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1641 WS3

1. P0013951 16 Coolant temperature sensor 17 Piston cooling pressure sensor 18 Oil pressure sensor 19 Starter motor 20 Starter motor relay 21 Speed sensor crankshaft 22 Speed sensor camshaft 22 47701632 10 2010 30 0 General TAD1250 1252VE P0013952 1 Coolant level sensor 11 Starter motor relay 2 Speed sensor camshaft 12 Speed sensor crankshaft 3 Unit injector one for each cylinder 13 Connector for diagnostic tool 6 pin 4 Extra stop 14 Engine interface 8 pin connector 5 Sensor air inlet pressure intake manifold temper 15 Water in fuel sensor ature 16 Engine control unit ECU 6 Main relay 17 Oil level temperature sensor 7 Fuel pressure sensor 18 Crankcase pressure sensor 8 IEGR valve 19 Oil pressure sensor 9 Coolant temperature sensor 20 Main fuse 10 A 10 Starter motor 21 Alternator 47701632 10 2010 23 30 0 General TAD1250 1252VE SE d i N PE 58 7 CY We aras E G P0013953 22 Air filter indicator 23 Piston cooling pressure 24 47701632 10 2010 TAD1350 1355GE N ON OO P O P0013972 I
2. 37 0 Wiring Diagrams TAD1250 1252VE 14 1645 18 9 123450 TZ 12 3456738 wo LO SS call ai S a ER 10 L ava IS 3 8 Ea ina L D V 19 L 1 11 q ep n de INTERNAL als R BL 1 51 0 87 1234567 EGR EE SB gom B S 2 4 6 TOPPERS x x R SBR 2 ee 20 R DI 0 vi a SEL Gan E 2 87 3 7 430 Nes H SER S Aa wm Sa Sek a j le SREE q 2 S ale 2 sB 2 44 Sos ab 2 2 33 Z ke S A P D zl zim fea Go alal d x D Ola Wo a gt aa seo ee aaa Slo 31 3 4 311116 17 18 28272314 10 8 5256 302925 5760 585961 5155 n n 33 E wo 32 BA ST ai sit 7 472215 29 4546 3738 3640 4448 5256 2832 1216 2024 59 62 60 61 8 3334275857 ol S P wo SEE S6 a 5 BB e SR 299799994 a co SEkb 29 S oo oS 32 FF SEI SS 35 SSI S 33 3 NS UE CAPILLERING i ES gl P Pstoppersxiop P 9 Ti Di 1234 MAIN RELAY HOLD een 30 21 8A wo 7 AA d CYL 2 d 28 27 Z ss 25 EN 12345 26x B 0 CYL4 22 L Ka 26x 3 CYL 5 23 P Z CYL 6 180 37 0 Wiring Diagrams 1 Sensor oil level oil temperature Cable colors 2 Sensor oil pressure BL Blue P Pink BN Brown R Red 3 Sensor fuel pressure GN Green SB Black 4 Sensor coolant temperature GR Gray VO Violet OR Orange W White 5 Sensor crankcase pressure LBL Light blue Y Yellow 6 Switch coolant level LBN Light brown
3. r i 9 2 Turn the main switch off T A IMPORTANT d O g The system must be disconnected from system voltage 0000 and the starter key must be in position 0 when the engine E S U D control unit connector is disconnected or connected D DD 3 Remove the connector from the engine control unit g 4 e VH Move the lock catch 1 upwards and pull the con ooog nector 2 out DU U D U ooo0 4 Use multimeter 9812519 to measure the resistance DUDU 0 U in the engine cable s black upper connector for the injectors IMPORTANT Be very careful when measuring inside the connector ee to ensure that no pin is damaged NOTICE The measurement should exclude short cir cuiting or open circuit in the cable to the injector Measurement points Nominal value in connector A 20 62 Cylinder 1 R 1 4 30 at 20 C 12 62 Cylinder 2 R 1 4 30 at 20 C 28 62 Cylinder 3 R 1 4 30 at 20 C 24 59 Cylinder 1 R 1 4 30 at 20 C 16 59 Cylinder 2 R 1 4 30 at 20 C 32 59 Cylinder 3 R 1 4 30 at 20 C 52 61 Cylinder 4 R 1 4 30 at 20 C 44 61 Cylinder 5 R 1 4 30 at 20 C 36 61 Cylinder 6 R 1 4 30 at 20 C 56 60 Cylinder 4 R 1 4 30 at 20 C 48 60 Cylinder 5 R 1 4 30 at 20 C 40 60 Cylinder 6 R 1 4 30 at 20 C 162 47701632 10 2010 47701632 10 2010 30 2 Fault Tracing Checking IEGR wiring NOTICE Cut the current with the main switch Remove the valve
4. DOE 30 2 Fault Tracing Checking the sensor cable for open circuit or shortcircuit Air filter temperature sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Remove connector B from the engine control unit Use multimeter 9812519 to do a resistance meas urement against the engine control unit connector B 4 885675 31 EMS2 conn B 3 885675 18 EMS2 conn B NOTICE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit IMPORTANT Be very careful when measuring inside the connector to ensure that no pin is damaged 147 30 2 Fault Tracing lt Ce 885 675 P0013503 P0007231 148 Checking air inlet temperature sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Connect adapter cable 885675 to the sensor Do not connect the other end of the adapter cable 3 Use multimeter 9812519 to do resistance meas urement Measurement points Nominal value R 16445 0 822 Q at 0 C R 5000 0 220 Q at 25 C R 4027 O 160 Q at 30 C R 12470 40 Q at 60 C R 463 O 19 Q at 90 C R 1990 10 Q at 120 C Checking signal ca
5. Cable colors BL Blue P Pink BN Brown R Red GN Green SB Black GR Gray VO Violet OR Orange W White LBL Light blue Y Yellow LBN Light brown Cable cross section 0 75 mm unless otherwise stated 47701632 10 2010 39 0 General 39 0 General Index MID 128 Caption Flashcode Electrical fault value fault 5 4 3 6 3 8 2 9 2 1 5 9 5 7 3 1 6 6 3 2 6 2 106 3 4 3 5 107 5 5 5 5 108 KE 110 3 3 6 1 111 2 3 2 2 153 7 8 7 7 158 3 9 EMS 16 9 CIU 172 7 9 1184 MID 128 PID 45 Inlet air heater status page 50 MID 128 PID 94 Fuel Delivery Pressure page 52 MID 128 PID 97 Water in fuel indicator page 55 MID 128 PID 98 Engine oil level page 57 MID 128 PID 100 Engine oil pressure page 59 MID 128 PID 105 Intake manifold temperature page 62 MID 128 PID 106 Air inlet pressure page 64 MID 128 PID 107 Air filter pressure drop page 67 MID 128 PID 108 Barometric pressure page 70 MID 128 PID 110 Engine coolant temperature page 71 MID 128 PID 111 Coolant level page 74 MID 128 PID 153 Crankcase pressure page 76 MID 128 PID 158 ECU battery potential page 79 626 94 97 100 105 ech wo wo L wo MID 128 PID 172 Inlet air temperature page 80 MID 128 PID 173 Exhaust gas temperature page 82 MID 128 PID 175 Engine oil temperature page 84 175 3 7 5 8 MID 128 PID 190 Engine speed page 87 190 2 6 MID 128 PPID 3 Starter Output page 88 677 4 6 MI
6. Ez FQ Le P0013515 47701632 10 2010 95 30 2 Fault Tracing GN 4 R BL 2 EMS2 P0013516 a Connector B b IEGR 96 Cable description Internal exhaust gas recirculation IEGR is like the name says used for recirculation of exhaust gases This for lowering the emissions from the engine The IEGR control valve is located on the cylinder head under the valve cover It is used to regulate the oil pressure to the rocker arm shaft and from there to the IEGR double rocker The IEGR valve is a 2 way sole noid valve controlled by the engine control unit When the IEGR not activated an oil pressure on one side of the solenoid and the solenoid spring force on the other side of the solenoid keeps the solenoid in balance When the IEGR function is activated the solenoid changes position and the oil pressure to the rocker arm shaft increases The solenoid is activated when pin 30 in connector B changes its potential Measurements Checking IEGR wiring page 163 Checking the IEGR coil page 157 Checking IEGR solenoid page 158 47701632 10 2010 30 2 Fault Tracing MID 128 PPID 55 ECU temperature FMI 0 Data valid but above normal operational range Fault code explanation ECU temperature is too high Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 8 4 Value fault None Conditions for fault code The temperature inside the engine control unit is t
7. no fuel bleeding pump 3 88890053 16 EMS2 conn B with fuel bleeding pump 3 88890053 18 EMS2 conn B with fuel bleeding pump 3 88890053 17 EMS2 conn B with fuel bleeding pump CG O O O O OO OO OL CG O O OOO OO OL OOOOOOOOoOoOoOoOoOoooO Iesleleslesl ele les Lesen les leiel leie les NOTICE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit p0013475 IMPORTANT Be very careful when measuring inside the connector to ensure that no pin is damaged 47701632 10 2010 127 30 2 Fault Tracing Checking fuel pressure sensor Tools 885675 Break out cable 88890053 Break out cable 9812519 Multimeter 1 NOTICE Turn ignition off 2 Disconnect the connector from the sensor 3 TAD1250 1252 and TWD1643 Connect adapter cable 885675 between the sensor and the engine control unit TAD950 952 Connect adapter cable 88890053 between the sen sor and the engine control unit 4 Use multimeter 9812519 for voltage measurement 5 Turn ignition on Measurement points 4 3 U 0 5V no fuel bleeding pump at normal atmos pheric pressure 4 3 U 0 5V with fuel bleeding pump at normal atmos pheric pressure 128 47701632 10 2010 30 2 Fault Tracing Checking supply cable water in fuel switch Tools 9812519 Multimeter 1 NOTICE Turn ignition off 2 Disconnect the connector from the
8. opens up B Click the text Available conversions kits which is shown in bold face 6 Anew window opens Follow the instructions given in the window 7 Return to the Conversion kit Accessory kit page and follow the instructions to order a new conver sion kit 8 Volvo Penta s database is now updated It can take about a minute before a confirmation is sent 9 Programing of the control unit can now start Please refer to Reprogramming a control unit page 38 39 30 0 General P0007178 40 Fault tracing of cables and connectors Tools 9812519 Multimeter 9998482 Measuring tool Check all connectors visually Check the following e Look for oxidation which can impair contact in con nectors e Check that terminals are undamaged that they are correctly inserted into their connectors and that the cable is correctly terminated in the terminal e Check that there is good mechanical contact in the connector Use a loose pin to check this IMPORTANT The multi pin connectors for the engine control unit must only be checked with 9998482 Measuring tool e Carefully insert 9998482 Measuring tool into the multi pin connector Pull and push the connector in and out a few times and feel whether the terminal socket grasps the tool If the terminal socket does not grasp or if it feels slack the connection pins should be changed Please refer to Joining electrical cables for connectors page 4
9. Cable description The stop input signal to the engine control unit pin A27 can have one of two signal levels high low The A27 stop input on the EMS2 can be set via a parameter in Vodia to work in one of two ways Either the EMS2 stop input is set to energized to run which means that the stop input signal to the EMS2 pin A27 must be high in order for the engine to be able to run or the EMS2 stop input is set to energized to stop which means that the stop input signal on the EMS2 pin A27 must be high in order for the engine to stop In the first case the stop input signal level has to be low to shut down the engine In the second case the stop input signal level has to be high to shut down the engine Measurements Checking stop signal cable between ECU and CIU DCU page 154 91 30 2 Fault Tracing MID 128 PPID 8 Piston Cooling Oil Pressure FMI 1 Data valid but below operational range Fault code explanation Piston cooling oil pressure is too low Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 6 8 Value fault 6 7 Symptom Engine is derated The fault code is deactivated at engine speed below 1000 rpm Conditions for fault code Piston cooling pressure is too low Suitable action 1 Re check the piston cooling pressure If measurement shows that the piston cooling pressure is correct change the piston cooling pressure switch FMI 3 Vol
10. Possible reason An open circuit in CAN H or CAN L or both CAN links between EMS 2 and DCU CIU An open circuit in Power supply OV cable between EMS 2 and DCU CIU An open circuit in Power supply input cable between EMS 2 and DCU CIU CAN H short circuited to power supply in pin 4 Suitable action Check contact pressure in socket 51 and 55 in engine connector B Check for an open circuit or short circuit between cables in the cable harness between the DCU CIU and EMS 2 via the engine connector Cable description A CAN H Data Link to Engine YIW 1 2 B CAN L Data Link to Engine C SB 3 BE EES E R BL_5 D Power supply positive o pply p ce w E Ignition H WNISB 8 H W SB 8 F Stop EMS2 a DCU CIU G J1708A Data Link to Engine P0013534 H J1708B Data Link to Engine a A27 Engine connector Measurements Checking the CAN bus cable page 173 47701632 10 2010 123 30 2 Fault Tracing No fault code Fuel bleeding pump only TAD950 952VE Symptom Fuel bleeding pump doesn t start when the fuel press switch is activated Possible reason Open circuit in any of the cables to the pump motor Faulty fuel press switch Faulty pump motor Suitable action Check the cables to the pump motor Check the fuel press switch Try another pump motor Cable description The fuel system has a fuel bleeding pump that is used when the fuel system has to be bled A manual fuel press switch
11. ZA EN 0 75 Whe 11 558 a 0 75 ell S Z Z ZB 3 0 75 x 0 75 YW 75 YIW ye ge D 1 5 RIBL m os A g 075 GRIY 0 75 GRIY BEE E E 1 5 SB o GD I W p 5 Z8Sp o f 3 le m 7 O R BL 1 5 D Se A D ES RIBL S D i aa e o m gt D ew ER wegl ws LD D gt 0 75R J lt 0 75WISB X 7 me asp Si alo lt S sw SS X a 2 E 4 o Ao N zla LH N P0014271 aA T o GI 0 75R 194 47701632 10 2010 Z Battery Main switch Starter motor Alternator Main relay Aux stop Connector engine interface 8 pin Sensor coolant temperature oO ON DOO FW DY gt Sensor air inlet pressure inlet manifold tem perature 10 VODIA input diagnosis conn 6 pin 11 Connector development tool not used 12 Sensor crankcase pressure 13 Sensor camshaft 14 Sensor flywheel 15 Switch coolant level 16 Unit injector Cyl 1 6 17 Relay preheating 18 Fuse preheating 19 Main circuit breaker 10 A 20 Preheater 21 Preheat connector 4 pin 22 Sensor oil level oil temperature 23 EGR internal 24 Sensor oil pressure 25 Sensor fuel pressure 26 Air filter indicator 27 Control unit EMS 2 2 28 Wastegate valve 29 Visco elecric fan 30 WIF connector 47701632 10 2010 37 0 Wiring Diagrams Visco electric fan A Fan speed sensor supply B Clutch contol high C Clutch control low D Fan speed sensor ground E Fan speed output F Not connected Cable colors BL Blue
12. Electrical fault 3 7 Value fault 5 8 Conditions for fault code The voltage on pin A31 in the engine control unit exceeds 4 95 Volt Possible reason Open circuit in the oil temperature signal cable Open circuit in the oil temperature negative cable Fault in sensor Suitable action Check the cable harness between the sensor and the EMS2 Check the contact pressure in socket 31 in the engine connector A and in socket 10 in engine connector B Check the sensor Cable description The oil temperature and the oil level sensor is a com bined sensor The oil temperature sensor consists of a thermistor which forms a closed circuit with an internal resistor in the engine control unit EMS2 The ther mistor resistor changes in a non linear manner depending on the oil temperature The EMS2 provides the circuit with a reference voltage of 5 Volt via pin 31 in connector A The EMS2 measures the voltage drop over the thermistor via pin 18 and pin 31 on the EMS2 Pin 4 on the sensor is connected to battery negative via pin 18 in connector B on the EMS2 When the oil is cold the thermistor resistance is high and the EMS2 senses a high voltage drop As the oil warms up the resistance in the thermistor falls and the voltage drop across it falls Please refer to the table resistance temperature in this fault code chapter P0007203 EMS2 P0008588 a Connector A b Connector B c Oil temperature an
13. Engine Protection Map TAD950 952VE TAD1250 1252VE Derate to engine protection map Parameter Yellow Red 0 lamp lamp High coolant temper 98 C 101 C ature 208 4 F 213 8 F High oil temperature 125 C 128 C 257 0 F 262 4 F 103 C 106 C Soft 217 4 F 222 8 F derate 135 C Soft 275 0 F derate 95 C 105 C Soft 203 0 F 221 0 F derate 101 C 213 8 F High boost tempera 80 C 90 C ture 176 0 F 194 0 F High air inlet pres sure TAD950 952VE High air inlet pres 425 kPa 425 kPa sure 61 6 PSI 61 6 PSI TAD1250 1252VE Hard derate Hard derate When rapid Hard increase of derate pressure 425 kPa 61 6 PSI Crankcase pressure When rapid increase of pressure Piston cooling pres When sure switch is switch is activated activated Derate means that the engine torque is limited This means that engine speed is not affected or reduced as long as the torque limit isn t reached Hard derate means that the engine quickly will decrease the torque Soft derate means that the engine will decrease the torque according to a function as a result of how much the alarm value has been exceeded Low oil pressure limit TAD950 952VE 500 rpm 1000 rpm 1800 rpm 2300 rpm 160 kPa 200 kPa 225 kPa 250 kPa 23 2 PSI 29 0 PSI 32 6 PSI 36 3 PSI TAD1250 1252VE 500 rpm 1000 rpm 1900 rpm 2300 rpm 160 kPa
14. F Z L 47701632 10 2010 Battery Main switch Starter motor Alternator Main relay Aux stop Connector engine interface Sensor coolant temperature oO ON DOO FW DY gt Sensor air inlet pressure inlet manifold tem perature 10 VODIA input diagnosis conn 11 Connector development tool not used 12 Sensor crankcase pressure 13 Sensor camshaft 14 Sensor flywheel 15 Switch piston cooling 16 Unit injector Cyl 1 6 17 Relay preheating 18 Fuse preheating 19 Main circuit breaker 10 A 20 Preheater 21 Switch coolant level 22 Sensor oil level oil temperature 23 Switch water in fuel 24 Sensor oil pressure 25 Sensor fuel pressure 26 EGR internal 27 Control unit EMS 2 2 28 Wastegate valve 47701632 10 2010 37 0 Wiring Diagrams Cable colors BL Blue P Pink BN Brown R Red GN Green SB Black GR Gray VO Violet OR Orange W White LBL Light blue Y Yellow LBN Light brown Cable cross section 0 75 mm unless otherwise stated 191 37 0 Wiring Diagrams TAD1640 42GE TAD1641 43VE VYOLIANNOOD g YOLOANNOD N N A N on Vd Vd N D v a w po a N x Ns NIS amp j N wkl amp 3 A
15. Workshop Manual I Group 30 Electrical system 5 0 9L 12L 13L 16L Industrial Engines Content General Information UE RT UR 2 Specifications 03 3 Specifications Electrical 00 nnnnno0aannnnnnnnnsesnnnnnrnenrnsnennnrnrnesesen 6 Safety and Other Instructions 05 1 Safety Instructions eee eee 11 Special tools 08 2 Special Service Tools 00000nnnnannnnnnnnnnenenensssssnsnnnrnrrenrereesesesesen 15 General Complete Vehicle Software tU General ERA TEA E e BLAM ahh Ae ster hie oes ates 17 30 2 Fault Tracing TTT 50 Cables and fuses 37 0 Wiring Diagrams sese ee eee eee 176 Miscellaneous 39 0 Generale Za eA aes E RA ede tae a at 199 Alphabetical index sese 201 References to Service Bulletins 0annnneeeeaenrererrrenrrsrresrrernn 203 00 0 General General information This Service Manual contains technical data descrip tions and maintenance and repair instructions for standard model Volvo Penta products A list of these products may be found in the section Specifica tions The product designation and the serial number and specification is indicated on the engine decal or type plate This information must be included in all corre spondence regarding the product The service manual is produced primarily for the use of Volvo Penta workshops and their qualified person nel It is assumed that any person using the Service Manual has a fundamental knowledge of the pr
16. 2 Disconnect the connector from the sensor TAD1250 1252 and TWD1643 Connect adapter cable 885675 to the cable har ness connector to the engine control unit TAD950 952 Connect adapter cable 88890053 to the cable har ness connector to the engine control unit 4 Use multimeter 9812519 to do resistance meas urement against the engine control unit Measurement points Nominal value 4 Battery negative R 0Q no fuel bleeding pump 885675 4 Battery negative R 0Q with fuel bleeding pump NOTICE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit 126 47701632 10 2010 30 2 Fault Tracing Checking the signal cable for interruption or shortcircuit Tools 885675 Break out cable 88890053 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the sensor TAD1250 1252 and TWD1643 Connect adapter cable 885675 to the cable har ness connector to the engine control unit TAD950 952 Connect adapter cable 88890053 to the cable har ness connector to the engine control unit Remove connector B from the engine control unit Use multimeter 9812519 to do a resistance meas urement against the engine control unit connector B Measurement points 2 885675 16 EMS2 conn B R 0 0 no fuel bleeding pump 2 885675 18 EMS2 conn B no fuel bleeding pump 2 885675 17 EMS2 conn B
