Introduction of the New 4-Cylinder

Inline Engine Generation OM626

Introduction into Service Manual

– This printout will not be recorded by the update service. Status: 05/2014 –
 Mercedes-Benz Service

Introduction of the New 4-Cylinder Inline Engine

Generation OM626

Daimler AG · Retail Operations (GSP/OR) · D-70546 Stuttgart

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 1

– This printout will not be recorded by the update service. Status: 05/2014 –
Product Portfolio
You can also find comprehensive information about our com-
plete product portfolio on our Internet portal:
Link: http://aftersales.mercedes-benz.com

Questions and Suggestions

If you have any questions or suggestions concerning this pro-
duct, please write to us.
E-mail: customer.support@daimler.com

©2014 by Daimler AG
This document, including all its parts, is protected by copyright. Any further processing or use requires the previous written consent of Daimler AG, Department GSP/
OR, D-70546 Stuttgart. This applies in particular to reproduction, distribution, alteration, translation, microfilming and storage and/or processing in electronic systems,
including databases and online services.
Image no. of title image: P00.00-5177-00
Image no. of poster: P00.00-5176-00
Order number of this publication: HLI 000 000 15 87

2 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Preface4

Overview5
Brief description 5
Engine data 6
Engine views 9

Mechanical system 14
Crankcase14
Engine oil pan 15
Crank assembly 16
Cylinder head 17
Belt drive 18
Chain drive 19
Valve assembly 20

Combustion21
Glowing21
Intake port shutoff 22
Forced induction 24
Fuel preheating 27
Fuel supply 28
Injection system 33
Exhaust gas recirculation 35
Exhaust treatment 40

Cooling and lubrication 46

Engine cooling system 46
Charge air cooling 52
Engine lubrication 53

Electrical and electronic systems 54

Engine management 54

Special tools 59
Special tools 59

Annex63
Abbreviations63
Index64

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 3

– This printout will not be recorded by the update service. Status: 05/2014 –
Preface
Dear Reader,
This Introduction into Service manual presents the new 4-cy-
linder diesel engine OM626 in model series 205. In terms of
the contents, the emphasis in this Introduction into Service
Manual is on presenting new and modified components and
systems.
The purpose of this brochure is to acquaint you with the tech-
nical highlights of this new engine in advance of its market
launch. This brochure is intended to provide information for
people employed in service, maintenance and repair as well
as for aftersales staff. It is assumed here that the reader is al-
ready familiar with the Mercedes-Benz model series currently
on the market.
This Introduction into Service manual is not intended as an
aid for repairs or for the diagnosis of technical problems.
For such needs, more extensive information is available
in the Workshop Information System (WIS) and XENTRY
Diagnostics.
bbNote
The printed documents are now available in WIS via
WIS Service Media. Further information on WIS Ser-
vice Media can be found in:
SI00.01-Z-0012A
4 Introduction of the New 4-Cylinder Inline Engine Generation | OM626
– This printout will not be recorded by the update service. Status: 05/2014 –
WIS is updated continuously. Therefore, the information
available there reflects the latest technical status of our ve-
hicles. This Introduction into Service manual presents initial
information relating to the new engine generation and, as
such, is not stored in WIS. The contents of this brochure are
not updated. No provision is made for supplements.
We will publicize modifications and new features in the re-
levant WIS documents. The information presented in this
system description may therefore differ from the more up-to-
date information found in the WIS. All the information relating
to specifications, equipment and options are valid as of the
publication deadline in May 2014 and may therefore differ
from the current production configuration.
Daimler AG
Retail Operations (GSP/OR)
bbNote
Information about the vehicles and about operating
the vehicle functions can also be found in the interac-
tive operator's manual on the Internet at:
www.mercedes-benz.de/betriebsanleitung
 Brief description

Overview
Engine OM626 D16 SCR is a newly developed 4-cylinder An overview of the main features of engine OM626:
inline diesel engine with common rail direct injection and a • Special two-mass flywheel
turbocharger. The engine is available in two power variants • Variable oil pump
(85 and 100 kW), each with a displacement of 1.6 liters, and • Two intake and exhaust valves per cylinder
will be introduced from September 2014 in model series 205. • Camshaft drive via timing chain
• Turbocharger with variable turbine geometry (VTG)
• Two-stage, water-cooled exhaust gas recirculation
• Optimized thermal management
• ECO start/stop function
• Exhaust treatment by the injection of urea (AdBlue®) into
the exhaust tract

P01.10-3231-00

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 5

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine data
Overview

Model series 205 C 180 BlueTEC C 200 BlueTEC

Engine model designation OM626.951 OM626.951

Exhaust emission EURO 6 EURO 6

regulation

Cylinder configuration/ Inline/4 Inline/4

number

Displacement cm3 1598 1598

Bore mm 80 80

Stroke mm 79.5 79.5

Valves per cylinder 4 4

Cylinder spacing mm 88 88

Compression ratio ε 15.4 : 1 15.4 : 1

Rated output kW/Nm 85/3000...4600 100/3800

Rated torque Nm 280 300

at engine speed rpm 1500...2800 500...4300

Fuel type Diesel Diesel

Injection system Common rail Common rail

Maximum injection bar 1600 1600

pressure

Boost pressure bar 2.75 2.75

6 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine data

Overview
120

100

80

350

P [kW]
300 60

250

200 40
M [Nm]

150

100 20

50

0 20
1000 2000 3000 4000 5000 6000
n [1/min]
P01.00-3537-00

Torque and power curve - OM626 at 85 kW

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 7

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine data
Overview

120

100

80

350

P [kW]
300 60

250

200 40
M [Nm]

150

100 20

50

0 20
1000 2000 3000 4000 5000 6000
n [1/min]
P01.00-3536-00

Torque and power curve - OM626 at 100 kW

8 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine views

Overview
Y88

R39/1
B2/5

B6/1

B28/11

P01.10-3234-00

Top view of engine

B2/5 Hot film MAF sensor R39/1 Vent line heating element
B6/1 Camshaft Hall sensor Y88 Coolant thermostat shutoff valve pressure transducer
B28/11 Pressure sensor downstream of air filter

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 9

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine views
Overview

P01.10-3232-00

View of engine from left

B4/32 Charge air pressure and temperature sensor M16/6 Throttle valve actuator
B11/4 Coolant temperature sensor M55 Intake port shutoff actuator motor
G2 Alternator S43/1 Oil pressure switch
M1 Starter

10 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine views

Overview
P01.10-3236-00

View of engine from right

B16/14 EGR temperature sensor, low pressure
B19/7 Temperature sensor upstream of catalytic converter
B19/9 Temperature sensor upstream of diesel particulate filter
B19/11 Temperature sensor upstream of turbocharger
B28/8 DPF differential pressure sensor
B60 Exhaust pressure sensor
G3/2 Oxygen sensor upstream of catalytic converter
Y27/7 Low-pressure exhaust gas recirculation actuator
Y31/5 Boost pressure control pressure transducer

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 11

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine views
Overview

P01.10-3233-00

View of engine from rear

B4/7 Fuel pressure sensor B70 Crankshaft Hall sensor
B16/10 EGR temperature sensor, high pressure Y27/8 High-pressure exhaust gas recirculation actuator

12 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine views

Overview
P01.10-3235-00

Engine view from below

S43 Oil level check switch

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 13

– This printout will not be recorded by the update service. Status: 05/2014 –
 Crankcase
Mechanical system

Engine OM626 incorporates a crankcase made of cast iron.

