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
  7
• 3.3 Checking vacuum system
  7
• Removing and installing engine
  8
• 1 Removing and installing motor
  8
• 1.1 Removing motor
  8
• 1.2 Separating engine and gearbox
  31
• 1.3 Securing engine on engine and gearbox support
  36
• 1.4 Installing engine
  38
• 2 Assembly mountings
  42
• 2.1 Assembly overview - assembly mountings
  42
• 2.2 Supporting engine in installation position
  43
• 2.3 Adjusting assembly mountings
  48
• 3 Engine cover panel
  50
• 3.1 Removing and installing engine cover
  50
• Crankshaft group
  52
• 1 Cylinder block (pulley end)
  52
• 1.1 Assembly overview - poly V-belt drive
  52
• 1.2 Removing and installing poly-V belt
  56
• 1.3 Removing and installing tensioner for poly V-belt
  61
• 1.4 Removing and installing bracket for ancillaries
  61
• 1.5 Removing and installing engine bracket
  64
• 1.6 Assembly overview - cylinder block (pulley end)
  72
• 1.7 Removing and installing sealing flange on pulley end
  74
• 1.8 Renewing crankshaft oil seal - belt pulley end
  77
• 2 Cylinder block, gearbox end
  81
• 2.1 Assembly overview - cylinder block, gearbox end
  81
• 2.2 Removing and installing flywheel
  82
• 2.3 Removing and installing sealing flange on gearbox side
  84
• 3 Crankshaft
  97
• 3.1 Assembly overview - crankshaft
  97
• 3.2 Renewing needle bearing in crankshaft
  98
• 3.3 Crankshaft dimensions
  101
• 4 Pistons and conrods
  102
• 4.1 Assembly overview - pistons and conrods
  102
• 4.2 Measuring piston projection at TDC
  107
• 4.3 Separating new conrod
  109
• 4.4 Checking radial clearance of conrods
  110
• Cylinder head, valve gear
  111
• 1 Cylinder head
  111
• 1.1 Assembly overview - cylinder head
  111
• 1.2 Removing and installing cylinder head
  115
• 1.3 Assembly overview - cylinder head cover
  125
• 1.4 Removing and installing cylinder head cover
  127
• 1.5 Removing and installing vacuum pump
  131
• 1.6 Checking compression
  133
• 2 Toothed belt drive
  136
• 2.1 Assembly overview - toothed belt
  136
• 2.2 Removing and installing toothed belt
  138
• 3 Valve gear
  161
• 3.1 Assembly overview - valve gear
  161
• 3.2 Measuring axial play of camshaft
  163
• 3.3 Measuring radial play of camshaft
  164
• 3.4 Removing and installing camshaft oil seal
  165
• 3.5 Removing and installing camshaft
  172
• 3.6 Checking hydraulic compensation elements
  181
• 3.7 Removing and installing valve stem seals
  182
• 4 Inlet and exhaust valves
  191
• 4.1 Valve dimensions
  191
• 4.2 Reworking valve seats
  191
• 4.3 Checking valve guides
  191
• 4.4 Checking valves
  193
• Lubrication
  194
• 1 Sump, oil pump
  194
• 1.1 Assembly overview - sump/oil pump
  194
• 1.2 Removing and installing sump
  200
• 1.3 Removing and installing oil level and oil temperature sender
  204
• 1.4 Removing and installing oil pump
  206
• 1.5 Engine oil:
  207
• 2 Engine oil cooler
  209
• 2.1 Assembly overview - engine oil cooler
  209
• 2.2 Removing and installing engine oil cooler
  210
• 3 Oil filter, oil pressure switch
  213
• 3.1 Assembly overview - oil filter
  213
• 3.2 Removing and installing oil filter housing
  214
• 3.3 Removing and installing oil pressure switch
  218
• 3.4 Checking oil pressure and oil pressure switch
  219
• 4 Balancer shaft module
  222
• 4.1 Assembly overview - balancer shaft module
  222
• 4.2 Removing and installing balance shaft module
  225
• Cooling
  235
• 1 Cooling system/coolant
  235
• 1.1 Coolant hose connection diagram
  235
• 1.2 Checking cooling system for leaks
  236
• 1.3 Draining and adding coolant
  240
• 2 Coolant pump, regulation of cooling system
  247
• 2.1 Assembly overview - coolant pump, thermostat
  247
• 2.2 Removing and installing coolant pump
  247
• 2.3 Removing and installing 4/2-way valve with thermostat
  249
• 2.4 Electric coolant pump
  255
• 2.5 Removing and installing coolant temperature sender
  260
• 3 Coolant pipes
  265
• 3.1 Assembly overview - coolant pipes
  265
• 3.2 Removing and installing coolant pipes
  267
• 4 Radiator, radiator fan