17. Abnormal frequency pulse width or period Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 4 Value fault None Engine is difficult to start uses only cam sensor e Incorrectly mounted flywheel sensor Suitable action Check wiring between flywheel sensor and EMS2 Check the installation of the flywheel sensor Attempt to localize the source of interference Check and clean the flywheel sensor Check the contact pressure in socket 37 and 38 in engine connector A Cable description The flywheel sensor is an inductive sensor The fly wheel sensor is used to monitor engine speed It is also used to measure the cylinder acceleration The flywheel has three times eighteen depressions for one rotation These depressions are detected by the fly EMS2 wheel sensor and generate a pulsed signal which the engine control unit uses to detect flywheel rotation speed Two cylinders share one sector of the depres sions cylinders 1 and 6 2 and 5 3 and 4 on the fly P0007252 a Connector A wheel This means that it is not possible to know which b Engine speed sensor crankshaft cylinder Measurements Checking flywheel sensor wiring page 166 Checking flywheel sensor page 167 P0008694 TAD950 952VE TAD1350 1352GE TWD 1643GE TAD1250 1252VE P0002860 110 47701632 10 2010 30 2 Fault Tracing MID
18. Ensure that the warning symbols or information decals on the product are always clearly visible Replace decals which have been damaged or painted over Avoid getting oil on your skin Protracted or repeated exposure to oil can cause skin to become dry Irritation dryness eczema and other skin problems may then result From a health standpoint used oil is more dangerous than new Use protective gloves and avoid oil soaked clothes and rags Wash regularly espe cially before eating Use suitable barrier creams to counteract drying out of the skin and to aid dirt removal Stop the engine and turn off the electrical supply at the main switch es before carrying out work on the electrical system Avoid opening the coolant filling cap when the engine is hot Steam or hot coolant can spray out and system pressure will be lost Open the filler cap slowly and release the pressure in the cooling system if the filler cap or valve has to be opened or if a plug or coolant hose has to be removed when the engine is hot Hot oil can cause burns Avoid skin contact with hot oil Ensure that the lubrication system is not under pressure before any work is begun Never start or operate the engine with the oil filler cap removed because of the risk of oil ejection Never start the engine without installing the air filter The rotating compressor turbine in the tur bocharger can cause severe injury Foreign objects entering the intake ducts ca
19. Fault code explanation Faulty sensor Fault in sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 7 8 Value fault 7 7 Conditions for fault code The voltage on pin B28 in the engine control unit is less than 0 30 Volt Possible reason Open circuit in the sensor 5 Volt supply Open circuit in the sensor signal cable Short circuited sensor signal cable to battery negative Faulty sensor Suitable action Check the cable harness between the crankcase pressure sensor and the EMS2 Check the contact pressure in socket 17 and 28 in the engine connector B Check the sensor Cable description The sensor which measures the crankcase pressure is an active sensor i e it must have operating voltage The engine control unit connector B pin 17 supplies the sensor pin 1 with 5 Volt The sensor pin 4 is connected to battery negative via the engine control EMS2 unit connector B pin 18 The output signal from the pressure sensor pin 2 to the engine control unit connector B pin 28 is a voltage signal which is proportional to the crankcase pressure It is the velocity of a rising crankcase sure that trigger the alarm The output signal is linear within the sensors working range P0007226 a Crankcase pressure b Connector B 47701632 10 2010 T7 30 2 Fault Tracing 78 Component specification Working range 0 4 1 4 bar 40 140 kP
20. R 554 O at 500 C R 618 QO at 600 C R 679 QO at 700 C R 738 O at 800 C R 795 O at 900 C U 1 48 V at 300 C U 1 56 V at 350 C U 1 64 V at 400 C U 1 71V at 450 C U 1 78V at 500 C U 1 91V at 600 C U 2 02 V at 700 C U 2 12V at 800 C U 2 21V at 900 C R 849 O U 2 30V at 1000 C at 1000 C Checking negative cable oil 885675 Break out cable 9812519 Multimeter NOTICE Cut the current with the main switch N Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit A Use multimeter 9812519 to do resistance meas urement against the engine control unit 47701632 10 2010 30 2 Fault Tracing Checking signal cable oil temperature switch Tools 885675 Break out cable 9812519 Multimeter win OI 1 NOTICE Turn ignition off 2 Disconnect the connector from the sensor 3 Connect adapter cable 885675 to the cable har ness connector to the engine control unit 4 Use multimeter 9812519 for voltage measurement 5 Turn ignition on 1 Turn ignition off 2 Connect adapter cable 885675 between the sensor and the engine control unit 3 Turn ignition on Measurement points Nominal value 3 4 U 0 5 4 5 V
21. Safety Instructons eee eee 11 Special Service Tools 15 Specifications Elechical 6 Technical Data 49 eiia EE ei 6 Trimming the injector 161 Vodia logging throttle sional 175 Wiring Diagrams sees eee eee 176 202 47701632 10 2010 References to Service Bulletins Group No Date Refers to 203 Report form Do you have any comments or other views about this manual If so make a copy of this page write down your views and send them to us The address is at the bottom We would prefer you to write in Swedish or English AB Volvo Penta Service Communication Dept 42200 SE 405 08 G teborg Sweden OLOZ OL eu ZS9LOLLY
22. Value fault 7 7 Symptom The engine is shut down if the engine protection parameter is activated Conditions for fault code Crankcase pressure rises too fast Possible reason Blocked crankcase ventilation Faulty crankcase pressure sensor Worn or damaged cylinder liners piston or piston rings Suitable action Check whether the crankcase ventilation is blocked Clean the crank case ventilation system Check all cable and connectors between the EMS2 and the crankcase pressure sensor Check the crankcase pressure sensor Control measure the crankcase pressure Check whether cylinder liner piston or piston rings are worn or dam aged FMI 3 Voltage above normal or shorted high Fault code explanation Faulty sensor Fault in sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 7 8 Value fault 7 7 Conditions for fault code The voltage on pin B28 in the engine control unit exceeds 4 78 Volt Possible reason Short circuit between sensor signal cable and 5V supply or battery volt age to crankcase pressure sensor Open circuit in the sensor negative cable Faulty sensor Suitable action Check the cable harness between the crankcase pressure sensor and the EMS2 Check the contact pressure in socket 18 in the engine connector B Check the sensor 76 47701632 10 2010 30 2 Fault Tracing FMI 5 Current below normal or open circuit
23. altered its center of gravity special lifting devi ces may be needed to obtain the correct bal ance for safe handling Never perform any work on an engine that is only suspended from the lifting equipment 13 05 1 Safety Instructions 14 The components in the electrical and fuel sys tems on Volvo Penta products are designed and manufactured to minimize the risk of fire and explosion The engine must not be run in areas where there are explosive materials Only use fuels and lubricating oils recom mended by Volvo Penta Refer to the Operator s Manual for the product in question Use of fuels that are of a lower grade may damage the engine the injection pump and the injectors On a diesel engine low grade fuel can cause the control rod to bind and the engine to over rev with the risk of engine damage and personal injury as a result Low fuel and oil grades may result in high service maintenance and repair costs Fuel delivery pipes must not be bent or straight ened under any circumstances Cracks may occur Damaged pipes must be replaced Exercise extreme caution when leak detecting on the fuel system and testing the fuel injector nozzles Use eye protection The jet from a fuel nozzle has very high pressure and great pene tration power Fuel can force its way deep into body tissue and cause severe injury There is a risk of blood poisoning septicemia Never use a high pressure washer for cleaning the engine Pa
24. important that the correct type of sealants and locking fluids are used on joints where such are required In each service manual section concerned the seal ants used in product manufacture are indicated The same sealants or sealants with equivalent proper ties must be used for maintenance work Make sure that mating surfaces are dry and free from oil grease paint and anti corrosion agent before applying sealant or locking fluid Always follow the manufacturer s instructions regarding applicable temperatures hardening times and such Two basic types of compound are used RTV preparations Room Temperature Vulcaniz ing Used most often together with gaskets e g sealing gasket joints or are brushed on gaskets RTV seal ants are completely visible when the part has been removed Old RTV sealant must be removed before the component is sealed again Use denatured alco hol Anaerobic agents These agents cure harden in the absence of air These preparations are used when two solid compo nents e g two cast components are fitted together without a gasket Common uses are also to lock and seal plugs stud threads taps oil pressure monitors etc Hardened anaerobic preparations are glassy and for this reason the preparations are colored to make them visible Hardened anaerobic preparations are highly resistant to solvents and old compound can not be removed On re assembly it is important to carefully degrease a
25. urement against the engine control unit NOTICE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit lt e S e 885 675 P0001266 Checking oil pressure sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Turn ignition off 2 Disconnect the connector from the sensor D 1 Ra Q AS Connect adapter cable 885675 between the sensor and the engine control unit 4 Use multimeter 9812519 for voltage measurement B Turn ignition on Measurement points Nominal value 2 4 U 0 5 V at normal S atmospheric pressure 47701632 10 2010 133 30 2 Fault Tracing Checking signal cable voltage inlet manifold pressure temperature sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Turn ignition off 2 Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Use multimeter 9812519 for voltage measurement 5 Turn ignition on 1 Turn ignition off 2 Connect adapter cable 885675 between the sensor and the engine control unit 3 Turn ignition on Measurement points Nominal value 1 2 U 0 5 4 5 V depended of the temperature 885675 P0013483 134 47701632 10 2010 30 2 Fault Tracing Checking negative cable inlet manifold pressure temperature sensor Tools 885675 Break out cable 9812519 Multimeter NOTICE Cut the
26. 1 5 S S s d S Ara o S RBL1 5 5 o 9J BL el 3 Ai KR d WY WA a weg gs DSS i DD S S D E E S e WS SB Li g SB 2 5 Io SB 2 5 wao S Rw gt aHa Y SB aoe R25 A GO RIBL 1 0 d z D N N d IP K N om jo up a AN A S a ol E LJ zl E 701632 10 2010 Battery Main switch Starter motor Alternator Main relay Aux stop Connector engine interface Sensor coolant temperature oO ON DOO FW DY gt Sensor air inlet pressure inlet manifold tem perature 10 VODIA input diagnosis conn 11 Connector development tool not used 12 Sensor crankcase pressure 13 Sensor camshaft 14 Sensor flywheel 15 Switch piston cooling 16 Unit injector Cyl 1 6 17 Relay preheating 18 Fuse preheating 19 Main circuit breaker 10 A 20 Preheater 21 Switch coolant level 22 Sensor oil level oil temperature 23 Switch water in fuel 24 Sensor oil pressure 25 Sensor fuel pressure 26 Air filter indicator 27 Connector remote stop 28 Jumper removable 29 EGR internal 30 Control unit EMS 2 2 31 Wastegate valve 32 Visco elecric fan 47701632 10 2010 37 0 Wiring Diagrams Visco electric fan A Fan speed sensor supply B Clutch contol high C Clutch control low D Fan speed sensor ground E Fan speed output F Not connected Cable colors BL Blue P Pink BN Brown R Red GN Green SB Black GR Gray VO Violet OR Orange W White LBL
27. 115 472231 4546 373 832 5256 4448 61 59 62 27 333458 8 57 2 8 30 Hab ala ala 3 33 J2 aa 2 B a 2 d S Si Ad 2 el l E gt Y a o O SISI ele alo z z C Q al Mainrelay TT n S clo SS S SIS 5 Zeg Hold Ru YISB Bad a os N 29 AT j SBI m e R A 7 3 20 0 6BAR CYL6 4231 24 31 2 3 p S SB Iq Z R 3 2 Ni ao Je 28 27 YLS E E YL4 si ze 654321 is 3 EES 1 A a BSa OYES 18 R BL1 5 nj j KL15 50 ae HERE 3 3 30 i By B CYL 2 T 23 eps 21 3 R25 c B25 S R25 CYL1 S S co N 26 DC Kai IK Rai i i i i i i i i r D 1 H SCHPOS 1 oa I T T CH o o is O D 47701632 10 2010 188 37 0 Wiring Diagrams 1 Sensor oil level oil temperature Cable colors 2 Sensor fuel pressure BL Blue P Pink BN Brown R Red 3 Sensor crankcase pressure GN Green SB Black 4 Sensor coolant temperature GR Gray VO Violet OR Orange W White 5 Switch coolant level LBL Light blue Y Yellow 6 Switch piston cooling pressure LBN Light brown E See Cable cross section 0 75 mm unless otherwise 8 Connector not used stated 9 Extra stop 10 J1939 CAN bus 11 Battery negative 12 Battery plus 13 Voltage after key 14 Stop button press button 15 J1587 bus 16 Jumper 17 Aux stop 18 VODIA input diagnosis conn 19 Main relay 20 Main circuit breaker 10 A 21 Starter motor 22 Battery 24 V 23 Alternator 24 Pre heating 25 Relay pre heating 26 Unit injector Cyl 1 6 27 Senso
28. 128 SID 32 Wastegate output driver FMI 3 Voltage above normal or shorted high Fault code explanation Faulty regulator Faulty regulator circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Conditions for fault code The voltage on pin B38 on the EMS2 deviates from normal voltage value Possible reason Short circuited wastegate regulator signal cable to 5V voltage or to bat tery voltage Faulty wastegate regulator Suitable action Check all cable and connectors between EMS2 and wastegate regu lator Change wastegate regulator FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Faulty regulator Faulty regulator circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Conditions for fault code The voltage on pin B38 on the EMS2 deviates from normal voltage value Possible reason Open circuit in wastegate battery voltage supply cable Short circuited wastegate regulator signal cable to battery negative or to lower voltage Faulty wastegate regulator Suitable action Check all cable and connectors between EMS2 and wastegate regu lator Change wastegate regulator 47701632 10 2010 111 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault code explanation Faulty regulator Faulty regulator ci
29. 21 Starter motor 22 Battery connection points 23 Crankshaft sensor 24 Piston cooling switch 28 47701632 10 2010 P0013964 TWD1643GE P0013528 TAD1350 55GE P0007171 47701632 10 2010 30 0 General Component description Starter motor During starting a gear on the starter rotor shaft is moved axially so that it engages with the ring gear on the engine s flywheel The axial movement as well as the activation of the starter motor is controlled by a solenoid on the starter motor The starter solenoid in turn is connected via the starter relay which is activated when the starter key is turned to position IIl the starter button is pressed Wastegate regulator The TAD1350 55GE and TWD 1643 engine is equip ped with a turbocharger with a wastegate valve The wastegate valve controls the amount of exhaust gas flow which should pass through the exhaust turbine An electronically controlled regulation valve waste gate regulator which is controlled by the engine control unit controls the air pressure supplied to the wastegate valve Boost air pressure taken from the inlet manifold is used to control the amount that the wastegate opens 29 30 0 General P0013965 P0008694 P0008694 30 Alternator The alternator is belt driven and is located at the left front of the engine Unit injector The unit injectors are located under the valve cover mounted in the cylinder head Th
30. 4 Use multimeter 9812519 to do resistance meas urement against the engine control unit P0013495 47701632 10 2010 153 30 2 Fault Tracing P0013510 154 Checking stop signal cable between ECU and CIU DCU Tools 88890016 Break out cable 9998699 Break out box 9812519 Multimeter NOTICE Cut the current with the main switch Connect adapter cable 88890016 with measurebox 9998699 between the engine and the CIU DCU Use the engine connector Use multimeter 9812519 for voltage measurement Turn ignition on Measurement points in Nominal value measurebox 18 21 energized to stop U 0 8 x battery voltage 18 21 energized to run U Battery voltage 47701632 10 2010 30 2 Fault Tracing Checking signal cable coolant temperature switch Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Turn ignition off 2 Disconnect the connector from the sensor 3 Connect adapter cable 885675 to the cable har ness connector to the engine control unit 4 Use multimeter 9812519 for voltage measurement NOTICE Turn ignition on 1 Turn ignition off 2 Connect adapter cable 885675 between the sensor and the engine control unit 3 Turn ignition on Measurement points Nominal value 1 2 U 0 5 4 5 V depended of the temperature P0004938 47701632 10 2010 155 30 2 Fault Tracing 156 Checking negative cable coolant temperature
31. A LA a N N wo as S R a w Ae N E WW Ka oa A A S ofle HN 3 ZS G w A a a E a N N o BLIW y y Ve vd a R Li OD a BLIGR_ CAN 2 ANE O o 3 2 S 8 8 2 D oO A o R BL 1 5 D i W 1 5 cy a g 6 E o RIBL 1 5 o i D a aa D 2 T 2 Q w bal a Ka Y olsp1s SR io g Q 8 SIA H rs 9 a 2 2 H Co S a H iw Lo g M w D oF N le RBL a N a we o j Vd bd n Y 2 oe NI N S a d TE a N N a N tet 2 X a 2 o Ras BI WISB SBI P 2 alo GE Ee Wen fon fa fa o S MM A Na kd Sl Vi N A D f P0012804 S 192 47701632 10 2010 zx Lisg Z8GLr BOLL 37 0 Wiring Diagrams Connector engine interface 9 Cable cross section 0 75 mm unless otherwise Sensor coolant temperature stated 1 Battery Cable colors BL Blue P Pink 2 Starter motor BN Brown R Red 2 Alternator GN Green SB Black 4 Main relay GR Gray VO Violet OR Orange W White 5 Stop switch LBL Light blue Y Yellow 6 Control unit EMS 2 LBN Light brown 7 8 9 Sensor air inlet pressure inlet manifold tem perature 10 Connector diagnostic J1587 11 Connector application tool 12 Sensor crankcase pressure 13 Sensor camshaft 14 Sensor flywheel 15 Switch piston cooling pressure 16 Unit injector Cyl 1 6 17 Pre heater relay 18 Fuse 19 Fuse 10A 20 Pre heater 21 Switch coolant level 22 Sensor oil level 23 Switch water in fuel 24 Se