The ventilation bores between the cylinders are cast in. With-
several transverse and longitudinal struts, it has extremely-
high rigidity.

P01.40-2343-00

Crankcase
1 Crankcase 3 Crankshaft bearing cap bolts
2 Crankshaft bearing cap

14 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine oil pan

Engine oil pan
The vehicle is fitted with a two-piece engine oil pan made
of aluminum alloy. The ribbing on the oil pan is designed to
reduced noise emissions and guarantee the required strength
for the attachment of the ancillaries.
Mechanical system
Oil level check switch
The engine oil levels in the oil level check switch and in the
engine oil pan equalize via a feed bore and a drain bore. The
float is deflected in relation to the oil level. The reed contact
is open at engine oil levels below “Min.”, and is closed by the
magnetic field of the ring magnet at engine oil levels above
“Min.”.

P18.00-2390-00

Engine oil pan

1 Engine oil pan S43 Oil level check switch

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 15

– This printout will not be recorded by the update service. Status: 05/2014 –
 Crank assembly
Mechanical system

Crank assembly, general Pistons

The crank assembly provides an almost square ratio of stroke
to bore. This ratio permits a large valve diameter and thus
optimum filling of the combustion chamber.
The pistons installed are made of steel with special oil scra-
per rings. The oil scraper rings are U-shaped and thus highly
flexible. This flexibility allows the rings to conform to the
distortions of the cylinder barrels which result from the influ-
ences of temperature and pressure. This reduces friction and
energy expenditure.

P05.00-2105-00

Crank assembly
1 Pistons 3 Crankshaft
2 Counterweights 4 Crankshaft pulley

16 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Cylinder head

Mechanical system
The cylinder head is made of an aluminum alloy. The two The cylinder head is characterized by its double water jacket.
overhead camshafts each operate two intake valves and two This water jacket allows constant cooling of the areas expo-
exhaust valves per cylinder. sed to thermal loads.

P01.30-2462-00

Cylinder head

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 17

– This printout will not be recorded by the update service. Status: 05/2014 –
 Belt drive
Mechanical system

The coolant pump, the alternator and the refrigerant com- The drive system consists of a poly-V belt with 7 grooves
pressor are driven by the belt drive via the crankshaft belt which is tensioned via an automatic belt tensioner.
pulley.

P13.20-2116-00

Belt drive
1 Crankshaft pulley 4 Belt tensioner
2 Coolant pump A9 Refrigerant compressor
3 Guide pulley G2 Alternator

18 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Chain drive

The crankshaft drives the chain sprocket of the exhaust
camshaft via a bush chain. Another gearwheel mounted on
the exhaust camshaft drives the intake camshaft. There is
also a roller chain to drive the engine oil pump.
Mechanical system
The chain drive system consists of a maintenance-free bush
chain, the maintenance-free roller chain, a guide rail and a
tensioning rail. A hydraulic chain tensioner tightens the bush
chain at the tensioning rail.

P05.10-2508-00

Chain drive
1 Exhaust camshaft bush chain sprocket 6 Crankshaft sprocket
2 Intake camshaft gearwheel 7 Engine oil pump roller chain
3 Hydraulic chain tensioner 8 Engine oil pump
4 Camshaft bush chain 9 Tensioning rail
5 Camshaft chain guide rail

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 19

– This printout will not be recorded by the update service. Status: 05/2014 –
 Valve assembly
Mechanical system

The valves are operated by the camshafts via roller-type cam

followers and hydraulic tappets. The exhaust camshaft is dri-
ven by the crankshaft via the bush chain. The exhaust cams-
haft drives the intake camshaft via the meshing gearwheels
of the two camshafts.

P05.30-2188-00

Valve assembly
1 Intake camshaft 4 Exhaust valves
2 Exhaust camshaft 5 Hydraulic tappets
3 Intake valves

20 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Glowing

Combustion
Preglow system Glow output stage
The preglow system consists of the following components: The glow output stage is actuated directly by the CDI control
• CDI control unit unit with a pulse width modulated signal. The actuation of the
• Glow output stage glow plugs varies according to the requested glow power.
• Glow plugs
Glow plugs
The glow plugs are actuated by the CDI control unit via a The glow plugs are actuated directly by the glow output
glow output stage in relation to a pulse width modulated sig- stage. Depending on the actuation, the glow plugs can reach
nal. The glow output stage transmits diagnostic data directly temperatures of approx. 1000 °C.
to the CDI control unit.

P15.20-2236-00

Schematic diagram of preglow system

1 Glow output stage, diagnosis N3/9 CDI control unit
2 Glow output stage, actuation N14/3 Glow output stage
3 Glow plugs, actuation R9 Glow plugs

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 21

– This printout will not be recorded by the update service. Status: 05/2014 –
 Intake port shutoff
Combustion

The intake port shutoff (EKAS) function produces a rotation
of the intake air in the combustion chamber. This rotation
results in better mixture formation and more efficient com-
bustion. The intake port shutoff actuator motor is opened or
closed by the CDI control unit according to a performance
map.
Two separate intake ports, the fill inlet port and the swirl
port, are provided in the intake manifold for each cylinder. A
flap in the intake port shutoff actuator motor allows the fill
intake port to be closed. This means that only the swirl ports
are available for filling the cylinders, which increases the flow
rate and produces greater air turbulence.

P09.20-2326-00

Schematic diagram of variable swirl control

1 Fill inlet port M16/6 Throttle valve actuator
2 Swirl port M55 Intake port shutoff actuator motor
3 Intake ports A Fill inlet port intake air
4 Exhaust ports B Swirl port intake air

22 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Intake port shutoff

Combustion
Intake port shutoff actuator motor
The intake port shutoff actuator motor is mounted directly at
the throttle valve actuator. It is actuated by the CDI control
unit with a pulse width modulated signal.

