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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  3
• 2.1 Safety precautions when working on fuel system
  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 the SCR system
  5
• 2.6 Safety precautions when working on exhaust system
  5
• 3 Repair notes
  7
• 3.1 Rules for cleanliness
  7
• 3.2 Foreign objects in engine
  7
• 3.3 Checking vacuum system
  8
• Removing and installing engine
  9
• 1 Removing and installing engine
  9
• 1.1 Removing and installing engine
  9
• 1.2 Securing engine on engine and gearbox support
  22
• 1.3 Installing engine
  23
• 2 Assembly mountings
  27
• 2.1 Assembly overview - assembly mountings
  27
• 2.2 Supporting engine in installation position
  28
• 2.3 Adjusting assembly mountings
  36
• 3 Engine cover panel
  41
• 3.1 Removing and installing engine cover
  41
• Crankshaft group
  42
• 1 Cylinder block (pulley end)
  42
• 1.1 Assembly overview - poly V-belt drive
  42
• 1.2 Removing and installing poly-V belt
  46
• 1.3 Removing and installing tensioner for poly V-belt
  50
• 1.4 Removing and installing bracket for ancillaries
  51
• 1.5 Removing and installing engine bracket
  53
• 1.6 Assembly overview - cylinder block (pulley end)
  63
• 1.7 Removing and installing sealing flange on pulley end
  64
• 1.8 Renewing crankshaft oil seal - belt pulley end
  66
• 2 Cylinder block, gearbox end
  69
• 2.1 Assembly overview - cylinder block, gearbox end
  69
• 2.2 Removing and installing sealing flange on gearbox side
  70
• 3 Crankshaft
  79
• 3.1 Assembly overview - crankshaft
  79
• 3.2 Renewing needle bearing in crankshaft
  79
• 3.3 Crankshaft dimensions
  82
• 4 Pistons and conrods
  83
• 4.1 Assembly overview - pistons and conrods
  83
• 4.2 Measuring piston projection at TDC
  86
• 4.3 Separating new conrod
  87
• Cylinder head, valve gear
  89
• 1 Cylinder head
  89
• 1.1 Assembly overview - cylinder head
  89
• 1.2 Removing and installing cylinder head
  91
• 1.3 Assembly overview - cylinder head cover
  100
• 1.4 Removing and installing cylinder head cover
  101
• 1.5 Removing and installing vacuum pump
  104
• 1.6 Checking compression
  105
• 2 Toothed belt drive
  107
• 2.1 Assembly overview - toothed belt
  107
• 2.2 Removing and installing toothed belt
  109
• 3 Valve gear
  116
• 3.1 Assembly overview - valve gear
  116
• 3.2 Removing and installing camshaft oil seal
  117
• 3.3 Removing and installing camshaft
  121
• 3.4 Removing and installing valve stem seals
  128
• 4 Inlet and exhaust valves
  133
• 4.1 Valve dimensions
  133
• 4.2 Reworking valve seats
  133
• 4.3 Checking valve guides
  133
• Lubrication
  134
• 1 Sump, oil pump
  134
• 1.1 Assembly overview - sump/oil pump
  134
• 1.2 Removing and installing oil sump
  140
• 1.3 Removing and installing oil pump
  143
• 1.4 Engine oil:
  144
• 2 Engine oil cooler
  146
• 2.1 Assembly overview - engine oil cooler
  146
• 3 Oil filter, oil pressure switch
  148
• 3.1 Assembly overview - oil filter/oil pressure switch
  148
• 3.2 Removing and installing oil filter housing
  149
• 3.3 Checking oil pressure and oil pressure switch
  152
• 4 Oil circuit
  154
• 4.1 Removing and installing oil supply line for turbocharger
  154
• 5 Balancer shaft module
  156
• 5.1 Assembly overview - balancer shaft module
  156
• 5.2 Removing and installing balance shaft module
  159
• Cooling
  170
• 1 Cooling system/coolant
  170
• 1.1 Coolant hose connection diagram
  170
• 1.2 Checking cooling system for leaks
  174
• 1.3 Draining and adding coolant
  178
• 1.4 Assembly overview - engine preheater
  182
• 2 Coolant pump, regulation of cooling system
  186
• 2.1 Removing and installing coolant pump
  186
• 2.2 Removing and installing thermostat
  187
• 2.3 Removing and installing 4/2-way valve with thermostat
  189
• 3 Coolant pipes
  191
• 3.1 Assembly overview - coolant pipes