32. Checking negative cable inlet manifold pressure tem perature sensor page 135 Checking signal cable inlet manifold pressure sen sor page 138 Checking air inlet pressure sensor page 139 47701632 10 2010 30 2 Fault Tracing MID 128 PID 107 Air filter pressure drop FMI 1 Data valid but below operational range Fault code explanation Air pressure is too low Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 5 5 Value fault 5 6 Suitable action 1 Change the air filter FMI 3 Voltage above normal or shorted high Fault code explanation Faulty monitor Faulty monitor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 5 5 Value fault 5 6 Symptom Conditions for fault code The voltage on pin A29 on the EMS2 is too high Possible reason e Short circuit between the air pressure switch signal cable and battery voltage e Faulty switch Suitable action 1 Check the cable harness between the air pressure switch and EMS2 2 Check the switch 47701632 10 2010 67 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault code explanation Faulty monitor Faulty monitor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 5 5 Value fault 5 6 Symptom Conditions for fault code The voltage on pin A29 on the EMS2 is les
33. Conditions for fault code The voltage on pin B29 in the engine control unit is less than normal voltage Possible reason e Open circuit in ignition cable e Faulty start relay Suitable action Check the ignition cable Check the start relay on the starter motor Check the prestart relay only on TAD1250 1252VE Check the contact pressure in socket 29 in the engine connector B Cable description The engine control unit pin B29 senses when ignition is switched on that the start relay coil is intact When ignition on there is battery voltage potential on pin B29 When the starter is activated the voltage potential on pin B29 drops to OV On the TAD950 952VE and on the TAD1350 1355GE engines there is one starter relay on the startermotor The TAD1250 1252VE engine also has a prestart relay Measurements Checking starter motor relay page 153 47701632 10 2010 89 30 2 Fault Tracing MID 128 144 PPID 4 Starter input sensor FMI 3 Voltage above normal or shorted high Fault code explanation Starter input failure Fault indication CIU Flashcode Flash code Electrical fault 4 7 EMS Value fault None EMS Electrical fault 5 2 CIU Value fault None G Symptom The engine cannot be started The engine starts immediately when ignition is turned on Possible reason Ignition signal activated too long e Faulty key swich Suitable action 1 Check that the key switch is connected correctly 2 Check cable h
34. Light blue Y Yellow LBN Light brown Cable cross section 0 75 mm unless otherwise stated 187 37 0 Wiring Diagrams TWD1643GE N N L ABHL 141123 SS 16 11234516171 7812 6 453 17 D Vi 2 34 6 apy Bl 12 b el za E RJ E N dA a o ela S d 4 SRI p2 gt R BL SB bal g R BL1 5 E 7 9 1 4 R BL1 0 4 R BL1 5 3 oP B ol 19 1 B sB L 8 NG 9 YSS p SR be SS Si lt 2 30 S zieg 2 Oz qJ 2 zl l zje 2 2 R Y1 0 a R15 4 SIE 2 2 5 Ma m Ee a o a 5 SOS e Rts ER Kb 2 aa of S yl a d S oaa g OR1 0 3 113 41627 H 23 8 3 760 7 515552565859 6129 25 5 36 CONNECTOR B 37 hint 35 CONNECTOR A ie ie BA
35. Light blue Y Yellow 6 Control unit EDC LBN Light brown 7 8 9 Sensor air inlet pressure inlet manifold tem perature 10 Sensor oil pressure 11 Sensor oil level oil temperature 12 Sensor crankcase pressure 13 Sensor camshaft 14 Sensor flywheel 15 Sensor fuel pressure 16 Unit injector Cyl 1 6 17 Connector engine interface 18 Connector application tool 19 Connector serial J1587 20 AUX STOP 21 Jumper removeable 22 Fuse 10A 23 Switch fuel pump 24 Switck water in fuel 25 Connector remote water in fuel 26 Pre heater 27 Pre heater relay 28 Fuel pump 47701632 10 2010 177 37 0 Wiring Diagrams TAD950 952VE BL OR APILLERING secu 25 17 123456 R BL 1 5 SOLENOID SW IF R15 _ R145 R BL 1 5 E b gt w gt 738 3640 4448 5256 2832 1216 2024 amp PRESS SB 729 VA OIL PRESS BOOST TEMP 3 m AL Fb KE Ju 28 27 2 2 4 CAM CRANK Engine speed Engine spd MAIN RELAY HOLD P0014016 47701632 10 2010 178 37 0 Wiring Diagrams Sensor fuel pressure fuel temp LBN Light brown SACI EIECINE lord PUM
36. P Pink BN Brown R Red GN Green SB Black GR Gray VO Violet OR Orange W White LBL Light blue Y Yellow LBN Light brown Cable cross section 0 75 mm unless otherwise stated 195 37 0 Wiring Diagrams Wiring diagram CIU P0014020 196 2 poje a Sle ld o SB 2 5 gt B 15 ES IS ol lee R25 1 E Ce R15 a RIBL 1 5 E TT 4 w W SB l Slzlekcl YW SIENS Aaa e GR Y JR SIS GNIY 123456 78 27 GN SB D 12345678 GN OR i 26 24 Bi T R RIGR 28 r l E SB SB x R BN L 9 R l R SB R Y ZT 10 R a a D D C vo 11 R 7 a T SB e 7 12 R E S D 3 BN Q 25 R sB foun R SB RISB 4 N GR SB ep 7 RISB SI LBN WIEL Q 13 R l Y BL Y 14 R Q R SB LBN WIBN ei 15 R H W GN Q 16 R O BL OR Q7 R O P SB Q 18 R 4 VOW Q 19 R l GL Q 20 R A R GN e 21 R l 22 OR Da R W GL 28 1 SS ee R SB 2 Y BL R R BL 47701632 10 2010 37 0 Wiring Diagrams Coolant temperature instrument LBN Light brown Instrument illumination Cable cross section 0 75 mm unless otherwise Idling contact two way stated 1 Key switch 15 Cable colors 2 RPM potentiometer BL Blue ails BN Brown R Red 3 Tachometer code 14 GN Green SB Black 4 Oil pressure instrument GR Gray SE Violet OR Orange W White 5 Oil temperature instrument L
37. RC 0E E on D RIBL 1 5 R BL 1 5 BN 1 0 49 09 G a E RW SR1 5 lt SB 1 5 19 6G 8G Z 0929 eq SB 1 5 gt ol YW I 9S 2G SR SS S IS LL 9 62 L al GRIY a ZG 8G Le EC EC 8 D le lt lt jojo jejo o Y 1 0 1 0 YISB W SB w 2 D A RIBL 1 5 A S SB 1 5 D Q E D R BL 1 5 EEE Z U OL 19 H SB 2 5 Yw I so GRIY es LH Eo md gz D EEN E o Si R25 D gt apg aN 7 fp SE 35 mt G Ga an DS W SB SB R2 5 z o Ipsrezt OL P0012806 184 eg otigat fe L XI GLY gS A aw ANa OC 88 gz UJ LC LZ 47701632 10 2010 37 0 Wiring Diagrams Battery Cable colors Main switch BL Blue P Pink BN Brown R Red Starter motor GN Green SB Black Alternator GR Gray VO Violet OR Orange W White Main relay LBL Light blue Y Yellow Aux stop LBN Light brown Connector engine interface E f 9 Cable cross section 0 75 mm unless otherwise Sensor coolant temperature stated oO ON OO FW DY Sensor air inlet pressure inlet manifold tem perature 10 VODIA input diagnosis conn 11 Connector development tool not used 12 Sensor crankcase pressure 13 Sensor camshaft 14 Se
38. all cables in the charging system 4 Regulator fault Replace regulator when overcharge 1 Probably regulator fault Replace regulator 45 30 0 General P0008367 P0008466 46 Alternator fault tracing Checking the brushes and the regulator e NOTICE Cut the current with the main switch e Remove all connectors on the alternator B B etc e Remove the plastic cover over the diodes The plas tic cover is fixed with two nuts on B1 B2 anda pozidrive screw e Remove the three screws that holds the brushes and the regulator Checking the brushes e Measure the length of the brushes between the brush mating surface and the brush holder If any brush is damaged the brushes should be replaced Checking the regulator e Set 9812519 Multimeter to diode measurement e Connect the probes between the brushes Check that there is no short circuit e Switch the probe points and check that there is no short circuit e NOTICE If a regulator fault is suspected install a new regulator and test operate the charge system Checking the rotor e Set 9812519 Multimeter to diode measurement e Connect one probe to each slip ring The multimeter should show low resistance but not 0 ohm short circuit or infinity open circuit e Check that the slip rings do not have any burn marks or other damage 47701632 10 2010 30 0 General Short circuit test the rotor 1 Set the 9812519 Multimeter to diode measurem
39. be forced to run using the idle contact Preconditions NOTICE If the control panel ONLY communicates on the J1939 communi cation and NOT the redundancy of J1587 for start stop and throttle this fault code is active in the VODIA and that is normal Conditions for fault code EMS2 recieves no throttle signal on the J1939 bus from the CIU Suitable action 1 Check that the throttle potentiometer is connected correctly 2 Check cable harness between CIU and the CIU throttle potentiometer 3 Check the function of the throttle potentiometer A Cable description 1 2 3 GN SB J GN IY GN OR P0013518 A Throttle pot Measurements Vodia logging throttle signal page 175 100 47701632 10 2010 30 2 Fault Tracing MID 128 PPID 332 Thermostat FMI 3 Voltage above normal or shorted high Fault code explanation Faulty sensor Faulty circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Conditions for fault code The voltage on pin B34 on the EMS2 deviates from normal voltage value Possible reason e Short circuited coldstart valve signal cable to 5V voltage or to battery voltage e Faulty coldstart valve Suitable action 1 Check all cable and connectors between EMS2 and coldstart valve 2 Check coldstart valve FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation
40. can be handled nor mally 03 3 Specifications Electrical 03 3 Specifications Electrical Electrical System Technical Data Switch water in fuel Contact type Closes when water is detected Sensor fuel pressure 0 700 KPa 0 7 bar 0 1015 PS Speed sensor crankshaft camshaft Sensor oil pressure 0 700 KPa 07 bar 0 1015 KPa Combination sensor air inlet pressure inlet manifold temperature Voltage Working pressure range 50 400 kPa 0 5 4 bar 7 3 58 0 PSI Pressure signal 0 5 4 5 V Working temperature range 40 C to 130 C 40 F to 262 F Type Linear NTC Sensor coolant temperature O 47701632 10 2010 03 3 Specifications Electrical Type NTC Max tightening torque 25 Nm 18 4 Ibf ft Switch coolant level Contact type Closing with low coolant level Alternator Capacity 80 A at 24 V Starter motor Voltage Connector Capacity TAD1341 1345 Sensor crankcase pressure Voltage Working pressure range 40 140 kPa 0 4 1 4 bar 5 8 20 3 PSI Combination sensor oil level temperature Switch piston cooling pressure Contact type Closing for low piston cooling pressure Combination sensor air filter pressure temperature Voltage Max 24 V Switch point 5 0 5 kPa 50 5 mbar 0 73 0 073 PSI Working temperature range 40 C to 100 C 40 F to 244 F 47701632 10 2010 7 03 3 Specifications Electrical
41. connect the other end of the adapter cable 3 Use multimeter 9812519 to do resistance meas urement NOTICE Even if the nominal value is correct the sen sor could be faulty 47701632 10 2010 131 30 2 Fault Tracing ae de gt e La 92 885 675 P0001355 l Q S Cr 132 Checking supply cable oil pressure sensor Tools 885675 Break out cable 9812519 Multimeter NOTICE Turn ignition off Remove the connector from the sensor Connect adapter cable 885675 between the sensor and engine control unit N Use multimeter 9812519 for voltage measurement NOTICE Turn ignition on Measurement points Nominal value Checking negative cable oil pressure sensor Tools 885675 Break out cable 9812519 Multimeter NOTICE Cut the current with the main switch N Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit A Use multimeter 9812519 to do resistance meas urement against the engine control unit 47701632 10 2010 30 2 Fault Tracing Checking signal cable oil pressure sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch K CON 2 Disconnect the connector from the sensor 3 Connect adapter cable 885675 to the cable har GC Qe de ness connector to the engine control unit 4 Use multimeter 9812519 to do resistance meas
42. cover 1 2 3 Remove the connector from the IEGR solenoid 4 Remove connector B from the EMS2 5 Use multimeter 9812519 to do a resistance meas urement between connector B from the EMS2 to the loosend connector IMPORTANT Be very careful when measuring inside the connector to ensure that no pin is damaged 163 30 2 Fault Tracing Checking camshaft sensor wiring Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Remove the connector from the sensor Connect adapter cable 885675 to the connector Remove connector A from the EMS2 Use multimeter 9812519 to do a resistance meas urement from the sensor connector to connector A to verify that neither of the wires are broken or short circuited Measurement points Nominal value 1 sensor conn 38 conn A 2 sensor conn 37 conn A 1 sensor conn 2 sensor conn 00 OU IMPORTANT Be very careful when measuring inside the connector to ensure that no pin is damaged OoooooooooooOoOoo0o0 ooopoppopp0pp0pp0npp0p0000 DOC P0013526 164 47701632 10 2010 30 2 Fault Tracing Checking camshaft sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Undo the connector from the sensor and remove the sensor from the cylinder head Check that the sensor does not have any external damage or any swar
43. depended of the temperature P0013507 47701632 10 2010 151 30 2 Fault Tracing Checking oil temperature sensor Tools 885675 Break out cable 9812519 Multimeter 1111117 Amm o 1 NOTICE Cut the current with the main switch 2 Connect adapter cable 885675 to the sensor Do not connect the other end of the adapter cable 3 Use multimeter 9812519 to do resistance meas urement R 4981 O 503 Q at 0 C 19000 S 163 Q at 20 C R 809 O 59 Q at 40 C R 3780 24 Q at 60 C R 1910 10 Q at 80 C R 1040 5 Q at 100 C R 600 3 Q at 120 C P0013508 152 47701632 10 2010 30 2 Fault Tracing Checking starter motor relay Tools 9812519 Multimeter 1 NOTICE Turn off the main switch 2 Undo the red yellow cable on the startermotor UR 3 Use multimeter 9812519 to do resistance meas SN G SI urement towards the relay LAAT SPOS il d Nominal value V Wo R 8 140 H OLN a DNA P0013509 Checking negative cable air filter pressure switch Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the switch 3 Connect adapter cable 885675 to the cable har ness connector to the engine control unit
44. display CIU Flash code Flash code Electrical fault 9 9 Value fault None Symptom Engine might not start Conditions for fault code Signal value is irregular intermittent or incorrect Data communication inter rupted Suitable action 1 Reprogram the EMS2 2 Change the EMS2 47701632 10 2010 119 30 2 Fault Tracing MID 128 SID 250 SAE J1708 J1587 data link FMI 12 Faulty device or component Fault code explanation Communication fault J1587 J1708 Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 9 2 Value fault None Symptom Conditions for fault code Faulty data link Suitable action 1 Check all data links between DCU CIU and EMS2 2 Check the contact pressure in socket 33 and 34 in engine connector A 3 Check that the socket 22 and 37 in the CIU connector is undamaged Cable description A CAN H Data Link to Engine Ip GRN 2 B CAN L Data Link to Engine OJE Sr RIBL B l D Power supply input a E Elton C wese E Stop EMS2 a DCU CIU G J1708A Data Link to Engine P0013534 H J1708B Data Link to Engine a Engine connector 120 47701632 10 2010 30 2 Fault Tracing MID 128 144 SID 253 Calibration memory EEPROM FMI 2 Data erratic intermittent or incorrect FMI 12 Faulty device or component FMI 14 Special instructions Fault code explanation Communication fault Fault indication DCU Engine
45. fault 2 3 Value fault 2 2 Conditions for fault code The voltage on pin B23 in the engine control unit is too high Possible reason Short circuit to battery voltage on pin B23 Suitable action 1 Check the cable harness between the coolant level switch and the EMS2 P0004033 74 47701632 10 2010 EMS2 P0013497 a Connector B b Coolant level 47701632 10 2010 30 2 Fault Tracing Cable description The coolant level in the engine is monitored by a level switch Pin 23 on the engine control unit EMS2 pro vides pin 1 on the level switch with supply voltage Pin 2 on the level switch is connected to battery negative via pin 10 on the engine control unit The level switch has two states On Off The level switch consists of two sections the actual switch and a magnetic float which is built into the expansion tank The switch senses the position of the magnetic float When the coolant level falls the float operates the switch and a closed circuit is formed Measurements Checking supply cable coolant level switch page 143 Checking negative cable coolant level switch page 143 Checking coolant level switch page 144 75 30 2 Fault Tracing MID 128 PID 153 Crankcase pressure FMI 0 Data valid but above normal operational range Fault code explanation Crankcase pressure is rising too fast Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 7 8
46. is situated on the left side of the engine a When the fuel press switch is activated the fuel bleed ing pump starts to pump round the fuel P0014009 Fuel pressure o o Fuel bleeding pump P Start O d Fuel press switch 124 47701632 10 2010 30 2 Fault Tracing Measurements Checking the wiring Tools 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Remove the wire to be measured from the preheat relay Remove connector B from the EMS2 4 Use multimeter 9812519 to do a resistance meas urement between connector B see circuit descrip tion to the loosen wire R OO Checking supply cable fuel sensor Tools 885675 Break out cable 88890053 Break out cable 9812519 Multimeter 1 NOTICE Turn ignition off Disconnect the connector from the sensor TAD1250 1252 and TWD1643 Connect adapter cable 885675 to the cable har ness connector to the engine control unit TAD950 952 with bleeding pump Connect adapter cable 88890053 to the cable har ness connector to the engine control unit Use multimeter 9812519 for voltage measurement 5 Turn ignition on Measurement points 1 4 no fuel bleeding pump 2 4 with fuel bleeding pump p0013473 47701632 10 2010 125 30 2 Fault Tracing Checking negative cable fuel sensor Tools 885675 Break out cable 88890053 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch
47. not necessary to turn the main switches off e Only batteries may be used for start help A help start device can produce a very high voltage and damage the control unit and other electronics e Ifa connector is disconnected from a sensor be very careful to avoid allowing the contact pins to come into contact with oil water or dirt Electrical Welding 1 NOTICE Cut the current with the main switch IMPORTANT The system must be disconnected from system voltage when the engine control unit connectors are disconnected or connected 2 Undo the two connectors from the engine control unit before any electrical welding starts Turn the locking arm down at the same time as the connector is pulled outwards 3 Disconnect all connections to the alternator Connect the welder earth clamp to the component to be welded or as close as possible to the weld site The clamp must never be connected to the engine or in such a way that current can pass through a bearing IMPORTANT After welding is completed the disconnected com ponents such as alternator cables and battery cables must be connected in the correct order The battery cables must always be connected last 47701632 10 2010 P0002862 47701632 10 2010 30 0 General Engine Control Unit ECU Replace 1 NOTICE Cut the current with the main switch IMPORTANT The system must be disconnected from system voltage when the engine control unit connectors a