P09.20-2324-00

Intake port shutoff

1 Swirl port M16/6 Throttle valve actuator
2 Fill inlet port M55 Intake port shutoff actuator motor
3 Intake port shutoff changeover flap

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 23

– This printout will not be recorded by the update service. Status: 05/2014 –
 Forced induction
Combustion

Turbocharger
The turbocharger used features variable turbine geometry The converted energy, i.e. the drive power of the turbine
(VTG). The blades are S-shaped to improve the flow. Its com- and thus the compressor work and operating speed, can be
pact design results in low thermal and flow losses, providing regulated by moving the adjustable blades. In order to incre-
a high degree of turbocharging. ase the boost pressure the blades are “closed”, i.e. the flow
cross section between the blades is reduced. This increases
The turbocharger consists of three main assemblies: the pressure in front of the turbine wheel, increasing the
• Turbine wheel amount of exhaust energy converted. To reduce the boost
• Compressor pressure, the blades are “opened”, i.e. the flow cross section
• Bearing housing between the blades is enlarged. This reduces the pressure in
front of the turbine wheel, decreasing the amount of exhaust
In the compressor the clean air is drawn in and accelera- energy converted.
ted by the rotation of the compressor impeller. Inside the
scroll of the impeller housing the air speed is reduced, thus
increasing the pressure. The compressor is driven via the
turbocharger shaft, on which the compressor impeller and
the turbine wheels are rigidly mounted. The turbine wheel is
turned by the exhaust gases directed into the turbine wheel
housing. This reduces the exhaust gases from a high pressure
level to a lower pressure.

24 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Forced induction

Combustion
Forced induction, general
Turbocharging improves the cylinder charge, thus increasing The exhaust temperature and pressure are constantly moni-
the torque and power of the engine. tored in order to protect the turbocharger against overload. If
there is any risk of thermal or mechanical overload, the CDI
Boost pressure control control unit reduces the boost pressure.
The boost pressure is controlled electropneumatically via a
vacuum unit, which is actuated by an electropneumatic pres-
sure transducer. This pressure transducer is actuated by the
CDI control unit according to a performance map. To do this,
the CDI control unit evaluates the signals from the following
sensors:
• Coolant temperature sensor
• Charge air pressure and temperature sensor
• Exhaust pressure sensor
• Hot film MAF sensor
• Crankshaft Hall sensor
• Atmospheric pressure sensor (integrated in CDI control
unit)

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 25

– This printout will not be recorded by the update service. Status: 05/2014 –
 Forced induction
Combustion

P09.00-2143-00

Function schematic of forced induction

B2/5 Hot film MAF sensor 1 Temperature sensor upstream of turbocharger, signal
B4/32 Charge air pressure and temperature sensor 2 Fuel injectors, actuation
B11/4 Coolant temperature sensor 3 Coolant temperature sensor, signal
B19/11 Temperature sensor upstream of turbocharger 4 Engine speed, signal
B28/11 Pressure sensor downstream of air filter 5 Pressure sensor downstream of air filter, signal
B60 Exhaust pressure sensor 6 Charge air pressure and temperature sensor, signal
B70 Crankshaft Hall sensor 7 Exhaust pressure sensor, signal
N3/9 CDI control unit 8 Boost pressure control pressure transducer, actuation
Y31/5 Boost pressure control pressure transducer 9 Hot film MAF sensor, signal
Y76 Fuel injectors

26 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Fuel preheating

Combustion
Fuel preheating, general
To ensure that the fuel remains fluid even at low outside
temperatures, a heating element is installed at the fuel filter.
The fuel filter heating element is actuated directly by the CDI
control unit.

P47.20-2542-00

Fuel filter with heating element

B50 Fuel temperature sensor R54/1 Fuel filter heating element

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 27

– This printout will not be recorded by the update service. Status: 05/2014 –
 Fuel supply
Combustion

P47.00-2236-00

Schematic diagram of fuel circuit

19 Fuel system high-pressure pump Y76 Fuel injectors
B4/6 Fuel pressure sensor, high pressure Y94 Quantity control valve
B4/7 Fuel pressure sensor A Uncleaned fuel
B50 Fuel temperature sensor B Heated, cleaned fuel
M3 Fuel pump C Compressed fuel (high pressure)
R54/1 Fuel filter heating element D Fuel return flow

28 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Fuel supply

Combustion
Fuel supply, general
The fuel supply system provides the fuel injectors with a suf-
ficient quantity of filtered fuel from the fuel tank at a suffici-
ent pressure under all operating conditions.

45

88

75

B4/2

M3 B4/1

P47.10-2704-00

Fuel tank
45 Filler neck B4/1 Fuel level indicator fuel tank fill level sensor, left
75 Fuel tank B4/2 Fuel level indicator fuel tank fill level sensor, right
88 Fuel feed module M3 Fuel pump

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 29

– This printout will not be recorded by the update service. Status: 05/2014 –
 Fuel supply
Combustion

Fuel pump control Fuel feed

The fuel pump is actuated by the fuel system control unit with The fuel pump draws the fuel out of the swirl pot through a
a pulse width modulated. This actuation occurs whenever a strainer and pumps it through the fuel filter to the fuel system
request from the CDI control unit CDI arrives at the fuel sys- high-pressure pump.
tem control unit over the drivetrain CAN.
Low-pressure fuel circuit
The current fuel pressure is registered by the fuel pressure The low-pressure fuel circuit consists of the following
sensor. The fuel system control unit compares the “specified components:
fuel pressure” with the “actual fuel pressure” and actuates • Fuel tank
the fuel pump accordingly. Depending on the requirements of • Fuel pump
the engine, the pressure is governed to between 4 and 5 bar. • Fuel lines
• Fuel filter with heating element
Safety fuel shutoff • Fuel temperature sensor
A safety fuel shutoff function guarantees road safety and the • Fuel pressure sensor
safety of the occupants. The CDI control unit activates the
safety fuel shutoff function under the following conditions:
• Absence of the engine speed signal
• Crash signal present

30 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Fuel supply

Combustion
High-pressure fuel system
The high-pressure fuel system consists of the following Based on a performance map, the CDI control unit calculates
components: the cylinder-selective injection quantity for the respective
• Fuel system high-pressure pump operating condition. The injection quantity is dependent on
• Rail the fuel pressure in the rail and the actuation period of the
• High-pressure lines fuel injectors. The fuel pressure in the rail is controlled by the
• Fuel pressure sensor, high pressure quantity control valve. The actual fuel pressure present in the
• Fuel injectors rail is registered by the high-pressure fuel pressure sensor
• Quantity control valve and limited to a maximum of 1600 bar by the quantity control
valve. Both pieces on information are continuously registered
The fuel reaches the fuel injectors from the rail via the high- by the CDI control unit.
pressure lines. The fuel injectors spray the finely atomized
fuel into the combustion chamber.

