• 2.5 Safety precautions when working on exhaust system
  5
• 3 Repair notes
  6
• 3.1 Rules for cleanliness
  6
• 3.2 Checking vacuum system
  7
• Removing and installing engine
  8
• 1 Removing and installing engine
  8
• 1.1 Removing engine
  8
• 1.2 Separating engine and gearbox
  48
• 1.3 Securing engine on engine and gearbox support
  50
• 1.4 Installing engine
  51
• 2 Assembly mountings
  60
• 2.1 Assembly overview - assembly mountings
  60
• 2.2 Supporting engine in installation position
  66
• 2.3 Adjusting assembly mountings
  72
• 3 Engine cover panel
  76
• 3.1 Removing and installing engine cover
  76
• Crankshaft group
  77
• 1 Cylinder block (pulley end)
  77
• 1.1 Assembly overview - poly V-belt drive
  77
• 1.2 Removing and installing poly-V belt
  80
• 1.3 Removing and installing tensioner for poly V-belt
  84
• 1.4 Removing and installing vibration damper
  88
• 1.5 Removing and installing bracket for ancillaries
  89
• 1.6 Renewing crankshaft oil seal - belt pulley end
  91
• 1.7 Removing and installing sealing flange on pulley end
  92
• 1.8 Removing and installing engine bracket
  95
• 2 Cylinder block, gearbox end
  110
• 2.1 Assembly overview - cylinder block, gearbox end
  110
• 2.2 Removing and installing flywheel
  111
• 2.3 Removing and installing sealing flange on gearbox side
  112
• 3 Crankshaft
  122
• 3.1 Assembly overview - crankshaft
  122
• 3.2 Renewing needle bearing in crankshaft
  123
• 3.3 Crankshaft dimensions
  125
• 3.4 Measuring axial clearance of crankshaft
  125
• 3.5 Measuring radial clearance of crankshaft
  125
• 4 Pistons and conrods
  127
• 4.1 Assembly overview - pistons and conrods
  127
• 4.2 Removing and installing pistons
  130
• 4.3 Measuring piston projection at “TDC”
  131
• 4.4 Separating new conrod
  133
• 4.5 Checking radial clearance of conrods
  134
• Cylinder head, valve gear
  135
• 1 Cylinder head
  135
• 1.1 Assembly overview - cylinder head
  135
• 1.2 Removing and installing cylinder head
  138
• 1.3 Assembly overview - cylinder head cover
  167
• 1.4 Removing and installing cylinder head cover
  168
• 1.5 Removing and installing vacuum pump
  176
• 1.6 Checking compression
  177
• 2 Toothed belt drive
  179
• 2.1 Assembly overview - toothed belt
  179
• 2.2 Removing and installing toothed belt
  184
• 3 Valve gear
  199
• 3.1 Assembly overview - valve gear
  199
• 3.2 Measuring axial play of camshaft
  200
• 3.3 Measuring radial play of camshaft
  201
• 3.4 Removing and installing camshaft oil seal
  202
• 3.5 Removing and installing camshaft
  204
• 3.6 Checking hydraulic compensation elements
  211
• 3.7 Removing and installing valve stem seal
  212
• 4 Inlet and exhaust valves
  219
• 4.1 Valve dimensions
  219
• 4.2 Reworking valve seats
  219
• 4.3 Checking valve guides
  219
• 4.4 Checking valves
  219
• Lubrication
  220
• 1 Sump, oil pump
  220
• 1.1 Assembly overview - sump/oil pump
  220
• 1.2 Removing and installing sump
  222
• 1.3 Removing and installing oil level and oil temperature sender G 266
  227
• 1.4 Removing and installing oil pump
  228
• 1.5 Engine oil:
  229
• 2 Engine oil cooler
  231
• 2.1 Assembly overview - engine oil cooler
  231
• 2.2 Removing and installing engine oil cooler
  232
• 2.3 Checking engine oil cooler for leaks
  234
• 3 Oil filter, oil pressure switch
  237
• 3.1 Assembly overview - oil filter housing
  237
• 3.2 Removing and installing oil filter housing
  238
• 3.3 Checking oil pressure and oil pressure switch
  241
• 3.4 Removing and installing oil pressure switch F1
  244
• 4 Oil circuit
  246
• 4.1 Assembly overview - oil circuit
  246
• 4.2 Removing and installing oil supply line
  248
• 4.3 Oil spray jets/nozzles
  254
• Cooling
  255
• 1 Cooling system/coolant
  255
• 1.1 Coolant hose connection diagram
  255
• 1.2 Checking cooling system for leaks
  259
• 1.3 Draining and adding coolant
  261
• 2 Coolant pump, regulation of cooling system
  266
• 2.1 Assembly overview - coolant pump, thermostat
