Safety Precautions 2

Introduction 2

Service procedures .............................................

When working with EMS 2 .................................

27

27

Control module (EMS 2), replace .......................

28

General information 5

Unit injector, replacing .........................................

29

About this Workshop Manual 5

Starting with auxiliary batteries ..........................

30

Spare parts 5

Certified engines 5

Function check ....................................................

31

Diagnostic function for VODIA ...........................

31

Service procedures 6

Our joint responsibility 6

Fault tracing ........................................................

32

Tightening torques 6

Symptoms and possible causes ........................

32

Torque-angle tightening 7

Lock nuts 7

Diagnostic function ..............................................

33

Strength classes 7

Malfunction message .........................................

33

Sealant 7

Effect on engine ..................................................

33

Operation ............................................................

34

General 8

Location of engine signs 8

Fault codes (EMS 2) ............................................

36

Tools 9

Electrical fault tracing .........................................

46

Special tools 9

General ..............................................................

46

Functional check of wiring and

Technical data 10

connector blocks ................................................

46

Functional check of wiring and connector blocks

47

Design and function 12

Splicing cables for cable connectors ..................

48

The EMS 2 system 12

Checking/fault tracing components ....................

49

Component description, sensors and monitors ... 15

Control module (EMS 2) 18

Electrical system .................................................

57

Control Interface Unit (CIU) 18

Important information - electrical system ...........

57

Unit injector 19

Electrical system, overview ...............................

68

Alternator 19

Wiring diagram EMS 2 .......................................

60

Starter 19

Wiring diagram CIU ............................................

61

Component location 20

Wiring diagram DCU ...........................................

62

Limit values 21

Limit values, control module (EMS 2)

TAD1640–1642GE, TWD1643GE 21

Limit values, control module (EMS 2)

TAD1641–1643VE, TAD1650VE 23

Limp-Home function 26