P07.16-4120-00

High-pressure fuel system

19 Fuel system high-pressure pump Y76 Fuel injectors
B4/6 Fuel pressure sensor, high pressure Y94 Quantity control valve

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 31

– This printout will not be recorded by the update service. Status: 05/2014 –
 Fuel supply
Combustion

P47.00-2235-00

Function schematic of fuel supply

B4/6 Fuel pressure sensor, high pressure 1 Fuel injectors, actuation
B4/7 Fuel pressure sensor 2 Accelerator pedal sensor, signal
B37 Accelerator pedal sensor 3 Quantity control valve, actuation
B50 Fuel temperature sensor 4 Fuel temperature, signal
M3 Fuel pump 5 Fuel filter heating element, actuation
N3/9 CDI control unit 6 Fuel pressure, signal
N118 Fuel system control unit 7 Fuel pressure, signal
R54/1 Fuel filter heating element 8 Fuel pump, specified pressure request
Y76 Fuel injectors
Y94 Quantity control valve
CAN C1 Drivetrain CAN

32 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Injection system

Combustion
Injection control Preinjection
Engine OM626 uses the Bosch CR41 electronic engine The aim of preinjection is to reduce combustion noise and
management system to manage the common rail injection exhaust emissions. Fuel is injected up to 2 times prior to the
system. The engine management system calculates the injec- actual main injection. This results in gentler combustion.
tion period and the fuel pressure on the basis of the following
sensors and signals: Main injection
• Hot film MAF sensor The main injection generates the power and torque, and is
• Intake air temperature sensor controlled by the injection period and the injection timing
• Fuel pressure sensor, high pressure point.
• Charge air pressure and temperature sensor
• Camshaft Hall sensor Post injection
• Coolant temperature sensor Post injection is used to increase the exhaust temperature
• Charge air temperature sensor and thus to assist the regeneration process of the DPF and
• Pressure sensor downstream of air filter the conversion process of the exhaust components in the
• Accelerator pedal sensor oxidation catalytic converter.
• Fuel temperature sensor
• Crankshaft Hall sensor
• Oxygen sensor
• Temperature sensor upstream of diesel particulate filter
• Temperature sensor upstream of turbocharger
• DPF differential pressure sensor
• Atmospheric pressure sensor (integrated in CDI control
unit)

The injection control has the following subfunctions:

• Preinjection
• Main injection
• Post injection

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 33

– This printout will not be recorded by the update service. Status: 05/2014 –
 Injection system
Combustion

P07.16-4121-00

Function schematic of injection control

B2/5 Hot film MAF sensor 1 Camshaft Hall sensor, signal
B4/32 Charge air pressure and temperature sensor 2 Oxygen sensor, signal
B4/6 Fuel pressure sensor, high pressure 3 Temperature sensor upstream of turbocharger, signal
B6/1 Camshaft Hall sensor 4 Temperature sensor upstream of diesel particulate filter, signal
B11/4 Coolant temperature sensor 5 Fuel injectors, actuation
B19/9 Temperature sensor upstream of diesel particulate filter 6 Accelerator pedal sensor, signal
B19/11 Temperature sensor upstream of turbocharger 7 Coolant temperature sensor, signal
B28/11 Pressure sensor downstream of air filter 8 Engine speed, signal
B37 Accelerator pedal sensor 9 Charge air temperature sensor, signal
B50 Fuel temperature sensor 10 Fuel temperature, signal
B70 Crankshaft Hall sensor 11 Throttle valve actuator, signal
G3/2 Oxygen sensor 12 Throttle valve actuator, actuation
M16/6 Throttle valve actuator 13 Quantity control valve, actuation
N3/9 CDI control unit 14 Intake air temperature sensor, signal
Y76 Fuel injectors 15 Pressure sensor downstream of air filter, signal
Y94 Quantity control valve 16 Fuel pressure, signal

34 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Exhaust gas recirculation

Combustion
P14.20-2375-00

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 35

– This printout will not be recorded by the update service. Status: 05/2014 –

36
Schematic diagram of exhaust gas recirculation
1 Charge air cooler
50 Turbocharger
B2/5 Hot film MAF sensor
M16/6 Throttle valve actuator
M16/57 Exhaust flap controller
M55 Intake port shutoff actuator motor
– This printout will not be recorded by the update service. Status: 05/2014 –
Introduction of the New 4-Cylinder Inline Engine Generation | OM626
Combustion
Y27/7 Low-pressure exhaust gas recirculation actuator
Y27/8 High-pressure exhaust gas recirculation actuator
A Intake air
B Exhaust gas
C High-pressure EGR
D Low-pressure EGR
Exhaust gas recirculation
 Exhaust gas recirculation

Combustion
Exhaust gas recirculation, general Low-pressure circuit exhaust gas recirculation
Exhaust gas recirculation reduces the nitrogen oxide (NOx) Low-pressure exhaust gas recirculation is only active at
level in the exhaust by the following processes: coolant temperatures above 60 °C and in the idle to mode-
• Reducing oxygen concentration in the combustion rate partial-load ranges. After evaluating the input signals, the
chamber CDI control unit actuates the low-pressure exhaust gas recir-
• Reducing the combustion temperature by reducing the culation actuator according to a performance map. At high
rate of combustion exhaust gas recirculation rates with the low-pressure exhaust
• Reducing the combustion temperature by means of the gas recirculation actuator fully open, the exhaust flap control-
higher heat capacity of the recirculated exhaust gases ler is also partially closed. The recirculation rate is regulated
compared to the intake air by varying the actuation. Furthermore, the cleaned exhaust
gas is directed via the exhaust gas recirculation cooler and
Exhaust gas recirculation is active from idle speed up to the fed via the low-pressure exhaust gas recirculation actuator to
upper partial-load range. The recirculation rate depends on the mixing tube in the cylinder head.
several different variables:
• Engine load and rpm
• Intake and charge air temperatures
• Exhaust temperatures
• Exhaust pressure
• Time limit

High-pressure circuit exhaust gas recirculation

After evaluating the input signals, the CDI control unit ac-
tuates the high-pressure exhaust gas recirculation valve
according to a performance map. The recirculation rate is
regulated by varying the actuation.