  266
• 2.2 Removing and installing coolant pump
  269
• 2.3 Removing and installing thermostat
  270
• 2.4 Checking thermostat
  273
• 2.5 Removing and installing 4/2-way valve with thermostat
  273
• 2.6 Electric coolant pump
  279
• 2.7 Removing and installing coolant temperature sender
  283
• 3 Coolant pipes
  288
• 3.1 Assembly overview - coolant pipes
  288
• 3.2 Removing and installing coolant pipes
  290
• 4 Radiator, radiator fan
  306
• 4.1 Assembly overview - radiator/radiator fan
  306
• 4.2 Removing and installing radiator
  309
• 4.3 Removing and installing radiator cowl with radiator fan
  314
• Turbocharging/supercharging
  318
• 1 Turbocharger
  318
• 1.1 Assembly overview - turbocharger
  318
• 1.2 Removing and installing turbocharger
  324
• 1.3 Renewing vacuum unit for turbocharger
  347
• 2 Charge air system
  355
• 2.1 Assembly overview - charge air system
  355
• 2.2 Removing and installing charge air cooler
  359
• 2.3 Assembly overview - charge-air hose connections
  363
• 2.4 Checking charge air system for leaks
  366
• Mixture preparation - injection
  369
• 1 Injection system
  369
• 1.1 Schematic overview - fuel system
  369
• 1.2 Assembly overview - fuel system
  374
• 1.3 Filling/bleeding fuel system
  386
• 1.4 Checking fuel system for leaks
  386
• 2 Vacuum system
  388
• 2.1 Connection diagram - vacuum system
  388
• 3 Injectors/high-pressure accumulator (rail)
  392
• 3.1 Assembly overview - injectors
  392
• 3.2 Adapting correction values for injectors
  393
• 3.3 Testing jammed-open injectors
  393
• 3.4 Check pressure retention valve in fuel return line
  395
• 3.5 Removing and installing injectors
  397
• 3.6 Removing and installing fuel rail
  402
• 3.7 Removing and installing high-pressure lines
  406
• 4 High-pressure pump
  413
• 4.1 Assembly overview - high-pressure pump
  413
• 4.2 Removing and installing high-pressure pump
  414
• 5 Senders and sensors
  420
• 5.1 Removing and installing fuel pressure regulating valve N 276
  420
• 5.2 Checking fuel pressure regulating valve N276
  422
• 5.3 Removing and installing fuel pressure sender G 247
  423
• 5.4 Checking fuel pressure sender G 247
  425
• 5.5 Checking fuel metering valve N 290
  425
• 5.6 Removing and installing pressure differential sender G505
  426
• 6 Lambda probe
  432
• 6.1 Assembly overview - Lambda probe
  432
• 6.2 Removing and installing Lambda probe
  436
• 7 Air filter
  439
• 7.1 Assembly overview - air filter housing
  439
• 7.2 Removing and installing air filter housing
  441
• 8 Intake manifold
  445
• 8.1 Assembly overview - intake manifold
  445
• 8.2 Removing and installing intake manifold
  447
• 8.3 Removing and installing throttle valve module J338
  451
• 9 Engine control unit
  453
• 9.1 Removing and installing engine control unit
  453
• Exhaust system
  468
• 1 Exhaust pipes and silencers
  468
• 1.1 Assembly overview - silencers
  468
• 1.2 Aligning exhaust system free of stress
  473
• 1.3 Installation position of clamp
  475
• 2 Emission control
  476
• 2.1 Assembly overview - emission control
  476
• 2.2 Removing and installing particulate filter
  484
• 2.3 Removing and installing catalytic converter
  505
• 3 Exhaust gas temperature regulation
  510
• 3.1 Assembly overview - exhaust gas temperature regulation
  510
• 3.2 Removing and installing parts of exhaust gas temperature regulation
  513
• 4 Exhaust gas recirculation
  524
• 4.1 Assembly overview - exhaust gas recirculation
  524
• 4.2 Checking changeover for exhaust gas recirculation cooler
  525
• 4.3 Removing and installing exhaust gas recirculation cooler
  526
• 4.4 Checking exhaust gas recirculation cooler for leaks
  531
• 4.5 Cleaning exhaust gas recirculation system
  534
• Glow plug system
  541
• 1 Glow plug system
  541
• 1.1 Removing and installing glow plug
  541
• 1.2 Checking glow plugs
  543
• 1.3 Removing and installing Hall sender G40
  543
• 1.4 Removing and installing engine speed sender G 28
  545