  191
• 4 Radiator, radiator fan
  195
• 4.1 Assembly overview - radiator/radiator fan
  195
• 4.2 Removing and installing radiator
  198
• 4.3 Removing and installing radiator cowl with radiator fan
  199
• Turbocharging/supercharging
  200
• 1 Exhaust turbocharger
  200
• 1.1 Assembly overview - turbocharger
  200
• 1.2 Removing and installing turbocharger
  206
• 1.3 Renewing vacuum unit for turbocharger
  210
• 2 Charge air system
  218
• 2.1 Assembly overview - charge air system
  218
• 2.2 Assembly overview - charge-air hose connections
  220
• 2.3 Checking charge air system for leaks
  221
• Mixture preparation - injection
  224
• 1 Injection system
  224
• 1.1 Schematic overview - fuel system
  224
• 1.2 Assembly overview - fuel system
  226
• 1.3 Filling/bleeding fuel system
  229
• 1.4 Checking fuel system for leaks
  230
• 2 Injectors/high-pressure accumulator (rail)
  231
• 2.1 Check pressure retention valve in fuel return line
  231
• 2.2 Removing and installing injectors
  232
• 2.3 Removing and installing high-pressure lines
  236
• 2.4 Removing and installing fuel rail
  238
• 3 Vacuum system
  242
• 3.1 Assembly overview - vacuum system
  242
• 3.2 Checking vacuum system
  243
• 4 Air filter
  247
• 4.1 Assembly overview - air filter housing
  247
• 4.2 Removing and installing air filter housing
  249
• 4.3 Checking changeover flap for intake air preheating
  250
• 4.4 Removing and installing changeover flap for intake air preheating
  251
• 5 Intake manifold
  254
• 5.1 Assembly overview - intake manifold
  254
• 5.2 Removing and installing intake manifold
  254
• 6 Senders and sensors
  258
• 6.1 Checking fuel pressure regulating valve
  258
• 6.2 Removing and installing fuel pressure regulating valve N276
  259
• 6.3 Removing and installing fuel pressure sender
  261
• 7 High-pressure pump
  265
• 7.1 Removing and installing high-pressure pump
  265
• 8 Engine (motor) control unit
  269
• 8.1 Removing and installing engine control unit
  269
• 9 Lambda probe
  287
• 9.1 Removing and installing lambda probe
  287
• Exhaust system
  291
• 1 Exhaust pipes and silencers
  291
• 1.1 Assembly overview - silencers
  291
• 1.2 Separating exhaust pipes from silencers
  299
• 1.3 Aligning exhaust system free of stress
  301
• 1.4 Check exhaust system for leaks
  303
• 1.5 Installation position of clamp
  304
• 2 Exhaust gas cleaning
  306
• 2.1 Assembly overview - emission control
  306
• 2.2 Removing and installing particulate filter
  316
• 2.3 Removing and installing particulate filter with NOx storage catalytic converter
  324
• 2.4 Removing and installing NOx storage catalytic converter
  332
• 3 SCR system (selective catalytic reduction)
  334
• 3.1 Assembly overview - tank for reducing agent
  334
• 3.2 Draining reducing agent tank
  335
• 3.3 Removing and installing reducing agent tank
  338
• 3.4 Assembly overview - delivery module for reducing agent
  340
• 3.5 Assembly overview - reducing agent delivery line
  342
• 3.6 Removing and installing reducing agent supply line
  343
• 3.7 Removing and installing injector for reducing agent
  345
• 3.8 Removing and installing heater element (heater cup)
  346
• 4 Exhaust gas recirculation
  351
• 4.1 Assembly overview - exhaust gas recirculation
  351
• 4.2 Removing and installing exhaust gas recirculation filter
  354
• 4.3 Removing and installing exhaust gas recirculation cooler
  356
• 4.4 Checking exhaust gas recirculation cooler for leaks
  360
• 4.5 Removing and installing temperature sensor for exhaust gas recirculation
  363
• 4.6 Cleaning exhaust gas recirculation system
  367
• Glow plug system
  374
• 1 Glow plug system
  374
• 1.1 Removing and installing automatic glow period control unit J179
  374
• 1.2 Removing and installing glow plug
  375
• 1.3 Removing and installing Hall sender
  382
• 1.4 Removing and installing engine speed sender
  386