High-pressure exhaust gas recirculation actuator

The high-pressure exhaust gas recirculation actuator is a pop-
pet valve which can be opened via an electric actuator motor.
By means of a Hall sensor the position of the poppet valve is
detected and output as a voltage. The exhaust gas recircula-
tion actuator is opened and closed via a positional controller
in the CDI control unit. When deenergized, the exhaust gas
recirculation actuator is closed.
The high-pressure exhaust gas recirculation actuator allows
the exhaust gas to be recirculated directly from the exhaust
manifold to the intake manifold of the engine without any
further cooling or cleaning. Because of the high exhaust pres-
sures it is called high-pressure exhaust gas recirculation.

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 37

– This printout will not be recorded by the update service. Status: 05/2014 –
 Exhaust gas recirculation
Combustion
Low-pressure exhaust gas recirculation valve
The low-pressure exhaust gas recirculation valve is a flap
valve which can be opened via an electric actuator motor. By
means of a Hall sensor the position of the flap valve is de-
tected and output as a voltage. The exhaust gas recirculation
valve is opened and closed via a positional controller in the
CDI control unit. When deenergized, the exhaust gas recircu-
lation valve is closed.
Exhaust gas recirculation
1 Charge air cooler
2 Exhaust gas recirculation cooler (water-cooled)
M16/6 Throttle valve actuator
Y27/7 Low-pressure exhaust gas recirculation actuator
Y27/8 High-pressure exhaust gas recirculation actuator
38
– This printout will not be recorded by the update service. Status: 05/2014 –
The low-pressure exhaust gas recirculation actuator removes
the exhaust gases downstream of the diesel particulate filter
and feeds in fresh air before the turbocharger. The exhaust
gases are removed after the turbocharger at correspondingly
low exhaust pressures, therefore this is referred to as low-
pressure exhaust gas recirculation. In low-pressure EGR, the
temperature of the recirculated exhaust gases is reduced by
a water-cooled exhaust gas recirculation cooler. Low-pres-
sure exhaust gas recirculation can only function correctly in
conjunction with the exhaust flap.
P09.41-2752-00
A Uncooled charge air
B Cooled charge air
C Exhaust gases downstream of diesel particulate filter
D Cooled exhaust gases
Introduction of the New 4-Cylinder Inline Engine Generation | OM626

Function schematic of exhaust gas recirculation
B2/5 Hot film MAF sensor
B4/32 Charge air pressure and temperature sensor
B11/4 Coolant temperature sensor
B16/10 EGR temperature sensor, high pressure
B16/14 EGR temperature sensor, low pressure
B19/7 Temperature sensor upstream of catalytic converter
B19/9 Temperature sensor upstream of diesel particulate filter
B19/11 Temperature sensor upstream of turbocharger
B28/11 Pressure sensor downstream of air filter
B37 Accelerator pedal sensor
B60 Exhaust pressure sensor
B70 Crankshaft Hall sensor
M16/6 Throttle valve actuator
M16/57 Exhaust flap controller
N3/9 CDI control unit
Y27/7 Low-pressure exhaust gas recirculation actuator
Y27/8 High-pressure exhaust gas recirculation actuator
Introduction of the New 4-Cylinder Inline Engine Generation | OM626
– This printout will not be recorded by the update service. Status: 05/2014 –
Exhaust gas recirculation
Combustion
P14.20-2376-00
1 Low-pressure exhaust gas recirculation temperature sensor, signal
2 High-pressure exhaust gas recirculation temperature sensor, signal
3 Temperature sensor upstream of turbocharger, signal
4 Temperature sensor upstream of diesel particulate filter, signal
5 Temperature sensor upstream of catalytic converter, signal
6 Accelerator pedal sensor, signal
7 Coolant temperature sensor, signal
8 Engine speed, signal
9 Boost pressure, signal
10 Exhaust pressure sensor, signal
11 Throttle valve actuator, signal
12 Throttle valve actuator, actuation
13 Exhaust flap controller, actuation
14 Exhaust flap controller, signal
15 Engine load, signal
16 Low-pressure exhaust gas recirculation actuator, actuation
17 High-pressure exhaust gas recirculation actuator, actuation
18 Pressure sensor downstream of air filter, signal
39
 Exhaust treatment
Combustion

SCR system (AdBlue®), general The SCR system contains the following system
SCR stands for Selective Catalytic Reduction. In the SCR components:
system, an aqueous urea solution is injected into the exhaust • AdBlue® metering valve
system immediately before the SCR catalytic converter. The • AdBlue® control unit
chemical reactions it produces (thermolysis and hydrolysis) • AdBlue® pressure line heating element
reduce the nitrogen oxides in the exhaust gas. • AdBlue® delivery module
• AdBlue® tank module
AdBlue® • AdBlue® tank
AdBlue® is the brand name for a clear, synthetically manu- • AdBlue® filler neck
factured 32.5% solution of highly-pure urea in demineralized • AdBlue® tank temperature sensor
water. • AdBlue® fill level sensor
• AdBlue® tank heating element
• AdBlue® delivery pump
• AdBlue® extraction pump
• Control unit of NOx sensor downstream of diesel particu-
late filter
• NOx sensor downstream of diesel particulate filter
• Control unit of NOx sensor downstream of SCR catalytic
converter
• NOx sensor downstream of SCR catalytic converter
• Temperature sensor upstream of SCR catalytic converter
• SCR catalytic converter

40 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Exhaust treatment

Combustion
AdBlue® control unit AdBlue® delivery module
The AdBlue® control unit controls the following functions The AdBlue® delivery module performs the following
according to performance maps: subtasks:
• AdBlue® delivery • Pressure generation
• Injection of the reduction agent (injection quantity and • Pressure measurement
injection period) • Flow reversal
• Antifreeze protection and recirculation of the reduction
agent Several components are integrated in the AdBlue® delivery
• Communications with the CDI control unit over the drive- module:
train sensor CAN • AdBlue® delivery pump
• AdBlue® extraction pump
• AdBlue® tank heating element
• AdBlue® fill level sensor

To generate pressure, the AdBlue® control unit actuates the

AdBlue® delivery pump integrated in the AdBlue® delivery
module with a pulse width modulated signal according to a
performance map.

The AdBlue® control unit registers the system pressure ge-

nerated by the AdBlue® delivery pump via the current curve
of the pulse width modulated signal.