48. of air inlet pressure and atmos pheric pressure The sensor supplies the control unit with a voltage signal proportional to the absolute pres sure The sensor receives a reference signal of 5 Volts from the control unit The intake manifold temperature sensor comprises a non linear resistor where the resistance is dependant on the temperature of the resistor body The resistance drops as temperature rises Oil pressure sensor The oil pressure is measured by a sensor located next to the control unit The sensor is fitted in the engine block so that meas urements are performed in the lubrication systems main oil galley The pressure signal is a voltage signal proportional to the pressure The sensor reference voltage is 5 Volts IEGR Internal exhaust gas recirculation IEGR is used for recirculation of exhaust gases This for lowering the emissions from the engine The IEGR control valve is located on the cylinder head under the valve cover Oil level temperature sensor The sensor is located in the oil sump The purpose of the level sensor is to detect if the oil level becomes too low A current is passed through the sensor and the voltage measured across it is then pro portional to the oil level An alarm signal is sent when the oil level is too low The temperature sensor consists of a non linear resistor where the resistance is dependent on the temperature of the resistor body The resistance drops as temperature ri
49. personal injury Stop the engine before working on the cooling system Marine engines Close the sea cock cooling water inlet valve before work on the cooling sys tem is begun Make sure that oil fuel soaked rags and used fuel and oil filters are stored in a safe manner Rags soaked in oil can spontaneously ignite under certain circumstances Used fuel and oil filters are environmentally hazardous waste and must be handed to an approved waste management facility for destruction as must any used lubrication oil contaminated fuel paint residue solvents degreasers and wash residue Never work alone when removing heavy com ponents even when using lifting devices such as locking tackle lifts When using a lifting device two people are usually required to do the work one to take care of the lifting device and the other to ensure that components are lifted clear and not damaged during the lifting operations The existing lugs on the engine should be used for lifting Always check that the lifting equip ment used is in good condition and has the load capacity to lift the engine engine weight includ ing gearbox or extra equipment For safe han dling and to avoid damaging components fitted to the top of the engine the engine must be lifted with a correctly adjusted lifting boom All chains or wires must run parallel to each other and as perpendicular to the engine as possible If other equipment attached to the engine has
50. pro tect the engine and to inform about any problems that occur If a malfunction is discovered this is announced by warning lamps a flashing diagnostic lamp or in plain language on the instrument panel depending on the equipment used If a fault code is obtained as a flash ing code or in plain language this is used for guidance in any fault tracing Fault codes can also be read by Volvo s VODIA tool at authorized Volvo Penta work shops In case of serious disturbances the engine is shut down completely or the control unit decreases the power output depending on the application Once again a fault code is set for guidance in any fault trac ing 47701632 10 2010 30 0 General TAD950 952VE O Om E LG KM Component location P0013950 Coolant level sensor Preheater Unit injector Crankcase pressure sensor Extra stop Sensor air inlet pressure intake manifold temper ature IEGR valve 47701632 10 2010 10 11 12 13 14 15 Main relay Oil level temperature sensor Fuel pressure sensor Engine control unit ECU Water in fuel sensor Diagnostic outlet Alternator Main fuse 10 A 21 30 0 General TAD950 952VE
51. switch Use multimeter 9812519 to do voltage measure ment towards the engine control unit 4 NOTICE Turn ignition on Measurement points Nominal value Yellow conductor U Battery voltage x 0 8 Black conductor y e a A AY yy lmm Wc Y N a mamm p0013376 47701632 10 2010 129 30 2 Fault Tracing Checking negative cable water in fuel switch Tools 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the switch Use multimeter 9812519 to do resistance meas urement against the engine control unit Measurement points Nominal value Black conductor R 0Q Battery negative s II P0013419 Checking water in fuel switch Tools 9990014 Break out cable 9998699 Break out box 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Connect adapter cable 9990014 with measurebox 9998699 between EMS 2 connector B and the switch Use multimeter 9812519 for voltage measurement Turn ignition on Measurement points Nominal value 10 8 Switch immersed in U 0 8 x battery voltage fuel 10 8 Switch immersed in U 0 8 x battery voltage water 5V 130 47701632 10 2010 30 2 Fault Tracing Checking oil level sensor Tools 885675 Break out cable WM Tools 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Connect adapter cable 885675 to the sensor Do not
52. switch Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the sensor 3 Connect adapter cable 885675 to the cable har ness connector to the engine control unit 4 Use multimeter 9812519 to do resistance meas urement against the engine control unit Checking negative cable piston cooling oil temperature switch Tools 9998534 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Undo the connector from the switch Connect the adapter cable 9998534 to the cable harness con nector that is connected to the engine control unit 3 Use the multimeter 9812519 to do resistance measurement against the engine control unit 47701632 10 2010 30 2 Fault Tracing Checking supply cable piston cooling oil temperature switch Tools 9998534 Break out cable 9812519 Multimeter 1 NOTICE Turn the starter key to the stop position 2 Undo the connector from the switch Connect the adapter cable 9998534 to the cable harness con nector that is connected to the engine control unit 3 Use multimeter 9812519 for voltage measure ment 4 Turn the starter key to position drive position 885675 Checking the IEGR coil Tools 9990014 Break out cable 9998699 Break out box 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Connect adapter cable 9990014 with measurebox 9998699 bet
53. the function of the throttle potentiometer Check the contact pressure in socket 2 3 and 3 in the CIU connector FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Faulty throttle potentiometer Faulty throttle potentiometer circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 8 Value fault None Symptom Engine goes to idle If the accelerator is released at first and then pressed down again the engine can be forced to run using the idle contact Preconditions NOTICE If the control panel ONLY communicates on the J1939 communi cation and NOT the redundancy of J1587 for start stop and throttle this fault code is active in the VODIA and that is normal Possible reason e Short circuited throttle potentiometer signal cable to battery negative e Faulty sensor Suitable action 1 Check that the throttle potentiometer is connected correctly 2 Check cable harness between CIU and the CIU throttle potentiometer 3 Check the function of the throttle potentiometer 47701632 10 2010 99 30 2 Fault Tracing FMI 9 Abnormal update rate Fault code explanation EMS2 is missing the throttle signal Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 8 Value fault None Symptom Engine goes to idle If the accelerator is released at first and then pressed down again the engine can
54. turbo compressor unit is in according the engine speci fication FMI 3 Voltage above normal or shorted high Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 4 Value fault 3 5 Symptom Engine smokes more than normally during acceleration or load increase Conditions for fault code The voltage on pin A22 on the EMS2 is more than 4 77 Volt Possible reason e Open circuit in the sensors negative cable Short circuited sensor signal cable to 5V voltage or battery voltage Faulty sensor Suitable action Check the cable harness between the air inlet pressure sensor and EMS2 Check the contact pressure in socket 11 in engine connector A Check the sensor 64 47701632 10 2010 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 4 Value fault 3 5 Symptom Engine smokes more than normally during acceleration or load increase Conditions for fault code The voltage on pin A22 on the EMS2 is less than 0 07 Volt Possible reason Open circuit in air inlet pressure signal cable Open circuit in 5V supply cable to sensor Short circuited air inlet pressure signal cable to sensor negative cable Faulty sensor Suitable a
55. wider When the wastegate valve is fully open the exhaust gas flow to the exhaust turbine is at its lowest The control valve is current controlled by the engine control valve using a PWM signal As the current sup plied to the control valve increases the boost air pres sure increases The boost air pressure is constantly monitored by a sensor installed in the inlet manifold Measurements Checking negative cable wastegate valve page 168 Checking supply cable wastegate valve page 169 Checking the wastegate valve page 170 113 30 2 Fault Tracing MID 128 SID 70 Air inlet heater driver 1 FMI 3 Voltage above normal or shorted high Fault code explanation Faulty relay Faulty relay circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Symptom Fuse for shorting wire breaks Possible reason e Short circuit to battery voltage in sense wire e Heating element broken Suitable action 1 Check all cable and connections to heating element 2 Check function of preheat relay 3 Check heating element FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Faulty relay Faulty relay circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Symptom Start problems in cold climate Short circuit to battery negative in sense wire Su
56. 180 kPa 225 kPa 250 kPa 23 2 PSI 26 1 PSI 32 6 PSI 36 3 PSI 8 47701632 10 2010 Derate to engine protection map Yellow lamp Red lamp Forced shutdown High exhaust temperature 98 C 208 4 F 125 C 257 0 F 80 C 176 0 F 500 kPa 72 5 PSI 580 C 1076 0 F TAD1350 1355GE gt 103 C 217 4 F gt 130 C 266 0 F gt 85 C 185 0 F 510 kPa 74 0 PSI 610 C 1130 0 F 03 3 Specifications Electrical gt 103 C 217 4 F gt 130 C 266 0 F gt 85 C 185 0 F gt 510 kPa 74 0 PSI gt 610 C 1130 0 F Crankcase pressure When rapid increase of When rapid increase of pressure pressure Piston cooling pressure Pe When switch is activated When switch is activated 47701632 10 2010 9 03 3 Specifications Electrical TWD1643GE Derate to engine protection map Yellow lamp Red lamp Forced shutdown High coolant temperature 98 C gt 103 C gt 103 C 208 4 F 217 4 F 217 4 F High oil temperature 125 C gt 130 C gt 130 C 257 0 F 266 0 F 266 0 F High inlet manifold temperature 80 C gt 85 C gt 85 C 176 0 F 185 0 F 185 0 F High exhaust temperature 580 C 610 C gt 610 C 1076 0 F 1130 0 F 1130 0 F Crankcase pressure When rapid increase of When rapid increase of pressure pressure Piston cooling pressure Poe When switch is activated When switch
57. 2 Check the secon dary locking in the connector e H possible shake the cables and pull the connectors during measurement to discover whether the cable harness is damaged e Check that the cables are not damaged Avoid clamping cables in tight bends close to the connec tor e Check the function of the secondary locking Contact problems Intermittent contact or temporary recurring faults can be difficult to fault trace and are frequently caused by oxidation vibration or poorly terminated cables Wear can also cause faults For this reason avoid dis connecting a connector unless it is necessary Other contact problems can be caused by damage to pins sockets and connectors etc Shake cables and pull connectors during measure ment to find where the cable is damaged 47701632 10 2010 47701632 10 2010 30 0 General Contact resistance and oxidation Resistance in connectors cables and junctions should be approx 0 Q A certain amount of resistance will occur however because of oxidation in connectors If this resistance is too great malfunctions occur The amount of resistance that can be tolerated before mal functions occur varies depending on the load in the circuit Open circuit Possible reasons for faults could be chafed or broken cables or connectors which have come undone Use the wiring schedule to check the cables which are relevant to the function Start off with the most probable cable in
58. 5V DC FMI 3 Voltage above normal or shorted high Fault code explanation Fault in circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 9 3 Value fault None Conditions for fault code Abnormally high voltage or short circuit to higher voltage on pin B17 Possible reason Short circuit to battery voltage Suitable action 1 Check the supply voltage to the sensors which have set fault codes 2 Check sensor cables 3 Check the sensors FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Fault in circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 9 3 Value fault None Symptom None Conditions for fault code Abnormally low voltage or short circuit to battery negative has on pin B17 Possible reason Short circuit sensor supply voltage cable to battery negative fuel pres sure sensor Short circuit sensor supply voltage cable to battery negative crankcase sensor Suitable action Check the supply voltage to the above mentioned sensors Check sensor cables Check the sensors Cable description Pin B17 on the EMS2 distributes 5 Volt supply voltage to the crankcase pressure sensor and the fuel pressure sensor 116 47701632 10 2010 30 2 Fault Tracing MID 128 144 SID 231 SAE J1939 data link FMI 2 Data erratic intermittent or incorrect Faul
59. 7 9 Value fault None Symptom Conditions for fault code The voltage on pin B18 on the EMS2 is less than 0 07 Volt Possible reason e Short circuit between both cables to the air filter temperature sensor e Faulty sensor Suitable action 1 Check the cable harness between air filter temperature sensor and EMS2 2 Check the sensor FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 7 9 Value fault None Conditions for fault code The voltage on pin B31 on the EMS2 is more than 4 95 Volt Possible reason Open circuit in signal cable to the air filter temperature Open circuit in negative cable to the air filter temperature sensor Faulty sensor Suitable action Check the cable harness between air filter temperature sensor and EMS2 Check the contact pressure in socket 18 and 31 in the engine connector B Check the sensor 80 47701632 10 2010 P0013492 P0013493 a Connector A b Connector B c Air filter pressure and temperature 47701632 10 2010 30 2 Fault Tracing Cable description The air filter temperature sensor consists of a thermis tor which forms a closed circuit with an internal resistor in the engine control unit EMS2 The thermistor resis tor changes in a non linear manner depending on the air temperature The EM
60. 7 Switch piston cooling pressure l 2 Cable cross section 0 75 mm unless otherwise 8 Switch water in fuel stated 9 Connector block not used 10 Internal EGR 11 Extra stop 12 J1939 CAN bus 13 Battery negative 14 Battery plus 15 Voltage after key 16 Stop button 17 J1587 J1708 bus 18 Diagnostic tool 19 Main relay 20 Starter motor relay 21 Main circuit breaker 10 A 22 Starter motor 23 Battery 24 V 24 Pre heating 25 Alternator 26 Unit injector Cyl 1 6 27 Sensor flywheel 28 Sensor camshaft 29 Sensor air inlet pressure temperature 30 Air filter indicator 31 Connector block B 32 Connector block A 33 Control unit EMS 2 47701632 10 2010 181 du 10 Cal 28 BATT 1708 GTZ 2 7 J1939 BATT SWITCHED 1587 H E BAT stop A B 12 4 567 2 z zie sll ala gt O o xj im 2 Tal RBL1 5 34 311 30 38 292537 57 CONNECTOR B R25 CONNECTORA ba A1 1 26 20 4448 52 BR 28 32 33 34 27 _58_57 MAIN RELAY HOLD 37 0 Wiring Diagrams TAD1350 1352GE N Jo P0014018 47701632 10 2010 182 Battery Main switch Starter motor Alternator Main relay Aux stop Connector engine interface Sensor coolant temperature oO ON DOO FW DY gt Sensor air inle
61. BL Light blue Y Yellow 6 7 8 9 1500 1800 rpm switch two way 10 Starter contact spring biased 11 Stop switch spring biased 12 Diagnosis contact spring return 13 Alarm low oil pressure 14 Alarm high oil temperature 15 Alarm high coolant temperature 16 Alarm low coolant level 17 Fuel alarm 18 Diagnostic lamp 19 Engine overspeed indication GE Horn VE 20 Operation indicator 21 Pre heating indication 22 Pre heating contact 23 8 pin connector engine interface 24 Governor switch 25 Battery voltage alarm 26 Termination resistance 120 Ohm 27 8 pin connector engine interface 28 Contact engine protector disconnect 29 Easy Link connector block 30 Control Interface Unit CIU 47701632 10 2010 197 37 0 Wiring Diagrams Wiring diagram DCU 11 YW 12345 67 818 Ss SE S 0 Di ba SB 2 5 RIBL 1 5 BL 2 5 W SB GR W SB 2 5 I R2 5 RIBL 2 5 BL 2 5 Ww W SB P0014021 Stop contact Start contact 1 pin connector Horn buzzer alarm Easy Link connector RPM potentiometer Indicator engine operation o N DOO A OO N gt 8 pin connector engine interface 9 8 pin connector engine interface 10 Termination resistance 120 Ohm 11 Display Control unit DCU 198 gt aif 2 SES 8 2 1234567 8 9 123 45 67 8 10 SB 2 5 R BL 1 6 BL 2 5 W SB A
62. Break out cable 9998699 Break out box The resistance of the CAN bus termination resistors one 120 Q resistor in the ECU and one 120 Q resistor in the cable harness are measured 1 NOTICE Cut the current with the main switch 2 Disconnect the 8 pin Deutsch connector at the DCU or disconnect at the CIU 3 Use multimeter 9812519 to do resistance meas urement towards the EMS 2 Measurement points Nominal value in the engine connector at the DCU Measurement points Nominal value in the CIU connector 11 12 U 600 NOTICE Even if the measured value equals the nom inal value the data bus cable could be faulty due to short circuit between a data bus cable and another cable in the harness 1 Connect adapter cable 88890016 with measurebox 9998699 between the EMS 2 and the CIU DCU 2 Use multimeter 9812519 to a voltage measure ment Measurement points Nominal value in the measurebox 16 17 between CAN U 2 3V 2 7V bus NOTICE Even if the measured value equals the nom inal value the data bus cable could be faulty due to short circuit between a data bus cable and another cable in the harness 173 30 2 Fault Tracing 885 675 SSS Ka LW les e Ae e 885 675 P0001266 Ges 174 Checking negative cable crankcase pressure sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the sensor 3 Connect ada
63. C Measurements Checking negative cable piston cooling oil tempera ture switch page 156 Checking supply cable piston cooling oil temperature switch page 157 93 30 2 Fault Tracing MID 128 PPID 19 Internal EGR Status FMI 3 Voltage above normal or shorted high Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 8 5 Value fault None Symptom IEGR can not be turned on If the IEGR function would fail not being acti vated the result will be an increased exhaust production with high NOX and possible over speeding of the turbocharger Conditions for fault code The voltage on pin B30 on the EMS2 deviates from normal voltage value Short circuited IEGR signal cable to 5V voltage or to battery voltage Suitable action 1 Check cable harness between EMS2 and the IEGR FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 8 5 Value fault None Symptom IEGR can not be turned on If the IEGR function would fail not being acti vated the result will be an increased exhaust production with high NOX and possible over speeding of the turbocharger Conditions for fault code The voltage on pin B30 on the EMS2 deviates from normal voltage valu
