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

Chapter overview

• Technical data
  1
• 1 Identification
  1
• 1.1 Engine number/engine data
  1
• 2 Safety information
  3
• 2.1 Safety regulations for 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 the SCR system
  4
• 2.6 Safety precautions when working on exhaust system
  5
• 3 Repair instructions
  7
• 3.1 Rules for cleanliness
  7
• 3.2 Foreign objects in engine
  8
• 3.3 Checking vacuum system
  8
• Removing and installing engine
  9
• 1 Removing and installing motor
  9
• 1.1 Removing motor
  9
• 1.2 Separating engine and gearbox
  33
• 1.3 Securing engine on engine and gearbox support
  38
• 1.4 Installing engine
  40
• 2 Assembly mountings
  44
• 2.1 Assembly overview - assembly mountings
  44
• 2.2 Supporting engine in installation position
  46
• 2.3 Adjusting assembly mountings
  62
• 3 Engine cover panel
  72
• 3.1 Removing and installing engine cover
  72
• Crankshaft group
  74
• 1 Cylinder block (pulley end)
  74
• 1.1 Assembly overview - poly V-belt drive
  74
• 1.2 Removing and installing poly-V belt
  78
• 1.3 Removing and installing tensioner for poly V-belt
  83
• 1.4 Removing and installing bracket for ancillaries
  84
• 1.5 Removing and installing engine bracket
  86
• 1.6 Assembly overview - cylinder block (pulley end)
  102
• 1.7 Renewing crankshaft oil seal - belt pulley end
  105
• 1.8 Removing and installing sealing flange on pulley end
  108
• 2 Cylinder block, gearbox end
  113
• 2.1 Assembly overview - cylinder block, gearbox end
  113
• 2.2 Removing and installing flywheel
  114
• 2.3 Removing and installing sealing flange on gearbox side
  116
• 3 Crankshaft
  127
• 3.1 Assembly overview - crankshaft
  127
• 3.2 Renewing needle bearing in crankshaft
  128
• 3.3 Crankshaft dimensions
  130
• 4 Pistons and conrods
  131
• 4.1 Assembly overview - pistons and conrods
  131
• 4.2 Separating new conrod
  136
• 4.3 Measuring piston projection at TDC
  137
• 4.4 Checking radial clearance of conrods
  139
• Cylinder head, valve gear
  140
• 1 Cylinder head
  140
• 1.1 Assembly overview - cylinder head
  140
• 1.2 Removing and installing cylinder head
  144
• 1.3 Removing and installing cylinder head cover
  155
• 1.4 Assembly overview - cylinder head cover
  159
• 1.5 Removing and installing vacuum pump
  161
• 1.6 Checking compression
  162
• 2 Toothed belt drive
  164
• 2.1 Assembly overview - toothed belt
  164
• 2.2 Removing and installing toothed belt
  166
• 3 Valve gear
  188
• 3.1 Assembly overview - valve gear
  188
• 3.2 Measuring axial play of camshaft
  190
• 3.3 Measuring radial play of camshaft
  191
• 3.4 Removing and installing camshaft
  192
• 3.5 Removing and installing camshaft oil seal
  201
• 3.6 Checking hydraulic compensation elements
  206
• 3.7 Removing and installing valve stem seals
  207
• 4 Inlet and exhaust valves
  216
• 4.1 Valve dimensions
  216
• 4.2 Reworking valve seats
  216
• 4.3 Checking valve guides
  216
• 4.4 Checking valves
  218
• Lubrication
  219
• 1 Sump, oil pump
  219
• 1.1 Assembly overview - sump/oil pump
  219
• 1.2 Removing and installing sump
  225
• 1.3 Removing and installing oil pump
  230
• 1.4 Removing and installing oil level and oil temperature sender
  233
• 1.5 Engine oil:
  234
• 2 Engine oil cooler
  235
• 2.1 Assembly overview - engine oil cooler
  235
• 2.2 Removing and installing engine oil cooler
  236
• 3 Oil filter, oil pressure switch
  240
• 3.1 Assembly overview - oil filter housing, oil pressure switch
  240
• 3.2 Removing and installing oil pressure switch
  241
• 3.3 Checking oil pressure
  242
• 3.4 Checking oil pressure and oil pressure switch
  243
• 3.5 Removing and installing oil filter housing
  244
• 4 Balancer shaft module
  249
• 4.1 Assembly overview - balancer shaft module
  249
• 4.2 Removing and installing balance shaft module
  252
• Cooling
  262
• 1 Cooling system/coolant
  262
• 1.1 Coolant hose connection diagram
  262
• 1.2 Draining and adding coolant
  263
• 1.3 Checking cooling system for leaks
  269
• 2 Coolant pump, regulation of cooling system
  274
• 2.1 Assembly overview - coolant pump, thermostat
  274
• 2.2 Removing and installing coolant pump
  274
• 2.3 Removing and installing 4/2-way valve with thermostat
  276
• 2.4 Removing and installing coolant temperature sender
  282
• 3 Coolant pipes