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 41

– This printout will not be recorded by the update service. Status: 05/2014 –
 Exhaust treatment
Combustion
At “circuit 15 OFF” the AdBlue® control unit initiates the
power-down sequence. While the control unit powers down,
the AdBlue® delivery pump extracts the remaining AdBlue®
reduction agent from the AdBlue® pressure line and the
AdBlue® metering valve via the AdBlue® extraction pump
actuated by the AdBlue® control unit, and directs it back
towards the AdBlue® tank. At the same time, the AdBlue®
metering valve is opened to prevent a vacuum from forming.
This return process lasts for between 8 and 10 s depending
on the vehicle application.
AdBlue® delivery module
1 Electrical connection
42
– This printout will not be recorded by the update service. Status: 05/2014 –
The AdBlue® tank heating element ensures that liquid Ad-
Blue® reduction agent is drawn from the AdBlue® tank even
at low temperatures.
Furthermore, the AdBlue® pressure line is heated according
to a performance map by the AdBlue® pressure line heating
element. This return feed of the remaining AdBlue® reduc-
tion agent prevents the AdBlue® pressure line and the Ad-
Blue® delivery module from freezing at approx. –10 °C and
being damaged.
P14.40-2544-00
2 AdBlue® line connection
Introduction of the New 4-Cylinder Inline Engine Generation | OM626
 Exhaust treatment

Combustion
NOx sensors control unit
The NOx sensors control units are supplied by “VDO
Automotive AG”. The NOx sensors register the NOx and O2
concentrations in the exhaust gas downstream of the diesel
particulate filter and SCR catalytic converter, and forward
this information in the form of voltage signals to the NOx sen-
sors control units. These process the information and trans-
mit it over the drivetrain sensor CAN to the CDI control unit.

P14.40-2545-00

Control unit of NOx sensor downstream of diesel particulate filter

N37/7 Control unit of NOx sensor downstream of diesel particulate filter N37/7b1 NOx sensor downstream of diesel particulate filter

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 43

– This printout will not be recorded by the update service. Status: 05/2014 –
 Exhaust treatment
Combustion

AdBlue® metering valve

The AdBlue® metering valve sprays the reduction agent
(AdBlue®) into the exhaust tract in front of the SCR catalytic
converter. As the AdBlue® metering valve is not ice pressure-
proof, the reduction agent must be extracted from the Ad-
Blue® metering valve when the engine is switched off.
In sub-zero outside temperatures with a cold exhaust tract,
the AdBlue® metering valve is electrically heated in order to
prevent the AdBlue® metering valve from freezing when the
vehicle is operated. This is done by energizing the coil in the
AdBlue® metering valve at which the float needle does not
open.

P14.40-2552-00

AdBlue® metering valve

1 Electrical connection 3 Coolant feed
2 Reduction agent inlet 4 Coolant return

44 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Exhaust treatment

Combustion
P14.40-2553-00

Function schematic of exhaust treatment

A103/2 AdBlue® delivery module 1 Oxygen sensor, signal
B16/15 Temperature sensor upstream of SCR catalytic converter 2 Temperature sensor upstream of turbocharger, signal
B19/7 Temperature sensor upstream of catalytic converter 3 Temperature sensor upstream of diesel particulate filter, signal
B19/9 Temperature sensor upstream of diesel particulate filter 4 Temperature sensor upstream of catalytic converter, signal
B19/11 Temperature sensor upstream of turbocharger 5 Temperature sensor upstream of SCR catalytic converter, signal
B28/8 DPF differential pressure sensor 6 Accelerator pedal sensor, signal
B37 Accelerator pedal sensor 7 DPF differential pressure sensor, signal
B70 Crankshaft Hall sensor 8 Engine speed, signal
G3/2 Oxygen sensor upstream of catalytic converter 9 Intake port shutoff actuator motor, actuation
M55 Intake port shutoff actuator motor 10 Fuel injectors, actuation
N3/9 CDI control unit 11 AdBlue® injection, request
N37/7 Control unit of NOx sensor downstream of diesel particulate filter 12 NOx sensor heater, actuation
N37/8 Control unit of NOx sensor downstream of SCR catalytic converter 13 NOx sensor heater, actuation
N118/5 AdBlue® control unit 14 AdBlue® metering valve, actuation
Y76 Fuel injectors 15 AdBlue® fill level, message
Y129 AdBlue® metering valve 16 AdBlue® injection, request
CAN C1 Drivetrain CAN

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 45

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine cooling system
Cooling and lubrication

P20.00-2512-00

Schematic diagram of coolant circuit

1 Coolant expansion reservoir 8 Coolant pump
2 OM626 9 Exhaust gas recirculation cooler
3 Heater heat exchanger M43/6 Low-temperature circuit circulation pump 1
4 Coolant thermostat A Cold coolant
5 Coolant outlet fitting B Hot coolant
6 Engine oil heat exchanger C Coolant circuit ventilation
7 Engine radiator

46 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine cooling system

Cooling and lubrication

Engine cooling system, general Coolant circuit
The engine cooling system in the OM626 consists of the fol- The engine is cooled by a crossflow cooling system. The spe-
lowing components: cial feature of engine OM626 is that the cylinder head has a
• Coolant pump double water jacket. This makes it possible to deliver coolant
• Engine radiator directly from the coolant pump to the components subjected
• Coolant expansion reservoir to high thermal loads. Efficient and constant cooling is there-
• Heater heat exchanger fore guaranteed.
• Engine oil heat exchanger
• Coolant thermostat
• Exhaust gas recirculation cooler
• Coolant thermostat shutoff valve
• Auxiliary coolant pump

Coolant thermostat
The coolant thermostat is an expansion-element thermostat.
This expansion element expands at a coolant temperature of
approx. 85 °C to open the entire coolant circuit.

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 47

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine cooling system
Cooling and lubrication

Exhaust gas recirculation cooler

For low-pressure exhaust gas recirculation, the exhaust ga-
ses are removed downstream of the diesel particulate filter.
These gases are directed through the water-cooled exhaust
gas recirculation cooler where they are cooled. The cooled
exhaust gases are fed back into the charge air via the low-
pressure exhaust gas recirculation actuator.

P14.20-2374-00

Exhaust gas recirculation cooler

48 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine cooling system

Cooling and lubrication

Coolant outlet fitting
The coolant outlet fitting contains an integrated shutoff valve.
It is opened and closed by vacuum at coolant temperatures
above approx. 80 °C. The coolant thermostat shutoff valve
pressure transducer is used to control the vacuum.

P20.00-2511-00

Coolant outlet fitting

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 49

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine cooling system
Cooling and lubrication

Coolant thermostat shutoff valve pressure transducer

The coolant thermostat shutoff valve pressure transducer is
an electromagnetic valve in the coolant circuit. It remains
closed up to a coolant temperature of approx. 80 °C. At a
coolant temperature of approx. 80 °C the coolant thermostat
shutoff valve pressure transducer is actuated by the CDI con-
trol unit and opens.