64. CE Turn ignition off 2 Disconnect the connector from the sensor Connect adapter cable 885675 between the sensor and the engine control unit Use multimeter 9812519 for voltage measurement 5 Turn ignition on Measurement Nominal value points 1 4 U 1 1 V at normal atmospheric pressure Checking supply cable air filter pressure switch Tools 885675 Break out cable 9812519 Multimeter O Eech NOTICE Turn ignition off N Disconnect the connector from the switch Connect adapter cable 885675 between the switch and engine control unit oO A Use multimeter 9812519 for voltage measurement NOTICE Turn ignition on 1 Disconnect the connector from the switch P0013494 oa 47701632 10 2010 139 30 2 Fault Tracing Checking air pressure switch Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Turn ignition off 2 Disconnect the connector from the switch Do not connect the other end of the adapter cable Connect adapter cable 885675 to the switch Use multimeter 9812519 for resistance measure ment SS NOTICE If the measured value is 2 2 kOhm when the engine is shut down the switch inside is stuck in active Le 885675 position P0013496 e KR Ss 140 47701632 10 2010 885 675 47701632 10 2010 30 2 Fault Tracing Checking coolant temperature sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main swit
65. CU battery potential 79 MID 128 PID 172 Inlet air Temperature 80 MID 128 PID 173 Exhaust gas temperature 82 MID 128 PID 175 Engine oil temperature 84 MID 128 PID 190 Engine speed 87 MID 128 PID 45 Inlet air heater status 50 MID 128 PID 94 Fuel Delivery Pressure 52 MID 128 PID 97 Water in fuel indicator 55 MID 128 PID 98 Engine oil level 57 MID 128 PPID 19 Internal EGR Status 94 MID 128 PPID 3 Starter Output 88 MID 128 PPID 332 Thermostat cee 101 MID 128 PPID 55 ECU temperature 97 MID 128 PPID 6 Key off input sensor 91 MID 128 PPID 8 Piston Cooling Oil Pressure 92 MID 128 PPID 98 Engine sync acknowledge 98 MID 128 PSID 201 Data link MiDiA4 123 MID 128 SID 1 2 3 4 5 6 Injector 1 6 103 MID 128 SID 21 Engine position 107 MID 128 SID 211 Sensor Supply Voltage 2 FIV DCO TTT 116 MID 128 SID 22 Timing sensor crank 109 MID 128 SID 232 5 V Supp eee eee eee 118 MID 128 SID 240 Program memory ee 119 MID 128 SID 250 SAE J1708 J1587 data link 120 MID 128 SID 32 Wastegate output driver 111 MID 128 SID 70 Air inlet heater driver 1 114 No fault code ngana gien deed eg 124 Programming an empty control unit 39 Repair Instructions eee eee eee 36 Repair Instruccions sees eee eee 3 Reprogramming a control unt 38
66. D 128 144 PPID 4 Starter input sensor page 90 4 7 5 2 MID 128 PPID 6 Key off input sensor page 91 520195 4 8 EMS 970 5 3 CIU 520192 6 8 6 7 2791 5 5 MID 128 PPID 8 Piston Cooling Oil Pressure page 92 MID 128 PPID 19 Internal EGR Status page 94 MID 128 PPID 55 ECU temperature page 97 MID 128 PPID 98 Engine sync acknowledge page 98 MID 128 144 PPID 132 Throttle calibrated position page 99 608 MID 128 PPID 332 Thermostat page 101 2988 MID 128 SID 1 2 3 4 5 6 Injector 1 6 page 103 651 656 MID 128 SID 21 Engine position page 107 636 MID 128 SID 22 Timing sensor crank page 109 637 MID 128 SID 32 Wastegate output driver page 111 1188 MID 128 SID 70 Air inlet heater driver 1 page 114 729 MID 128 SID 211 Sensor Supply Voltage 2 5V DC page 116 MID 128 144 SID 231 SAE J1939 data link page 117 6 5 EMS 6 4 CIU 9 3 9 9 3 4 5 7 0 4 5 O O CO l 2 8 7 1 7 Gi 2 5 2 4 3 4 9 3 4 5 3 4 5 7 12 2 3 8 2 3 8 3 4 5 3 4 5 9 3 LY A 1 I lt 1 I 1 I N MID 128 SID 232 5 V supply page 118 MID 128 SID 240 Program memory page 119 3 4 2 7 11 14 47701632 10 2010 199 39 0 General MID 128 SID 250 SAE J1708 J1587 data link page 120 608 9 2 12 MID 128 144 SID 253 Calibration memory 630 9 9 EMS 2 12 14 EEPROM page 121 9 8 CIU MID 128 144 SID 254 Controller 1 page 122 629 9 9 EMS 3 8 12 9 8 CIU MID 128 PS
67. Faulty sensor Faulty circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Conditions for fault code The voltage on pin B34 on the EMS2 deviates from normal voltage value Possible reason e Short circuited coldstart valve signal cable to battery negative or to lower voltage e Faulty coldstart valve Suitable action 1 Check all cable and connectors between EMS2 and coldstart valve 2 Check coldstart valve FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Faulty circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Conditions for fault code The voltage on pin B34 on the EMS2 deviates from normal voltage value Possible reason Suitable action 47701632 10 2010 Open circuit in coldstart valve signal cable Open circuit in coldstart valve battery voltage cable Faulty coldstart valve Check all cable and connectors between EMS2 and coldstart valve Check contact pressure in socket 34 engine connector B Check coldstart valve 101 30 2 Fault Tracing P0013519 34 WO F 57 60 R BL lt 4 EMS2 P0013520 A Junction point B Cold start valve 102 Cable description In order to avoid boiling in the charge air coolers at different loads and coolant temperatures the system is
68. ID 201 Data link MID144 page 123 Gomez 18 200 47701632 10 2010 Alphabetical index About this Workshop manual Alternator fault racing eee eee eee Checking air inlet pressure sensotr Checking air inlet temperature sensor Checking air pressure switch eee Checking camshaft sensor eee eee Checking camshaft sensor Wing eee Checking CAN bus cable Checking coolant level Switch Checking coolant temperature sensor Checking crankcase pressure Seng Checking exhaust gas temperature sensor Checking flywheel Sensor Checking flywheel sensor Wing eee Checking fuel pressure Sensor Checking IEGR solenoid AAA Checking IEGR wiring Checking inlet manifold temperature sensot Checking negative cable air filter pressure Checking negative cable coldstart valve Checking negative cable coolant level switch Checking negative cable coolant temperature Checking negative cable exhaust gas temper ALLE SONS OM TTT Checking negative cable fuel sensor Checking negative cable inlet manifold pres sure temperature sensot ee Checking negative cable oil pressure sensor Checking negative cable oil temperature Checking negative cable piston cooling oil tem perature switch eee e Checking negative cable wastegate valve Checking negative cable water in fuel switch Checking oil level sensor eee Checking oil pressure sensor C
69. ID consists of anumber which designates the control unit that sent the fault code message e g the engine control unit PID Parameter Identification Description The PID consists of a number that designates a parameter value to which the fault code relates oil pressure for example PPID Proprietary PID The same as the PID but this is a Volvo specific parameter Malfunctions SID Subsystem Identification Description The SID consists of a number that designates a component to which the fault code relates tach ometer for example PSID Proprietary SID The same as the SID but this is a Volvo specific component FMI Failure Mode Identifier FMI indicates the type of fault please refer to the FMI table below SPN Suspect Parameter Number FMI table SAE standard Fui Displaytet ee 0 Value too high Data vaid but above normal operational range i 7 10 i E 14 SAE standard 2 Short circuit to battery voltage injector high voltage side Ea Short circuit to battery voltage injector low voltage side 4 Short circuit to battery negative injector low voltage or high voltage side 9 Open circuit in injector circuit 48 47701632 10 2010 30 0 General General advice NOTICE The following must be done before fault trac ing continues to avoid changing functional sensors If there is an active inactive fault code Remove the connector fro
70. P Switch Cable cross section 0 75 mm unless otherwise Sensor coolant temperature stated 1 Switch piston cooling Cable colors 2 Switch coolant level BL Blue P Pink BN Brown R Red 3 Sensor oil temperature and oil level GN Green SB Black 4 Switch water in fuel GR Gray VO Violet OR Orange W White 5 Sensor crankcase pressure LBL Light blue Y Yellow 6 7 8 9 Internal EGR 10 Extra stop 11 J1939 CAN bus 12 Battery negative 13 Battery plus 14 Voltage after key 15 Connection for stop button 16 J1587 1708 bus 17 Diagnostic outlet 18 Relay socket 19 Main relay 20 Main circuit breaker 10 A 21 Relay pre heating 22 Pre heating 23 Battery 24 V 24 Starter motor 25 Alternator 26 Unit injector Cyl 1 6 27 Sensor flywheel 28 Sensor camshaft 29 Sensor oil pressure 30 Sensor air inlet pressure temperature 31 Connector block B 32 Connector block A 33 Control unit EMS 2 47701632 10 2010 179 12 13 15 47 HL 47701632 10 2010
71. S2 provides the circuit with a reference voltage of 5 Volt The EMS2 measures the voltage drop over the thermistor via pin 18 and pin 31 on the EMS2 Pin 3 on the sensor is connected to bat tery negative via pin 18 on the EMS2 When the air into the filter is cold the thermistor resistance is high and the EMS2 senses a high voltage drop As the air into the filter warms up the resistance in the thermistor falls and the voltage drop across it falls Please refer to the table resistance temperature in this fault code chapter Measurements Checking signal cable air filter temperature switch page 145 Checking negative cable air filter temperature switch page 146 Checking the sensor cable for open circuit or shortcir cuit page 147 Checking air inlet temperature sensor page 148 81 30 2 Fault Tracing MID 128 PID 173 Exhaust gas temperature Conditions for fault code Exhaust temperature exceeds the set value of the engine protection param eter For parameters see the engine protection map Suitable action Check that the exhaust pipe has not been damaged and that there are no restrictions Check the sensor Check the exhaust back pressure FMI 4 Voltage below normal or shorted to lower voltage Possible reason e Short circuit between the sensor signal cable and the sensor negative cable e Faulty sensor Suitable action 1 Check the cable harness between the sensor and the EMS2 2 Check the se
72. The voltage on pin B16 on the EMS2 is less than 0 07 Volt Possible reason Open circuit in fuel sensor 5V supply cable Open circuit in fuel sensor signal cable Short circuited sensor signal cable to battery negative Faulty sensor Suitable action Check the cable harness between the fuel sensor and EMS2 Check the contact pressure in socket 16 and 17 in the engine connector B Check the sensor P0002552 A i Cable description R C The sensor is an active sensor i e the sensor must 17 41 receive operating voltage Pin 17 on the engine control 18 z unit EMS2 connector B provides pin 1 on the sensor with an operating voltage of 5 Volt Pin 4 on the sen 16 3 sor is connected to battery negative via pin 18 on the EMS2 The output signal from the pressure sensor pin EMS2 sl R BL 7 Some engines has a fuel bleeding pump The fuel 2 on the sensor to pin 16 on the EMS2 is a voltage signal that is proportional to the fuel pressure The out O a bleeding pump is used when the fuel system has to be 0013472 bled Connector B put signal is linear within the sensors working range L Fuel press switch Fuel pressure D O U gt Fuel bleeding pump 47701632 10 2010 53 30 2 Fault Tracing Utspanning V L 0 0 p0013477 54 100 200 300 400 500 600 700 Oljetryck kPa Component specification Working range 0 7 ba
73. U display CIU Flash code Flash code Electrical fault 7 1 7 6 Value fault None Symptom Faulty unit injector is shut off engine runs on 5 cylinders Limp home on rest of unit injectors Engine performance is reduced Abnormal sound NOTICE Identify which injector by the SID number Conditions for fault code Injector activated and cylinder balancing above limit If a fault code is set when the engine has an unsymmetrical load it can not be rectified At idle speed the engine control unit is trying to compensate for uneven running by adding more or less fuel to the injectors cylinder balanc ing If the engine load is too unsymmetrical the compensation is not enough and a fault code will be set Possible reason Unsymmetrical load of the engine Poor uneven compression Faulty injector Suitable action Clear the fault code with the Vodia tool Let the engine run at idle speed without any load and see if the faultcode reappear Perform test of cylinder compression using the VODIA tool Change only the faulty injector FMI 12 Faulty device or component Low unit injector hold current Fault code explanation Fault in the injection system Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 7 1 7 6 Value fault None Symptom Faulty unit injector is shut off engine runs on 5 cylinders Limp home on rest of unit injectors Engine performance is reduced Abnor
74. a Supply voltage 5 00 0 25 VDC Nominal output voltage at 25 C and at supply voltage 5 00 VDC 0 5 VDC 0 4 bar 40 kPa 4 5 VDC 1 4 bar 140 kPa Measurements Checking negative cable crankcase pressure sen sor page 174 Checking signal cable crankcase pressure sen sor page 174 Checking supply cable crankcase pressure sen sor page 175 Checking crankcase pressure sensor page 144 47701632 10 2010 30 2 Fault Tracing MID 128 PID 158 ECU battery potential FMI 1 Data valid but below operational range Fault code explanation Battery voltage too low Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault None EMS Value fault None EMS Electrical fault None CIU Value fault None CIU Symptom Could be engine starting problems Conditions for fault code Battery voltage less than 25 5 V engine running Possible reason e Altenator belt Flat poor batteries Fault in cables or connectors for battery altenator Faulty altenator Suitable action Check battery cables Check charge batteries Check altenator and drive belt 47701632 10 2010 79 30 2 Fault Tracing MID 128 PID 172 Inlet air temperature FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault
75. acing MID 128 PID 105 Intake manifold temperature FMI 0 Data valid but above normal operational range Fault code explanation Inlet manifold temperature is too high Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 2 Value fault 6 2 Symptom Engine is derated if the engine protection parameter is activated Conditions for fault code Inlet manifold temperature exceeds the set value of the engine protection parameter Possible reason Engine temperature is too high High surrounding temperature Faulty air inlet temperature sensor only on TAD1250 1252VE and TAD1350 1352GE Dust or dirt on the outside of the intercooler and the radiator Faulty inlet manifold temperature sensor Suitable action Check that the engine temperature is normal Check the air inlet temperature sensor only on TAD1250 1252VE and TAD1350 1352GE Clean the intercooler and the radiator Check the inlet manifold temperature sensor FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 2 Value fault 6 2 Conditions for fault code The voltage on pin A47 on the EMS2 is less than 0 07 Volt Possible reason e Short circuited sensor signal cable to battery negative e Faulty sensor Suitable action 1 Check the
76. al fault 9 3 Value fault None Conditions for fault code Abnormally high voltage or short circuit to higher voltage on pin A7 Possible reason Short circuit to battery voltage Suitable action 1 Check the supply voltage to the sensors which have set fault codes 2 Check sensor cables 3 Check the sensors FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Fault in circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 9 3 Value fault None Symptom None Conditions for fault code Abnormally low voltage or short circuit to battery negative on pin A7 Possible reason Short circuit sensor supply voltage cable to battery negative oil pres sure sensor Short circuit sensor supply voltage cable to battery negative air inlet pressure sensor Suitable action Check the supply voltage to the above mentioned sensors Check sensor cables Check the sensors Cable description Pin A7 on the EMS2 distributes 5 Volt supply voltage to the oil pressure sensor and the air inlet pressure sensor 118 47701632 10 2010 30 2 Fault Tracing MID 128 SID 240 Program memory FMI 2 Data erratic intermittent or incorrect FMI 7 Mechanical system not responding properly FMI 11 Unidentifiable error FMI 14 Special instructions Fault code explanation Communication fault Fault indication DCU Engine warning in DCU
77. arness between EMS2 and the CIU key switch 3 Check the function of the key switch FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Starter input failure Fault indication CIU Flashcode Flash code Electrical fault 4 7 EMS Value fault None EMS Electrical fault 5 2 CIU Value fault None iG Symptom The engine cannot be started The engine starts immediately when ignition is turned on Possible reason Short circuited ignition cable to battery negative e Faulty key swich Suitable action 1 Check that the key switch is connected correctly 2 Check cable harness between EMS2 and the CIU key switch 3 Check the function of the key switch 90 47701632 10 2010 30 2 Fault Tracing MID 128 PPID 6 Key off input sensor FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Fault indication Symptom Conditions for fault code Possible reason Suitable action 47701632 10 2010 Faulty circuit DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 4 8 EMS Value fault None EMS Electrical fault 5 3 CIU Value fault None CIU Engine can only be stopped using the auxiliary stop Engine can only be stopped using the auxiliary stop Short circuit between the engine stop signal in engine connector and battery negative 1 Check the stop signal cable between the engine control unit A27 and the CIU DCU
78. ask is to detect whether there is water in the fuel The EMS 2 senses the voltage drop between the pins B10 and B8 The pins are in contact with the fuel When there is no water in the fuel the voltage is 0 8 x battery voltage If there is any water in the fuel voltage will drop The sensor is connected via pin B10 on the engine control unit to battery negative Measurements Checking supply cable water in fuel switch page 129 Checking negative cable water in fuel switch page 130 Checking water in fuel switch page 130 47701632 10 2010 30 2 Fault Tracing MID 128 PID 98 Engine oil level FMI 1 Data valid but below operational range Fault code explanation Oil level too low Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 5 9 Value fault 5 7 Symptom Warning indication Suitable action 1 Check the oil level in the engine 2 Check that no oil leakage occurs 3 Check the oil level sensor FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Fault in sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 5 9 Value fault 5 7 Possible reason e Open circuit in the oil level sensor 5V supply cable e Faulty sensor Suitable action 1 Check the cable harness between the sensor and the EMS2 2 Check the contact pressure in socket 3 and 4 in the engine conne
79. ber Conditions for fault code Injector activated and faulty voltage in injector low side Possible reason e Short circuit to battery voltage on the pin on the respective injector s low voltage side EMS2 pin 36 40 44 48 52 56 and 12 16 20 24 28 32 e Short circuit between high voltage and low voltage sides e Short circuit to battery voltage in low voltage injector wire Suitable action 1 Check the cable harness between injectors and engine control unit EMS2 FMI 4 Voltage below normal or shorted to lower voltage Short to battery negative injector high voltage side Fault code explanation Fault in the injection system Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 7 1 7 6 Value fault None Symptom Faulty unit injector is shut off engine runs on 5 cylinders Limp home on rest of unit injectors Engine performance is reduced Abnormal sound NOTICE Identify which injector by the SID number Conditions for fault code Injector activated and faulty voltage in injector high side Possible reason e Short circuit to battery negative on the pin on the respective injector s high voltage side EMS2 pin 59 60 61 and 62 e Short circuit to battery negative in high voltage injector wire Suitable action 1 Check the cable harness between injectors and engine control unit EMS2 47701632 10 2010 103 30 2 Fault Tracing FMI 5 Current b