  286
• 3.1 Assembly overview - coolant pipes
  286
• 3.2 Removing and installing coolant pipes
  288
• 4 Radiator, radiator fan
  300
• 4.1 Assembly overview - radiator/radiator fan
  300
• 4.2 Removing and installing radiator
  300
• 4.3 Removing and installing radiator cowl with radiator fan
  302
• Turbocharging/supercharging
  304
• 1 Turbocharger
  304
• 1.1 Assembly overview - turbocharger
  304
• 1.2 Removing and installing turbocharger
  306
• 1.3 Renewing vacuum unit for turbocharger
  311
• 2 Charge air system
  318
• 2.1 Assembly overview - charge air system
  318
• 2.2 Assembly overview - charge-air hose connections
  319
• 2.3 Removing and installing charge air cooler
  320
• 2.4 Removing and installing charge pressure sender
  322
• 2.5 Checking charge air system for leaks
  322
• Mixture preparation - injection
  326
• 1 Injection system
  326
• 1.1 Schematic overview - fuel system
  326
• 1.2 Filling/bleeding fuel system
  328
• 1.3 Checking fuel system for leaks
  329
• 2 Vacuum system
  330
• 2.1 Assembly overview - vacuum system
  330
• 2.2 Checking vacuum system
  330
• 3 Injectors/high-pressure accumulator (rail)
  335
• 3.1 Assembly overview - injectors
  335
• 3.2 Adapting correction values for injectors
  338
• 3.3 Testing jammed-open injectors
  339
• 3.4 Checking return flow rate of injectors with engine running
  341
• 3.5 Checking return flow rate of injectors at starter speed
  344
• 3.6 Removing and installing injectors
  346
• 3.7 Removing and installing high-pressure lines
  350
• 3.8 Removing and installing fuel rail
  352
• 4 Intake manifold
  356
• 4.1 Assembly overview - intake manifold
  356
• 4.2 Removing and installing intake manifold
  357
• 4.3 Removing and installing throttle valve module
  361
• 5 Air filter
  364
• 5.1 Assembly overview - air filter housing
  364
• 5.2 Removing and installing air filter housing
  366
• 6 Senders and sensors
  368
• 6.1 Checking fuel pressure regulating valve
  368
• 6.2 Removing and installing fuel pressure regulating valve
  369
• 6.3 Removing and installing fuel pressure sender
  371
• 6.4 Removing and installing fuel temperature sender G81
  374
• 6.5 Removing and installing differential pressure sensor
  375
• 6.6 Removing and installing air mass meter
  377
• 7 High-pressure pump
  378
• 7.1 Assembly overview - high-pressure pump
  378
• 7.2 Removing and installing high-pressure pump
  380
• 8 Lambda probe
  385
• 8.1 Removing and installing Lambda probe
  385
• 9 Engine control unit
  387
• 9.1 Removing and installing engine control unit
  387
• 9.2 Removing and installing engine control unit with protective housing
  397
• Exhaust system
  414
• 1 Exhaust pipes and silencers
  414
• 1.1 Assembly overview - silencers
  414
• 1.2 Aligning exhaust system free of stress
  423
• 1.3 Installation position of clamp
  424
• 2 Emission control
  426
• 2.1 Assembly overview - emission control
  426
• 2.2 Removing and installing particulate filter
  430
• 2.3 Removing and installing catalytic converter
  439
• 3 SCR system (selective catalytic reduction)
  445
• 3.1 Assembly overview - tank for reducing agent
  445
• 3.2 Draining reducing agent tank
  446
• 3.3 Removing and installing reducing agent tank
  450
• 3.4 Assembly overview - reducing agent supply line
  453
• 3.5 Removing and installing reducing agent supply line
  454
• 3.6 Removing and installing injector for reducing agent
  457
• 3.7 Assembly overview - delivery module for reducing agent
  458
• 3.8 Removing and installing heater element (heater cup)
  460
• 4 Exhaust gas temperature regulation
  465
• 4.1 Assembly overview - exhaust gas temperature regulation
  465
• 4.2 Removing and installing exhaust gas temperature sender
  467
• 5 Exhaust gas recirculation
  473
• 5.1 Assembly overview - exhaust gas recirculation
  473
• 5.2 Removing and installing exhaust gas recirculation cooler
  475
• 5.3 Checking changeover for exhaust gas recirculation cooler
  478
• 5.4 Checking exhaust gas recirculation cooler for leaks
  479
• 5.5 Cleaning exhaust gas recirculation system
  484
• Glow plug system
  492
• 1 Glow plug system
  492
• 1.1 Removing and installing glow plug
  492
• 1.2 Removing and installing automatic glow period control unit
  494
• 1.3 Removing and installing Hall sender
  495
• 1.4 Removing and installing engine speed sender
  497