P20.10-2410-00

5 Coolant outlet fitting Y88 Coolant thermostat shutoff valve pressure transducer

50 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine cooling system

Cooling and lubrication

P20.00-2526-00
Function schematic of thermal management
B2/5 Hot film MAF sensor 1 Intake air temperature sensor, signal
B11/4 Coolant temperature sensor 2 Exhaust temperature, signal
B19/9 Temperature sensor upstream of diesel particulate filter 3 Exhaust temperature, signal
B19/11 Temperature sensor upstream of turbocharger 4 Fuel injectors, actuation
B37 Accelerator pedal sensor 5 Accelerator pedal sensor, signal
B50 Fuel temperature sensor 6 Coolant temperature sensor, signal
B70 Crankshaft Hall sensor 7 Engine speed, signal
M4/7 Fan motor 8 Fuel temperature, signal
M87 Radiator shutters actuator motor 9 Coolant thermostat shutoff valve pressure transducer, actuation
N3/9 CDI control unit 10 Wheel speed, signal
N127 Powertrain control unit 11 Coolant temperature, signal
Y76 Fuel injectors 12 Fan motor, specified rpm request (LIN)
Y88 Coolant thermostat shutoff valve pressure transducer 13 Fan motor, status (LIN)
CAN C1 Drivetrain CAN 14 Radiator shutters actuator motor, actuation (LIN)
15 Radiator shutters actuator motor, status (LIN)
16 Engine running, signal

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 51

– This printout will not be recorded by the update service. Status: 05/2014 –
 Charge air cooling
Cooling and lubrication

Charge air cooling, general

The charge air cooler cools the charge air previously com-
pressed, and therefore heated, by the turbocharger. Cooled
charge air lowers the combustion temperature and thus re-
duces emissions. This increases the cylinder charge and the
boost pressure can be increased.

P09.41-2752-00

1 Charge air cooler A Uncooled charge air

2 Exhaust gas recirculation cooler (water-cooled) B Cooled charge air
M16/6 Throttle valve actuator C Exhaust gases downstream of diesel particulate filter
Y27/7 Low-pressure exhaust gas recirculation actuator D Cooled exhaust gases
Y27/8 High-pressure exhaust gas recirculation actuator

52 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine lubrication

Cooling and lubrication

Engine oil pump
The oil pressure is generated by a vane-type pump which
pumps the oil through the oil circuit according to require-
ments. The engine oil pump is thermostatically controlled
and the delivery rate can be regulated via an adjustment ring
inside the engine oil pump.

P18.10-2218-00

Engine oil pump

1 Housing 3 Rotor
2 Engine oil guide ring 4 Countering spring

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 53

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine management
Electrical and electronic systems

CDI control unit

The engine features a newly developed CDI control unit. All of According to the input signals, the following
the functionality of the engine is contained in the CDI control systems and functions are controlled and coordinated
unit. The engine control system reads in the sensor data both by the CDI control unit:
directly and indirectly via the CAN network and actuates the • Fuel supply
corresponding actuators. • Fuel injection
• Engine rpm regulation
The most important features of the engine control system • Torque coordination
are: • ECO start/stop function
• Control of the fuel injectors • Forced induction
• Control of the throttle valve actuator • On-board diagnosis
• Control of exhaust gas recirculation • Engine limp-home mode
• Torque control • Exhaust gas recirculation
• Exhaust treatment
• Thermal management
• Preglowing

54 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Engine management

Electrical and electronic systems

P07.16-4122-00

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 55

– This printout will not be recorded by the update service. Status: 05/2014 –

56
Block diagram of CAN network
A1 Instrument cluster
A8/1 Transmitter key
A40/9 Audio/COMAND control panel
A103/1b1 AdBlue® tank temperature sensor
A103/1b5 AdBlue® fill level sensor
A103/1r1 AdBlue® tank heating element
A103/2 AdBlue® delivery module
A103/2m1 AdBlue® delivery pump
A103/2m2 AdBlue® extraction pump
B4/1 Fuel level indicator fuel tank fill level
sensor, left
B4/2 Fuel level indicator fuel tank fill level
sensor, right
B4/7 Fuel pressure sensor
B64/1 Brake vacuum sensor
CAN A Telematics CAN
CAN B Interior CAN
CAN C Engine CAN
CAN C1 Drivetrain CAN
CAN D Diagnostic CAN
CAN HMI User interface CAN
CAN I Drivetrain sensor CAN
Flex E Chassis FlexRay
G2 Alternator
K27/7 AdBlue® supply relay
LIN C1 Drivetrain LIN
LIN C3 Powertrain LIN
– This printout will not be recorded by the update service. Status: 05/2014 –
Introduction of the New 4-Cylinder Inline Engine Generation | OM626
L6/1 Left front axle rpm sensor
L6/2 Right front axle rpm sensor
L6/3 Left rear axle rpm sensor
L6/4 Right rear axle rpm sensor
M3 Fuel pump
M4/7 Fan motor
M43/6 Low-temperature circuit circulation
pump 1
M87 Radiator shutters actuator motor
N2/10 Supplemental restraint system control
unit
N3/9 CDI control unit
N10/6 Front SAM control unit
N14/3 Glow output stage
N22/1 Climate control control unit
N30/4 Electronic Stability Program control
unit
N37/7 Control unit of NOx sensor downstream
of diesel particulate filter
N37/7b1 NOx sensor downstream of diesel
particulate filter
N37/8 Control unit of NOx sensor downstream
of SCR catalytic converter
N37/8b1 NOx sensor downstream of SCR
catalytic converter
Electrical and electronic systems
N51/3 AIRMATIC control unit (with code (489)
AIRmatic (air suspension with level
adjustment and adaptive damping
system ADS))
N62/1 Radar sensors control unit (with code
(233) DISTRONIC PLUS, code (237)
Active Blind Spot Assist, code (238)
Active Lane Keeping Assist)
Engine management
69/1 Left front door control unit
N73 Electronic ignition lock control unit
N80 Steering column tube module control
unit
N118 Fuel system control unit
N118/5 AdBlue® control unit
N127 Powertrain control unit
R7/1 AdBlue® pressure line heating element
R9 Glow plugs
S9/1 Brake light switch
X11/4 Diagnostic connector
Y3/8n4 Fully integrated transmission control
unit
Y129 AdBlue® metering valve
 Engine management