80. ble 9812519 Multimeter NOTICE Turn ignition off Disconnect the connector from the switch wo N Connect adapter cable 885675 to the cable har ness connector to the engine control unit A Use multimeter 9812519 for voltage measurement NOTICE Turn ignition on Ln Checking negative cable coolant level switch Tools 885675 Break out cable 9812519 Multimeter NOTICE Cut the current with the main switch Disconnect the connector from the switch wo N Connect adapter cable 885675 to the cable har ness connector to the engine control unit A Use multimeter 9812519 to do resistance meas urement against the engine control unit P0007224 47701632 10 2010 143 30 2 Fault Tracing Checking coolant level switch Tools 9812519 Multimeter NOTICE The coolant level switch can be removed without having to drain the coolant Undo the connector and remove the switch from the expansion tank N Use multimeter 9812519 to do resistance meas urement against the switch Measurement points Nominal value Blue Black zon 3 Move a magnet along the switch and observe the resistance value The resistance should drop to approx 0 Ohm Measurement points Nominal value Blue Black R 00 Checking crankcase pressure sensor P0007225 Tools iB 885675 Break out cable G 9812519 Multimeter e NOTICE Turn ignition off Disconnect the connector from the sensor N L
81. ble exhaust gas temperature sensor Tools 9812519 Multimeter 1 NOTICE Turn ignition off 2 Remove the connector from the sensor 3 Use multimeter 9812519 for voltage measurement 4 NOTICE Turn ignition on 47701632 10 2010 P0007232 P0007233 Q 900 800 700 600 500 400 300 200 100 0 0 250 500 750 1000 P0007234 C 47701632 10 2010 30 2 Fault Tracing Checking negative cable exhaust gas temperature sensor Tools 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the sensor Use multimeter 9812519 to do resistance meas urement against the engine control unit Checking exhaust gas temperature sensor Tools 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Remove the connector from the sensor and remove the sensor from exhaust bend to check that the sensor has no visible damage 3 Use multimeter 9812519 to measure resistance between the two contact pins on the sensor The resistance shall agree with the values in the chart Measurement Nominal Nominal voltage value points resistance value measured over the sensor U 1 08 V at 100 C U 1 19 V at 150 C U 1 29 V at 200 C U 1 39 V at 250 C at 250 C 149 30 2 Fault Tracing 150 temperature switch Tools R 420 O at 300 C R 454 O at 350 C R 488 Q at 400 C R 5210 at 450 C
82. bles to the cam speed sensor is shifted Intermittent fault Incorrectly mounted cam speed sensor Suitable action Check the cable harness between the cam speed sensor and EMS2 Check that the cam speed sensor is connected as in the circuit descrip tion Check the cam speed sensor FMI 3 Voltage above normal or shorted high No signal Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 5 Value fault None Symptom The engine start time will increase uses only crankshaft sensor Conditions for fault code No camsignal when expected Possible reason e Incorrectly mounted cam speed sensor Open circuit in any or both of the cables to the crank speed sensor Short circuit between the cables to the cam speed sensor Faulty cam speed sensor Suitable action Check the installation of the cam speed sensor Check the cable harness between the cam speed sensor and EMS2 Check the cam speed sensor Check the contact pressure in socket 45 and 46 in engine connector A 47701632 10 2010 107 30 2 Fault Tracing FMI 8 Abnormal frequency pulse width or period Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 5 Value fault None Symptom The engine start time will increase u
83. cable harness between the inlet manifold temperature sen sor and EMS2 2 Check the sensor 62 47701632 10 2010 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 2 Value fault 6 2 Conditions for fault code The voltage on pin A47 on the EMS2 is more than 4 95 Volt Possible reason e Open circuit in inlet manifold temperature signal cable e Faulty sensor Suitable action 1 Check the cable harness between the inlet manifold temperature sen sor and EMS2 2 Check the contact pressure in socket 47 in engine connector A 3 Check the sensor e RD P0007173 Cable description The inlet manifold temperature sensor consists of a thermistor which forms a closed circuit with an internal resistor in the engine control unit EMS2 The ther mistor resistor changes in a non linear manner depending on the inlet manifold temperature The EMS2 EMS2 provides the circuit with a reference voltage of 0007209 5 Volt The EMS2 measures the voltage drop over the thermistor via pin 47 and pin 11 on the EMS2 Pin 1 on a Connector A the sensor is connected to battery negative via pin 11 on the EMS2 When the inlet manifold air is cold the thermistor resistance is high and the EMS2 senses a high voltage drop As the i
84. cal fault 3 6 Value fault 3 8 Symptom Conditions for fault code The fuel pressure alarm depends on the engine revolution Suitable action Check the fuel level Open all fuel cocks and check that no leakage occurs Change all fuel filters pre and fine filter Check that no fuel hose is squeezed or folded Check the fuel sensor by control measuring the fuel pressure see workshop manual Remove and clean the pressure release valve in the fuel feed pump FMI 3 Voltage above normal or shorted high Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 6 Value fault 3 8 Symptom Conditions for fault code The E on pin B16 on the EMS2 is more than 4 77 Volt Possible reason Suitable action 52 Open circuit in the sensors negative cable Short circuited fuel sensor signal cable to 5V voltage or to battery volt age Faulty sensor Check the cable harness between the fuel sensor and EMS2 Check the contact pressure in socket 18 in the engine connector B Check the sensor 47701632 10 2010 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 6 Value fault 3 8 Symptom Conditions for fault code
85. ch 2 Connect adapter cable 885675 to the sensor Do not connect the other end of the adapter cable 3 Use multimeter 9812519 to do resistance meas urement 1 2 R 9397 O 755 Q at 10 C 1 2 R 5896 0 430 Q at 0 C 1 2 R 2500 Q 148 Q at 20 C R 1175Q 56 Q at 40 C R 596 0 22 Q at 60 C R 323 0 10 Q at 80 C R 186 0 5 Q at 100 C 141 30 2 Fault Tracing P0004936 142 DOOD UDO Checking the sensor cable for open circuit or shortcircuit Coolant temperature sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Remove connector B from the engine control unit Use multimeter 9812519 to do a resistance meas urement against the engine control unit connector B Measurement points 2 885675 27 EMS2 conn B 2 885675 18 EMS2 conn B zon lt 1 885675 27 EMS2 conn B 1 885675 18 EMS2 conn B NOTICE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit IMPORTANT Be very careful when measuring inside the connector to ensure that no pin is damaged 47701632 10 2010 30 2 Fault Tracing Checking supply cable coolant level switch Tools 885675 Break out ca
86. cing Checking flywheel sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Undo the connector from the sensor and remove the sensor from the cylinder head Check that the sensor does not have any external damage or any swarf which has got stuck on it 3 Connect adapter cable 885675 to sensor NOTICE Do not connect the other end of the adapter cable to the engine cable harness since this can cause a measurement error 4 Use multimeter 9812519 for resistance measure ment 5 Use multimeter 9812519 for a AC voltage meas urement Move a metal object rapidly back and forwards not more than 1 mm in front of the sensor Check that the multimeter gives a reading 6 Install the sensor P0008931 47701632 10 2010 167 30 2 Fault Tracing Checking negative cable wastegate valve Tools 88890053 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the wastegate reg ulator 1 3 Connect adapter cable 88890053 to the cable har ness connector to the engine control unit 4 Use multimeter 9812519 to do resistance meas urement against the engine control unit aa 88890053 P0013530 PS 168 47701632 10 2010 30 2 Fault Tracing Checking supply cable wastegate valve Tools 88890053 Break out cable 9812519 Multimeter 1 NOTICE Turn ignition off 2 Remove the connector from th
87. ck that no engine oil leakage occurs Check the sensor by control measuring the engine FMI 3 Voltage above normal or shorted high Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 1 Value fault 6 6 Conditions for fault code The voltage on pin B11 on the EMS2 is more than 4 77 Volt Possible reason Open circuit in the sensors negative cable Short circuit between signal cable and 5V supply to oil pressure sensor Faulty sensor Suitable action Check the cable harness between the oil pressure sensor and EMS2 Check the contact pressure in socket 11 in the engine connector B Check the sensor 47701632 10 2010 59 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 1 Value fault 6 6 Conditions for fault code The voltage on pin B11 on the EMS2 is less than 0 07 Volt Possible reason Open circuit in 5V supply cable to oil pressure sensor Open circuit in signal cable to oil pressure sensor Short circuit between signal cable and battery negative to oil pressure sensor Short circuit between the sensor 5V supply cable and the sensor neg ative cable Faulty sensor Suitable action Check the cable harness bet
88. ction Check the cable harness between the boost pressure sensor and EMS2 Check the contact pressure in socket 7 and 22 in engine connector A Check the sensor P0007173 Cable description The sensor is an active sensor i e the sensor must receive operating voltage The air inlet pessure sensor measures the absolute pressure which is the sum of the air inlet pressure and atmospheric pressure 300 BN OR 47 kPa thus corresponds to a boost pressure of 200 kPa EMS2 when atmospheric pressure is 100 kPa P0007209 Pin 7 on the engine control unit EMS2 connector A provides pin 3 on the sensor with an operating voltage of 5 Volt Pin 1 on the sensor is connected to battery negative via pin 11 on the EMS2 The output signal from the pressure sensor pin 4 on the sensor to pin 22 on the EMS2 is a voltage signal that is proportional to the air inlet pressure The output signal is linear within the sensors working range a Connector A b Intake manifold temperature 47701632 10 2010 65 30 2 Fault Tracing o A ON 1 0 50 P0013490 66 100 200 300 400 Component specification Working range 0 5 4 0 bar 50 400 kPa Supply voltage 5 00 0 25 VDC Nominal output voltage at 25 C and at supply voltage 5 00 VDC 0 5 VDC 0 5 bar 50 kPa 4 5 VDC 4 bar 400 kPa Measurements Checking supply cable inlet manifold pressure sen sor page 138
89. ctly Check cable harness between EMS2 and the CIU key switch Check the function of the key switch Faulty start button on the DCU FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Starter output failure Fault indication EMS Flashcode Flash code Electrical fault 4 6 Value fault None Symptom The engine cannot be started The engine starts immediately when ignition is turned on Preconditions General check for starter motor problems e Check the starter motor cables and the connections e Check that the starter relay pull during the start attempt Conditions for fault code The voltage on pin B29 in the engine control unit is less than normal voltage Possible reason e Short circuited ignition cable to battery negative e Faulty key switch Suitable action Check the ignition cable Check that the key switch is connected correctly Check cable harness between EMS2 and the CIU key switch Check the function of the key switch 88 47701632 10 2010 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault indication EMS Flashcode Flash code Electrical fault 4 6 Value fault None Symptom The engine cannot be started The engine starts immediately when ignition is turned on Preconditions General check for starter motor problems e Check the starter motor cables and the connections e Check that the starter relay pull during the start attempt
90. ctor B 3 Check the sensor P0007203 47701632 10 2010 57 30 2 Fault Tracing EMS2 P0008588 a b C 58 Connector A Connector B Oil temperature and level Cable description The oil temperature and the oil level sensor is a com bined sensor The oil level sensor pin1 is fed a current pulse of approx 250mA during approx 600ms and the voltage output will be sampled three times during this time To obtain the oil level the oil temperature has to be used as a reference due to that the oil level output voltage will alter depending on the oil temperature Measurements Checking oil level sensor page 131 47701632 10 2010 30 2 Fault Tracing MID 128 PID 100 Engine oil pressure FMI 1 Data valid but below operational range Fault code explanation Oil pressure is too low Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 1 Value fault 6 6 Symptom Power is reduced due to error torque map if the engine protection parameter is activated Conditions for fault code Oil pressure depends on the engine revolution Oil pressure exceeds the set value of the engine protection parameter Possible reason Too low engine oil level Blocked oil filter Oil leakage Faulty oil pressure sensor Suitable action Check the engine oil level and the quality of the oil Change engine oil and oil filter to prevent blocked oil filter Che
91. current with the main switch N Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit A Use multimeter 9812519 to do resistance meas urement against the engine control unit 47701632 10 2010 135 30 2 Fault Tracing Checking the sensor cable for open circuit or shortcircuit Inlet manifold temperature sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit Remove connector A from the engine control unit Use multimeter 9812519 to do a resistance meas urement against engine control unit connector A Measurement points 2 885675 47 EMS2 conn A 2 885675 11 EMS2 conn A 1 885675 47 EMS2 conn A 1 885675 11 EMS2 conn A NOTICE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit IMPORTANT Be very careful when measuring inside the connector to ensure that no pin is damaged OOOOOOOoOoOoOoOoOoOoOoOnN OOOOoOoOoOoOoOoOoOoOoOoOoOon P0013485 136 47701632 10 2010 30 2 Fault Tracing Checking inlet manifold temperature sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Connect adap
92. d level 47701632 10 2010 85 30 2 Fault Tracing 86 Measurements Checking negative cable oil temperature switch page 150 Checking signal cable oil temperature switch page 151 Checking oil temperature sensor page 152 47701632 10 2010 30 2 Fault Tracing MID 128 PID 190 Engine speed FMI 0 Data valid but above normal operational range Fault code explanation Engine is was overspeeding Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault None Value fault 2 6 Symptom Engine speed limited Possible reason Too high engine speed Suitable action 1 After the engine has stopped search for the reason for the high speed 47701632 10 2010 87 30 2 Fault Tracing MID 128 PPID 3 Starter Output FMI 3 Voltage above normal or shorted high Fault code explanation Starter output failure Fault indication EMS Flashcode Flash code Electrical fault 4 6 Value fault None Symptom The engine cannot be started The engine starts immediately when ignition is turned on Preconditions General check for starter motor problems Check the starter motor cables and the connections Check that the starter relay pull during the start attempt Possible reason Short circuited ignition cable to 5V voltage or to battery voltage Ignition signal activated too long Faulty start button key switch Suitable action Check that the key switch is connected corre
93. e ec Te Connect adapter cable 885675 between the sensor and the engine control unit A Use multimeter 9812519 for voltage measurement Wu Turn ignition on Measurement points Nominal value 2 4 U 2 9 V at normal atmospheric pressure 885 675 P0001265 144 47701632 10 2010 G Son 47701632 10 2010 30 2 Fault Tracing Checking signal cable air filter temperature switch Tools 885675 Break out cable 9812519 Multimeter NOTICE Turn ignition off Disconnect the connector from the sensor w N Connect adapter cable 885675 to the cable har ness connector to the engine control unit A Use multimeter 9812519 for voltage measurement NOTICE Turn ignition on oa ch Turn ignition off N Connect adapter cable 885675 between the sensor and the engine control unit oO Turn ignition on Measurement points Nominal value 3 4 U 0 5 4 5 V depended of the temperature 145 30 2 Fault Tracing Checking negative cable air filter temperature switch Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the sensor 3 Connect adapter cable 885675 to the cable har ness connector to the engine control unit 4 Use multimeter 9812519 to do resistance meas urement against the engine control unit 146 47701632 10 2010 P0013502 47701632 10 2010 DOOD
94. e Short circuited IEGR signal cable to battery negative Suitable action 1 Check cable harness between EMS2 and the IEGR 94 47701632 10 2010 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 8 5 Value fault None Symptom IEGR can not be turned on If the IEGR function would fail not being acti vated the result will be an increased exhaust production with high NOX and possible over speeding of the turbocharger Open circuit in one or both of the cables to the IEGR Suitable action Check cable harness between EMS2 and the IEGR Check the contact pressure in socket 30 57 and 60 in the engine con nector B Check the IEGR coil FMI 7 Mechanical system not responding properly Fault code explanation Mechanical fault Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 8 5 Value fault None Symptom IEGR can not be turned on If the IEGR function would fail not being acti vated the result will be an increased exhaust production with high NOX and possible over speeding of the turbocharger Possible reason e IEGR solenoid mechanically stucked e Too low oil pressure to activate the IEGR Suitable action 1 Check the function of the IEGR solenoid 2 Check the engine oil pressure
95. e engine s fuel requirement is analyzed up to 100 times per second depending on engine rpm The amount of fuel injected into the engine and the injection timing are electronically controlled via the unit injec tor s solenoid controlled fuel valves This means that the engine always receives the correct volume of fuel in all operating conditions which offers lower fuel con sumption minimal exhaust emissions etc Speed sensor crankshaft The sensor is located in the left side of the flywheel housing The flywheel speed sensor is of the inductive type It reads off the crankshaft position and speed from grooves in the flywheel The signal is sent to the control unit which calculates injection timing and fuel quantity Speed sensor camshaft The position sensor is located in the upper timing gear cover The camshaft position sensor is of the inductive sensor type The sensor reads off a cogged wheel with 7 cogs The impulses from the camshaft sensor give the control unit information about which cylinder is in turn for injection and when it is performed 47701632 10 2010 P0007173 p0001348 E FQ X P0013515 P0002878 47701632 10 2010 30 0 General Air inlet pressure inlet manifold temperature sensor The air inlet pressure and intake manifold temperature are measured via a combined sensor positioned on the inlet pipe The air inlet pressure sensor measures absolute pres sure which is the sum