  279
• 4.1 Assembly overview - radiator/radiator fan
  279
• 4.2 Removing and installing radiator
  279
• 4.3 Removing and installing radiator cowl with radiator fan
  282
• 4.4 Removing and installing radiator fan
  283
• Turbocharging/supercharging
  285
• 1 Turbocharger
  285
• 1.1 Assembly overview - turbocharger
  285
• 1.2 Removing and installing turbocharger
  287
• 1.3 Renewing vacuum unit for turbocharger
  295
• 2 Charge air system
  302
• 2.1 Assembly overview - charge air system
  302
• 2.2 Removing and installing charge air cooler
  303
• 2.3 Assembly overview - charge-air hose connections
  305
• 2.4 Removing and installing charge pressure sender
  306
• 2.5 Checking charge air system for leaks
  307
• Mixture preparation - injection
  311
• 1 Injection system
  311
• 1.1 Schematic overview - fuel system
  311
• 1.2 Filling/bleeding fuel system
  313
• 1.3 Checking fuel system for leaks
  314
• 2 Injectors/high-pressure accumulator (rail)
  315
• 2.1 Assembly overview - injectors
  315
• 2.2 Adapting correction values for injectors
  318
• 2.3 Testing jammed-open injectors
  319
• 2.4 Removing and installing injectors
  321
• 2.5 Removing and installing fuel rail
  325
• 2.6 Removing and installing high-pressure lines
  329
• 3 High-pressure pump
  334
• 3.1 Assembly overview - high-pressure pump
  334
• 3.2 Removing and installing high-pressure pump
  336
• 4 Senders and sensors
  342
• 4.1 Checking fuel pressure regulating valve
  342
• 4.2 Removing and installing fuel pressure regulating valve
  343
• 4.3 Removing and installing fuel pressure sender
  345
• 4.4 Removing and installing air mass meter
  348
• 4.5 Removing and installing NOx sender 2 G687
  349
• 4.6 Removing and installing differential pressure sensor
  349
• 5 Lambda probe
  351
• 5.1 Removing and installing Lambda probe
  351
• 6 Vacuum system
  353
• 6.1 Vacuum hose connection diagram
  353
• 6.2 Checking vacuum system
  354
• 7 Air filter
  357
• 7.1 Assembly overview - air filter housing
  357
• 7.2 Removing and installing air filter housing
  359
• 8 Intake manifold
  362
• 8.1 Assembly overview - intake manifold
  362
• 8.2 Removing and installing intake manifold
  363
• 8.3 Removing and installing throttle valve module
  368
• 9 Engine control unit
  370
• 9.1 Removing and installing engine control unit
  370
• Exhaust system
  375
• 1 Exhaust pipes and silencers
  375
• 1.1 Assembly overview - silencers
  375
• 1.2 Aligning exhaust system free of stress
  378
• 1.3 Installation position of clamp
  379
• 2 Emission control
  381
• 2.1 Assembly overview - emission control
  381
• 2.2 Removing and installing particulate filter
  384
• 2.3 Removing and installing catalytic converter
  393
• 3 SCR system (selective catalytic reduction)
  399
• 3.1 Assembly overview - tank for reducing agent
  399
• 3.2 Draining reducing agent tank
  400
• 3.3 Removing and installing reducing agent tank
  404
• 3.4 Assembly overview - delivery module for reducing agent
  407
• 3.5 Removing and installing heater element (heater cup)
  409
• 3.6 Assembly overview - reducing agent supply line
  414
• 3.7 Removing and installing reducing agent supply line
  415
• 3.8 Removing and installing injector for reducing agent
  418
• 4 Exhaust gas temperature regulation
  420
• 4.1 Assembly overview - exhaust gas temperature regulation
  420
• 4.2 Removing and installing parts of exhaust gas temperature regulation
  422
• 5 Exhaust gas recirculation
  429
• 5.1 Assembly overview - exhaust gas recirculation
  429
• 5.2 Checking changeover for exhaust gas recirculation cooler
  431
• 5.3 Removing and installing exhaust gas recirculation cooler
  431
• 5.4 Checking exhaust gas recirculation cooler for leaks
  434
• 5.5 Cleaning exhaust gas recirculation system
  440
• Glow plug system
  448
• 1 Glow plug system
  448
• 1.1 Removing and installing glow plug
  448
• 1.2 Removing and installing automatic glow period control unit
  450
• 1.3 Removing and installing Hall sender
  451
• 1.4 Removing and installing engine speed sender
  452