Electrical and electronic systems

P07.16-4123-00

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 57

– This printout will not be recorded by the update service. Status: 05/2014 –

58
Block diagram of direct network
B2/5 Hot film MAF sensor
B2/5b1 Intake air temperature sensor
B4/6 Fuel pressure sensor, high pressure
B4/32 Charge air pressure and temperature
sensor
B6/1 Camshaft Hall sensor
B11/4 Coolant temperature sensor
B16/10 EGR temperature sensor, high pressure
B16/14 EGR temperature sensor, low pressure
B16/15 Temperature sensor upstream of SCR
catalytic converter
B19/7 Temperature sensor upstream of
catalytic converter
B19/9 Temperature sensor upstream of diesel
particulate filter
B19/11 Temperature sensor upstream of
turbocharger
B28/8 DPF differential pressure sensor
B28/11 Pressure sensor downstream of air
filter
– This printout will not be recorded by the update service. Status: 05/2014 –
Introduction of the New 4-Cylinder Inline Engine Generation | OM626
B37 Accelerator pedal sensor
B40/4 Oil pressure sensor
B50 Fuel temperature sensor
B60 Exhaust pressure sensor
B70 Crankshaft Hall sensor
G3/2 Oxygen sensor upstream of catalytic
converter
G3/2b1 Sensor element of oxygen sensor
upstream of catalytic converter
G3/2r1 Heater of oxygen sensor upstream of
catalytic converter
K40/8kH Starter circuit 50 relay
K40/8kG Engine compartment circuit 15 relay
K40/8kN Circuit 87M relay
M1 Starter
M4/7 Fan motor
M16/6 Throttle valve actuator
M16/57 Exhaust flap controller
M55 Intake port shutoff actuator motor
Electrical and electronic systems
N3/9 CDI control unit
R39/1 Vent line heating element
R54/1 Fuel filter heating element
S40/3 Clutch pedal switch
S43 Oil level check switch
S43/1 Oil pressure switch
Y27/7 Low-pressure exhaust gas recirculation
actuator
Engine management
Y27/8 High-pressure exhaust gas recirculation
actuator
Y31/5 Boost pressure control pressure
transducer
Y76/1 Cylinder 1 fuel injector
Y76/2 Cylinder 2 fuel injector
Y76/3 Cylinder 3 fuel injector
Y76/4 Cylinder 4 fuel injector
Y88 Coolant thermostat shutoff valve
pressure transducer
Y94 Quantity control valve
 Special tools

Special tools
Screw-in piece

Use Screw-in piece for compression

pressure or pressure loss measurement at
the glow plug hole.

MB number W626 589 01 91 00

FG 02

Set B
P58.20-2489-00

Category Mercedes-Benz Cars/Vans Basic Operation - Mandatory/

Approved for cooperation

Note In combination with compression tester/W001 589 76

21 00 (BO Mandatory/Approved for cooperation), com-
pression recorder/W001 589 78 21 00 (BO Mandatory/
Approved for cooperation), pressure loss tester/W450
589 17 21 00 (BO Mandatory/Approved for cooperation).

Struts

Use For removing/installing the complete engine with

transmission.

MB number W626 589 00 61 00

FG 01

Set B

Category Mercedes-Benz Cars Basic Operation - Mandatory/No

exemptions P58.20-2486-00

Note –

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 59

– This printout will not be recorded by the update service. Status: 05/2014 –
 Special tools
Special tools

Counterholder

Use For countering the vibration damper.

MB number W626 589 02 40 00

FG 03

Set B

Category Mercedes-Benz Cars/Vans Basic Operation - Mandatory/

No exemptions
P58.20-2490-00

Note –

Retaining lock

Use For blocking the high-pressure pump impeller.

MB number W626 589 03 40 00

FG 03

Set B

Category Mercedes-Benz Cars/Vans Basic Operation - Mandatory/

No exemptions
P58.20-2491-00
Note –

60 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Special tools

Special tools
Adjustment tool

Use For blocking the camshaft.

MB number W626 589 04 40 00

FG 07

Set B

Category Mercedes-Benz Cars/Vans Basic Operation - Mandatory/

No exemptions
P58.20-2492-00
Note –

Counterholder

Use For locking the exhaust camshaft sprocket in order to

preload the camshaft sprocket.

MB number W626 589 00 40 00

FG 05

Set C

Category Mercedes-Benz Cars/Vans Special Operation

P58.20-2485-00
Note –

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 61

– This printout will not be recorded by the update service. Status: 05/2014 –
 Special tools
Special tools

Retaining lock

Use For locking the starter ring gear when the transmission is
removed.

MB number W626 589 01 40 00

FG 01

Set B

Category Mercedes-Benz Cars/Vans Special Operation

P58.20-2487-00
Note –

Drift

Use For adjusting the engine at top dead center (TDC).

MB number W626 589 00 15 00

FG 03

Set B

Category Mercedes-Benz Cars/Vans Basic Operation - Mandatory/

No exemptions
P58.20-2484-00

Note –

62 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
 Abbreviations

Annex
CAN
Controller Area Network

CDI
Common rail diesel injection

DPF
Diesel particulate filter

EKAS
Intake port shutoff

EURO 6
Euro 6 emissions standard

LIN
Local interconnect network

NOx
Nitrogen oxide

PWM
Pulse width modulated

SCR
Selective Catalytic Reduction

VTG
Variable turbine geometry

Introduction of the New 4-Cylinder Inline Engine Generation | OM626 63

– This printout will not be recorded by the update service. Status: 05/2014 –
 Index
Annex

A
Exhaust treatment 1, 4, 37, 42, 53
Exhaust gas recirculation 1, 4, 10, 11, 31, 32, 33, 34, 36,
45, 53, 57
Forced induction 1, 22, 23, 25, 53

E
Intake port shutoff 1, 9, 20, 21, 32, 42, 57, 61
Injection 4, 38

H
Displacement 4, 5

K
Pistons 15
Coolant outlet fitting 47, 62
Coolant circuit 43, 44, 47
Crankcase 1, 13
Crank assembly 1, 15

L
Charge air cooling 1, 50

M
Engine oil pump 18, 51
Engine oil pan 1, 13, 14

N
Rated torque 5

R
Belt drive 1, 17

S
CDI control unit 20, 21, 23, 25, 26, 27, 28, 30, 33, 36, 38,
42, 47, 53, 55, 57

Z
Cylinder head 1, 13, 16, 33, 44, 62

64 Introduction of the New 4-Cylinder Inline Engine Generation | OM626

– This printout will not be recorded by the update service. Status: 05/2014 –
Daimler AG, GSP/OR, D-70546 Stuttgart
Order no. HLI 000 000 15 87, Printed in Germany 

– This printout will not be recorded by the update service. Status: 05/2014 –