96. e reason Fault in the communication with the DCU CIU No DCU CIU found Open circuit in the power supply cable between the engine control unit and the DCU CIU Faulty DCU CIU Suitable action Check the communication cables to the DCU CIU Check the power supply cable between the engine control unit and the DCU CIU Check that the DCU CIU is programmed for the correct engine type 98 47701632 10 2010 30 2 Fault Tracing MID 128 144 PPID 132 Throttle calibrated position FMI 3 Voltage above normal or shorted high Fault code explanation Faulty throttle potentiometer Faulty throttle potentiometer circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 8 Value fault None Symptom Engine goes to idle If the accelerator is released at first and then pressed down again the engine can be forced to run using the idle contact Preconditions NOTICE If the control panel ONLY communicates on the J1939 communi cation and NOT the redundancy of J1587 for start stop and throttle this fault code is active in the VODIA and that is normal Possible reason Open circuit in any or all of the throttle signals Short circuited throttle potentiometer signal cable to 5V voltage or to battery voltage Faulty sensor Suitable action Check that the throttle potentiometer is connected correctly Check cable harness between CIU and the CIU throttle potentiometer Check
97. e resistance of the CAN bus termination resistors one 120 Q resistor in the ECU and one 120 Q resistor in the cable harness are measured NOTICE Cut the current with the main switch N Disconnect the 8 pin Deutsch connector at the DCU or disconnect at the CIU Connect measurebox 9998699 with adaptercable 88890016 between the engine control unit and the DCU Use multimeter 9812519 to do resistance meas urement towards the EMS 2 16 17 U 60Q oO A P0013535 47701632 10 2010 171 30 2 Fault Tracing Cs or 29 15 1 E 909 in the CIU connector 338 Q Q Q 688 NOTICE Even if the measured value equals the nom S Ze inal value the data bus cable could be faulty due to 8 S g short circuit between a data bus cable and another cable in the harness P0013536 1 Connect adapter cable 88890016 with measurebox 9998699 between the EMS 2 and the CIU DCU 2 Use multimeter 9812519 to a voltage measure ment Measurement points Nominal value in the measurebox 16 CAN H U 2 3V 27V 18 power supply OV 17 CAN L U 2 3V 27V 18 power supply OV NOTICE Even if the measured value equals the nom inal value the data bus cable could be faulty due to short circuit between a data bus cable and another cable in the harness P0013537 172 47701632 10 2010 47701632 10 2010 30 2 Fault Tracing Checking the CAN bus cable Tools 9812519 Multimeter 88890016
98. e wastegate regula tor 3 Connect adapter cable 88890053 between the wastegate regulator and engine control unit Use multimeter 9812519 for voltage measurement NOTICE Turn ignition on 47701632 10 2010 169 30 2 Fault Tracing Checking the wastegate valve Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Remove the connector from the wastegate valve Connect adapter cable 885675 to the valve NOTICE Do not connect the other end of the adapter cable to the engine cable harness since this can cause a measurement error 3 Use multimeter 9812519 to check the resistance in the wastegate valve NOTICE Measurement is done to eliminate short circuiting or breaks in the wastegate valve Measurement points Nominal value 1 2 R 90 450 at 20 C 68 F 170 47701632 10 2010 30 2 Fault Tracing Checking preheater relay Tools 9990014 Break out cable 9812519 Multimeter NOTICE Turn ignition off Remove connector B from the EMS2 N Connect adapter cable 9990014 between connec tor B and engine control unit Use multimeter 9812519 for voltage measurement NOTICE Turn ignition on B7 B59 U 0V If there is an open circuit in the sense wiring circuit the multimeter will show Measurement points Fault value B7 B59 U 19 5 V Checking CAN bus cable Tools 9998699 Break out box 88890016 Break out cable 9812519 Multimeter Th
99. e when mixed with air in the correct proportions No Smoking Ensure that the work area is well ventilated and take the necessary safety precautions before welding or grinding work is begun Always ensure that there are fire extinguishers close at hand in the work area Batteries must never be exposed to open flames or electric sparks Never smoke in the vicinity of the batteries they generate hydrogen gas when charged which is explosive when mixed with air This gas is easily ignited and highly explosive A spark which can be caused by incorrect battery connection is sufficient to cause a battery to explode and cause damage Do not touch the connections during start attempts Sparking hazard Do not lean over batteries Never transpose the positive and negative battery posts when installing batteries Such a transposition can result in serious damage to electrical equipment Refer to the wiring dia gram Always use protective goggles when charging and handling the batteries Battery electrolyte contains sulfuric acid which is highly corrosive Should the battery electrolyte come into contact with unprotected skin wash it off immediately using soap and copious amounts of water If you get battery acid in your eyes flush at once with copious amounts of water and seek medical assistance immediately 47701632 10 2010 A 05 1 Safety Instructions Never start the engine with the valve cover removed There is a risk of
100. ed to battery negative via pin 18 on the EMS2 When the coolant is cold the thermistor resistance is high and the EMS2 senses a high voltage drop As the coolant warms up the resistance in the thermistor falls and the voltage drop across it falls Please refer to the table resistance temperature in this fault code chapter Measurements Checking signal cable coolant temperature switch page 155 Checking negative cable coolant temperature switch page 156 Checking coolant temperature sensor page 141 Checking the sensor cable for open circuit or shortcir cuit page 142 73 30 2 Fault Tracing MID 128 PID 111 Coolant level FMI 1 Data valid but above normal operational range Fault code explanation Coolant level is too low Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 3 Value fault 2 2 Symptom Engine is derated if the engine protection parameter is activated Suitable action Check the coolant level Bleed the coolant water system If low coolant level check the coolant water system for leakage by a pressure test Check the pressure valve in the coolant cup Check the wiring to the coolant level switch Check the coolant level switch FMI 3 Voltage above normal or shorted high Fault code explanation Faulty switch Faulty switch circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical
101. elow normal or open circuit Break in injector circuit Fault code explanation Fault in the injection system Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 7 1 7 6 Value fault None Symptom Faulty unit injector is shut off engine runs on 5 cylinders Limp home on rest of unit injectors Engine performance is reduced Abnormal sound NOTICE Identify which injector by the SID number Conditions for fault code Injector activated and faulty voltage in injector high or low side Possible reason Open circuit in low voltage wiring side or high voltage wiring side If three injection fault codes are set there is an Open circuit on the high side If one injection fault code is set there is an Open circuit on the low side Short circuit to battery voltage on the pin on the respective injector s high voltage side EMS2 pin 59 60 61 and 62 Short circuit to battery negative on the pin on the respective injector s low voltage side EMS2 pin 36 40 44 48 52 56 and 12 16 20 24 28 32 Suitable action Check the cable harness between injectors and engine control unit EMS2 Check the contact pressure in all sockets regarding the unit injectors in engine connector A 104 47701632 10 2010 30 2 Fault Tracing FMI 7 Mechanical system not responding properly Fault code explanation Fault in the injection system Fault indication DCU Engine warning in DC
102. emperature The resistance increases with rising exhaust temperature 47701632 10 2010 P0004033 P0013519 P0013963 47701632 10 2010 30 0 General Switch coolant level The switch is located in the expansion tank It s purpose is to detect if the coolant level in the cooling system expansion tank becomes too low The switch is a magnetically sensitive switch A float located around the switch affects the switch differently depend ing on the coolant level A alarm signal is sent when the coolant level is too low Cold start valve In order to avoid boiling in the charge air coolers at different loads and coolant temperatures the system is fitted with a cold start valve that is controlled by the EMS2 The cold start valve is normally open i e without voltage supply the valve is open Preheat relay In cold climate the intake air might need to be pre heated This is done by the preheater located on the intake manifold The preheater is controlled by the EMS2 via the pre heat relay 33 30 0 General P0007254 TAD950 952VE TAD1350 1355GE TWD1643GE TAD1250 1252VE P0002859 34 Control unit EMS 2 The control unit checks and controls the unit injectors so that the correct amount of fuel is injected into each cylinder It calculates and sets the injection angle The control is primarily performed using the speed sensors and the combined sensor for boost pressure boost
103. ent 2 Connect the probes between one of the slip rings and the stator body The multimeter should indicate OL otherwise the rotor has a short circuit P0008367 Manual fault tracing in bus cables Tools 9812519 Multimeter IMPORTANT Cut the current with the main switch before the cables are disconnected Use the multimeter to check the bus cables The con ductors in the bus cables should not be in contact with each other Disconnect a bus cable at each end and measure the resistance between the pins to check this The multi meter should show infinite resistance between each pin If the resistance is less than infinite there is a fault Measuring the engine cables Two types of measurements are done on the engine cable harness both resistance measurement and volt age measurement The measurements are done to ensure that no open circuits or short circuits occur If there is an open circuit the resistance is infinite and if there is a short circuit it is close to zero The resist ance values given in the workshop manual are approx imate and should be regarded as guidelines NOTICE When resistance measurement is done the engine should be stopped and system voltage should be cut off with the main switch All resistance measurement is done at 20 C 68 F and with a cold engine 47701632 10 2010 47 30 0 General Fault code information D MID Message Identification Description The M
104. er at regulated voltage output depends on the alternator revolution When the engine is started an excitation current is needed to wake up the alternator NOTICE It is the consumers batteries included which decides the output current from the alternator Measurements 1 Engine off 2 Use 9812519 Multimeter to do a voltage meas urement over the battery The nominal voltage over a full loaded battery is approx 25 4 V Engine on Run at 1500 rpm 4 Use 9812519 Multimeter to do a voltage meas urement over the battery and also over the alter nator The nominal charging voltage over the battery should be approx 27 8 28 6 V 47701632 10 2010 30 0 General Checking the charging system Tools 9812519 Multimeter Fault tracing charging system Battery check 1 Check that all connectors at the battery are cor rectly assembled 2 Check the condition of the cables to the bat tery Look for oxidation 3 Check the water level in the battery 4 Check if possible the specific gravity of all cells when no charge 1 Check the alternator belt tension 2 Check that all connectors at the alternator and at the battery are correctly assembled 3 Check the condition of all cables in the charging system 4 Regulator fault Replace regulator when undercharge 1 Check the alternator belt tension 2 Check that all connectors at the alternator and at the battery are correctly assembled 3 Check the condition of
105. etric pressure FMI 2 Data erratic intermittent or incorrect Fault code explanation Plausibility Fault indication DCU None CIU None Flash code Electrical fault None Value fault None Conditions for fault code Internal fault in the engine control unit Suitable action 1 Replace the engine control unit EMS 2 FMI 3 Voltage above normal or shorted high Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU None CIU None Flash code Electrical fault None Value fault None Symptom Ambient pressure is set to 1 0 bar Conditions for fault code Internal fault in the engine control unit Suitable action 1 Replace the engine control unit EMS 2 FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU None CIU None Flash code Electrical fault None Value fault None Symptom Ambient pressure is set to 1 0 bar Conditions for fault code Internal fault in the engine control unit Suitable action 1 Replace the engine control unit EMS 2 70 Cable description Sensor is placed inside the engine control unit 47701632 10 2010 30 2 Fault Tracing MID 128 PID 110 Engine coolant temperature FMI 0 Data valid but above normal operational range Fault code explanation Coolant temperature too high Fault indication DCU Engine warning in DCU di
106. f which has got stuck on it 3 Connect adapter cable 885675 to sensor NOTICE Do not connect the other end of the adapter cable to the engine cable harness since this can cause a measurement error 4 Use multimeter 9812519 for resistance measure ment 5 Use multimeter 9812519 for a AC voltage meas urement Move a metal object rapidly back and forwards not more than 1 mm in front of the sensor Check that the multimeter gives a reading 885_675 6 Install the sensor P0008931 47701632 10 2010 165 30 2 Fault Tracing Checking flywheel sensor wiring Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Remove the connector from the sensor Connect adapter cable 885675 to the connector Remove connector A from the EMS2 Use multimeter 9812519 to do a resistance meas urement from the sensor connector to connector A to verify that neither of the wires are broken or short circuited Measurement points Nominal value 1 sensor conn 38 conn A 2 sensor conn 37 conn A 1 sensor conn 2 sensor conn 00 OU N IMPORTANT Be very careful when measuring inside the connector to ensure that no pin is damaged EEE E TE Vee DOC Iesele ele fesleslesles les les les Les les les fe esleslesleslesfesleslesles les less leslesleslenl DOG P0013527 166 47701632 10 2010 30 2 Fault Tra
107. fitted with a cold start valve that is controlled by the EMS2 The cold start valve is normally open i e without voltage supply the valve is open The cold start valve is supplied with battery voltage at pin 4 Pin 1 is con nected to pin B34 at the EMS2 When the cold start valve is activated valve closes pin B34 alter its voltage potential from battery voltage to approx 0 2 Volt If the intake manifold temperature signal or the coolant temperature signal is lost the cold start valve opens Under normal conditions the cold start valve is opened at intake manifold temperature gt 50 AND coolant water temperature lt 86 Under normal conditions the cold start valve is closed at intake manifold temperature lt 45 OR coolant water temperature gt 92 Measurements Checking supply cable coldstart valve page 159 Checking negative cable coldstart valve page 160 47701632 10 2010 30 2 Fault Tracing MID 128 SID 1 2 3 4 5 6 Injector 1 6 FMI 3 Voltage above normal or shorted high Short to battery voltage injector low voltag side Fault code explanation Fault in the injection system Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 7 1 7 6 Value fault None Symptom Faulty unit injector is shut off engine runs on 5 cylinders Limp home on rest of unit injectors Engine performance is reduced Abnormal sound NOTICE Identify which injector by the SID num
108. function to the product or property NOTICE Is used to draw your attention to important information that will facilitate the work or operation in progress This symbol is used on our products in certain cases and refers to important information in the instruction book Make sure that warning and information symbols on the engine are clearly visible and legible Replace symbols which have been damaged or painted over A compilation of safety precautions that must be taken and risks which must be paid attention to is presented in the following pages 47701632 10 2010 11 05 1 Safety Instructions 12 Immobilize the engine by turning off the power supply to the engine at the main switch switches and lock it them in the off position before starting work Post a warning notice at the main circuit breaker As arule all service operations must be carried out with the engine stopped However some work such as adjustments will require the engine to be running Approaching an engine which is running is a safety risk Bear in mind that loose clothing or long hair can fasten in rotating parts and cause serious personal injury Be aware of hot surfaces exhaust pipes tur bos charge air pipes starting heaters etc and hot fluids in pipes and hoses on an engine that is running or has just stopped If work is done adjacent to a running engine a careless movement or a dropped tool may in the worst case lead to personal injury
109. g VODIA will guide you through the entire programming process 9 NOTICE Programming must be reported back to Volvo Penta within 28 days Log in to Volvo Penta Partner Network s web site www vppn com 10 Choose VODIA in the left hand menu CE CaF 11 Choose Report software in the left hand menu 12 Follow the instructions for Report software parameter Click Report software parameter P0005180 1 PDA Personal Digital Assistant palmtop computer 38 47701632 10 2010 P0006430 47701632 10 2010 30 0 General Programming an empty control unit When a new engine control unit is installed where no software has been downloaded the control unit must be programmed The new control unit must have the same part number as the old control unit If the control units do not have the same part number it will not be possible to program the new control unit until a Conversion kit has been ordered from Volvo Penta If the control units have the same part number the new control unit can be programmed as usual Please refer to Reprogramming a control unit page 38 If the part numbers do not coincide proceed as pos sible 1 Have both part numbers available 2 Log in to Volvo Penta Partner Network s web site www vppn com Choose VODIA in the left hand menu 4 Choose Conversion kit in the left hand menu A new page Conversion kit Accessory kit
110. h cables to the coolant temperature sensor e Faulty sensor Suitable action 1 Check the cable harness between coolant temperature sensor and EMS2 2 Check the sensor FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 3 Value fault 6 1 Conditions for fault code The voltage on pin B27 on the EMS2 is more than 4 95 Volt Possible reason Open circuit in signal cable to temperature sensor Open circuit in negative cable to temperature sensor Faulty sensor Suitable action Check the cable harness between coolant temperature sensor and EMS2 Check the contact pressure in socket 18 and 27 in the engine connector B Check the sensor P0002859 TAD1250 1252VE TAD950 952VE TWD1643GE 72 47701632 10 2010 EMS2 P0007217 a Coolant temperature b Connector B 47701632 10 2010 30 2 Fault Tracing Cable description The coolant temperature sensor consists of a thermis tor which forms a closed circuit with an internal resistor in the engine control unit EMS2 The thermistor resis tor changes in a non linear manner depending on the coolant temperature The EMS2 provides the circuit with a reference voltage of 5 Volt The EMS2 meas ures the voltage drop over the thermistor via pin 27 and pin 18 on the EMS2 Pin 1 on the sensor is connect
111. he connector in the reverse order to disassembly 8 Install the connector in the reverse order to disas sembly 9 Check that the connector and the mating connector on the engine control unit or power supply unit are clean and dry 47701632 10 2010 30 0 General 10 Join up the multi pin connector Please refer to Engine Control Unit ECU Replace page 37 for advice on joining up the connector 11 Start the engine and check carefully that no fault codes occur 47701632 10 2010 43 30 0 General Checking the starter motor voltage Tools 9812519 Multimeter General If battery voltage falls below 24 7 V the starter motor will not be able to crank the engine at normal speed A fully charged battery has an open circuit voltage of about 25 4 V NOTICE Measured on the batteries Voltage measurement check 1 Check that the battery voltage is at least 24 7 V when unloaded by using 9812519 Multimeter to measure between the battery poles Turn the main switch on Check that the voltage between terminal B on the starter motor and battery negatives connection point is the same as the battery voltage P0008397 44 47701632 10 2010 Generally about alternators The voltage output from an alternator must be limited to prevent the elecrolyte in the battery to evaporate The alternator output is regulated limited by the volt age regulator in the alternator The maximum current that the alternator can deliv
112. hecking oil temperature sensor eee Checking preheater relay Checking signal cable voltage inlet manifold pressure temperature Sengar eee Checking signal cable air filter temperature Checking signal cable exhaust gas tempera TUE SENSO ie och Settee Ee dee Checking signal cable inlet manifold pressure 47701632 10 2010 Checking signal cable oil temperature switch 151 Checking starter motor relay 153 Checking stop signal cable between ECU and CID GW E 154 Checking supply cable air filter pressure switch 139 Checking supply cable coldstart valve 159 Checking supply cable coolant level switch 143 Checking supply cable crankcase pressure GET 175 Checking supply cable fuel sensor 125 Checking supply cable inlet manifold pressure SONS OMA een dee EE SEN 138 Checking supply cable oil pressure sensor 132 Checking supply cable piston cooling oil tem perature switch e a aaa A 157 Checking supply cable wastegate valve 169 Checking supply cable water in fuel switch 129 Checking the CAN bus cable 173 Checking the charging system 45 Checking the IEGR co 157 Checking the injector wiring 162 Checking the sensor cable for open circuit or shorteirc it aaa ar a 136 142 147 Checking the signal cable for interruption or SHOrCIrCUIt ieri ae ea eT nda 70272 aaea eil 127 Checking the starter motor voltage 44 Checking the wastegate valve eee e 170 Checking the wir
113. hop using working methods and tools tried and tested by us The service manual describes work operations car ried out with the aid of Volvo Penta Special Tools where such have been developed Volvo Penta Spe cial Tools are designed to ensure the safest and most rational working methods possible It is therefore the responsibility of anyone using tools or working meth ods other than those we recommend to ensure that no risk of personal injury or mechanical damage is present or that malfunction can result In some cases special safety regulations and user instructions may be in force for the tools and chemi cals mentioned in the Service Manual These regu lations must always be followed and no special instructions regarding this are to be found in the Serv ice Manual By taking these basic precautions and using common sense it will be possible to guard against most ele ments of risk A clean workplace and a clean product will eliminate many risks of personal injury and mal function Above all when working on fuel systems hydraulic systems lubrication systems turbochargers inlet systems bearings and seals it is of the utmost impor tance that dirt and foreign objects are kept away as malfunctions or shortened service intervals may oth erwise result 47701632 10 2010 00 0 General Repair instructions Our mutual responsibility Each product comprises a large number of interacting systems and components A deviat
114. ing sssssesee ee sesee eers ereer eenn 125 Checking water in fuel Switch 130 Component description 29 Component location sse eee eee eee e 21 Design and Function sees eee 17 Electrical System D Electrical Weldmg sss ses essere eser ennenen 36 EMS 2 Engine Management System 008 17 Engine Control Unit ECU Replace sese eee 37 Engine Protection Map 8 Fault Cod s i 2 20 stained dsc ee ee eles 50 Fault Tracing ivi deen 50 Fault tracing of cables and connechors 40 General TTT 2 17 199 General advice draye debe el seeded eles 49 Ind eX is tee eee oe i ee 199 Joining electrical cables for connectors 42 Malfunctions t3 3 0402itah a a e Seder ads 48 Manual fault tracing in bus cables eee eee 47 MID 128 144 PPID 132 Throttle calibrated POSION Nenion a a a a a 99 MID 128 144 PPID A Starter input sensor 90 MID 128 144 SID 231 SAE J1939 data link 117 MID 128 144 SID 253 Calibration memory EEPROM erore a AR 121 MID 128 144 SID 254 Controller 1 122 MID 128 PID 100 Engine oil poreseure 59 MID 128 PID 105 Intake manifold temperature 62 MID 128 PID 106 Air inlet pressure ee 64 201 MID 128 PID 107 Air filter pressure drop 67 MID 128 PID 108 Barometric pressure 70 MID 128 PID 110 Engine coolant temperature 71 MID 128 PID 111 Coolant level 74 MID 128 PID 153 Crankcase pressure 76 MID 128 PID 158 E
115. ion from the tech nical specification may dramatically increase the environmental impact of an otherwise reliable sys tem It is therefore critical that the stated wear toler ances be adhered to that systems which can be adjusted be correctly set up and that only Volvo Penta Original Parts are used The intervals in the care and maintenance schedule must be followed Some systems e g fuel systems often require spe cial expertise and test equipment A number of com ponents are factory sealed for among other things environmental reasons Warranty sealed compo nents may not be worked on without authorization to perform such work Remember that most chemical products incorrectly used are harmful to the environment Volvo Penta recommends the use of biodegradable degreasers whenever components are cleaned unless otherwise specified in the Service Manual When working out doors take especial care to ensure that oils and wash residues etc are correctly properly for destruction Tightening torques Tightening torques for vital fasteners that must be applied using a torque wrench are indicated in the Service Manual chapter Tightening torques and in the Manual s work descriptions All torque indications apply to clean threads bolt heads and mating faces Indicated torque data apply to lightly oiled or dry threads If lubricants locking fluids or sealants are required for fasteners the correct type will be noted in the job descrip
116. is activated High air inlet pressure 500 kPa 510 kPa gt 510 kPa 72 5 PSI 74 0 PSI 74 0 PSI Oil pressure limit y kPa 350 300 250 200 150 100 50 0 0 500 1000 1500 2000 P0014011 x rpm x Engine speed y OU pressure Z Oil pressure limit 10 47701632 10 2010 05 1 Safety Instructions 05 1 Safety Instructions Safety Information This Service Manual contains repair instructions descriptions and technical data for products or product designs from Volvo Penta Ensure that you are using the correct service manual P0003451 Read the safety information below and the service manual section About this Workshop manual and Repair instructions carefully before repair and service work is begun A This symbol is used in the service manual and on the product to call attention to the fact that this is safety information Always read such information very carefully Safety texts in the manual have the following order of priority Zh DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury Z WARNING Indicates a hazardous situation which if not avoided could result in death or serious personal injury Zh CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate personal injury IMPORTANT Is used to draw your attention to something that may cause minor damage or a minor mal
117. is not sprayed into the cylinder in this position When the fuel valve is closed pressure is built up by the mechanically driven pump piston in the unit injec tor When sufficient pressure has developed fuel is injected into the cylinder via the unit injector s injector section The fuel valve is re opened and pressure in the unit injector decreases at the same time as the fuel injec tion to the cylinder stops 19 30 0 General 20 In order to determine when the fuel valve shall open or close the control unit has access to signals from sen sors and switch contacts Calculation of fuel quantity The quantity of fuel to be injected into the cylinder is calculated by the control unit The calculation deter mines the time that the fuel valve is closed when the fuel valve is closed fuel is sprayed into the cylinder The parameters which govern the amount of fuel injected are e Demanded engine speed e Engine protector functions e Temperature e Boost pressure Altitude correction The control unit contains an atmospheric pressure sensor and an altitude compensation function for engines that operate at high altitude This function lim its the fuel volume in relation to ambient air pressure This is to prevent smoke high exhaust temperature and to protect the turbocharger from overspeeding Diagnostic function The task of the diagnostic function is to discover and localize any malfunctions in the EMS 2 system to
118. itable action 1 Check function of preheat relay 2 Check all cable and connections to heating element 114 47701632 10 2010 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault code explanation Faulty relay Faulty relay circuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Symptom Might get start problems in cold climate Possible reason Preheater fuse broken An open circuit in sense wiring Heating element broken Suitable action Check preheater fuse Check contact pressure in socket 7 in engine connector B Check all cable and connections to heating element Check heating element Cable description In cold climate the intake air might need too be pre S heated This is done by the preheater located on the intake manifold A sense wire is connected between B C the preheater relay output and B7 The sense wire checks that the preheat element and the preheat fuse A EMS2 are not damaged The activation of the preheater is 0013533 controlled by the EMS2 via the preheat relay EMS2 pin B25 activates the preheat relay A Connector B B Junction point C Preheat relay Preheater fuse is located between preheat relay and heating element P0013532 Measurements Checking preheater relay page 171 47701632 10 2010 115 30 2 Fault Tracing MID 128 SID 211 Sensor Supply Voltage 2
119. m the sensor Check that there is no oxidation and that the connector pins are not damaged If there is a fault please refer to the instructions in Fault tracing of cables and connectors page 40 NOTICE Some fault codes become inactive when the engine is stopped Start the engine to check whether the fault code is still inactive with the engine running After an action with the connector Put the connector back Check if the fault code becomes inactive Check faults that could be related to that specific sen sor If the fault remains measure the cables and sensors to check them as instructed Network The system has two types of communication buses CAN A data link CAN bus links the nodes to each other CAN Controller Area Network is an industrial stand ard for distributed systems The CAN bus consists of a pair of copper conductors which are twisted 30 times per meter The nodes com municate via the CAN bus and they form a network together which exchanges information and benefits from each other s services The CAN bus is a serial bus and is the primary control bus J1587 The communication bus J1587 is also used for acces sories and for diagnostics This is a serial bus in accordance with standard SAE J1708 47701632 10 2010 49 30 2 Fault Tracing 30 2 Fault Tracing Fault Codes MID 128 PID 45 Inlet air heater status FMI 3 Voltage above normal or shorted high Fault code ex
120. mal sound NOTICE Identify which injector by the SID number Conditions for fault code Low injector hold current Injector activated 1 Suitable action Check the cables between the injector and the engine control unit Check the contact pressure in all sockets regarding the unit injectors in engine connector A Check the cable connection to the injector 47701632 10 2010 105 30 2 Fault Tracing Cable description The Delphi E3 electronic unit injectors used on the tier3 engines have two electronically controlled solenoids Each solenoid is individual controlled by the engine control unit The unit injectors receive voltage from pin 59 60 61 or 62 on the engine control unit To activate a unit injector solenoid the engine control unit connects the unit injectors low side to battery negative EMS2 P0008674 a Connector A b Cylinder Measurements Trimming the injector page 161 Checking the injector wiring page 162 106 47701632 10 2010 30 2 Fault Tracing MID 128 SID 21 Engine position FMI 2 Data erratic intermittent or incorrect Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 5 Value fault None Symptom The engine start time will increase uses only crankshaft sensor Conditions for fault code Incorrect timing Possible reason e Polarity fault The ca
121. n also cause mechanical damage Install all protective cov ers before the engine is started Only start the engine in a well ventilated space When running in a confined space exhaust fumes and crankcase gases must be led away from the engine bay or workshop area The majority of chemicals e g engine and trans mission oils glycol gasoline and diesel oil together with chemicals for workshop use such as degreasing agents paints and solvents are injurious to health Carefully read the instruc tions on the product packaging Always follow a product s safety directions e g use of protec tive mask glasses gloves etc Ensure that other personnel are not exposed to substances that are injurious to health Ensure good venti lation Handle used and leftover chemicals in the prescribed manner Clutch adjustments must be carried out with the engine stopped 47701632 10 2010 Always use protective glasses or goggles when carrying out work where a risk of splinters grinding sparks splashes from acid or other chemicals is present Your eyes are extremely sensitive injury may cause blindness Never use start gas or similar products as a starting aid They may cause an explosion in the inlet manifold Danger of personal injury All fuels as well as many chemicals are flam mable Do not allow open flames or sparks in their vicinity Gasoline some thinners and hydrogen gas from batteries are extremely flammable and explosiv
122. nd wipe dry components first before applying new sealant in accordance with the instructions 47701632 10 2010 Safety regulations for fluorocarbon rubber Fluorocarbon rubber is a common material in sealing rings for shafts and in O rings for example When fluorocarbon rubber is exposed to high tem peratures above 300 C 572 F hydrofluoric acid can form This is highly corrosive Contact with the skin can result in severe chemical burns Splashes in your eyes can result in chemical wounds If you breathe in the fumes your lungs can be permanently damaged Z WARNING Seals must never be cut with a torch or be burnt afterwards in an uncontrolled manner Risk for poisonous gases Z WARNING Always use chloroprene rubber gloves gloves for chemicals handling and goggles Handle the removed seal in the same way as corrosive acid All residue including ash can be highly corrosive Never use compressed air to blow clean Put the remains in a plastic container seal it and apply a warning label Wash the gloves under running water before removing them 47701632 10 2010 00 0 General The following seals are most probably made from flu orocarbon rubber Seal rings for the crankshaft camshaft idler shafts O rings regardless of where they are installed O rings for cylinder liner sealing are almost always made of fluorocarbon rubber Please note that seals which have not been exposed to high temperature
123. nent installation in a control panel The display communicates via the CAN link It is con nected to the CAN link between the engine control unit and the CIU or DCU Monitoring Engine speed boost pressure boost temperature coolant temperature oil pressure oil temperature fuel pressure engine hours battery voltage instan taneous fuel consumption and average fuel con sumption trip fuel Diagnostics Shows active fault codes in plain language Fuel control The engine s fuel requirement is analyzed up to 100 times per second depending on engine rpm The engine s injection amount and injection timing is con trolled electronically via fuel valves on the unit injec tors This means that the engine always receives the correct volume of fuel in all operating conditions which offers lower fuel consumption minimal exhaust emissions etc The control unit checks and controls the unit injectors to ensure that the correct volume of fuel is injected into each cylinder It calculates and sets the injection angle The control is primarily performed using the speed sensors and the combined sensor for boost pressure boost temperature The control unit affects the unit injectors via an elec tronic signal to the unit injectors electromagnetic fuel valve which can open and close When the fuel valve is open fuel flows past through the unit injectors holes and continuing out through the fuel channel Fuel
124. ng the throttle 47701632 10 2010 175 CAN BATT 1708 J1939 DATT SWITCHED J1587 iagrams D iring HL Sam stop AB a 19 wl Yl m 123456 SE D a oa 2 2 DIR 15 gt oO o v e of Ss Si SISI 24 18 pL P 28 am A at i E 2017 21 SS N E sB y 5 1234567 12 34567 5 x slo RIBL 1 5 23 R15 t SB R1 5 7 25 em s S ec LI LIIITI III 12 8 RIBL R KT TT 1 11 RE DEDINE S T TT el 2 wl wel Jet a D LO DE EI LO j e ln wl we gl 2 2 SI zo Ja d Ja gt ei el ei d 5 S ga a gt aa 3 SE S gg dag d s 1 23 3 4 10 8 5256 28 17 16 18 27 5760 25 29 5155 5859 6f CONNECTOR B 2 CONNECTOR A BA 7 2247 1 8 3334 27 58 57 ll 22 N a a w a S S gt MAIN RELAY HOLD SB 2 5 R Y R BL R25 37 0 Wiring Diagrams TAD940 41GE TAD940 43 37 0 W P0012802 47701632 10 2010 176 37 0 Wiring Diagrams Sensor coolant level f Cable cross section 0 75 mm unless otherwise Sensor coolant temperature stated 1 Battery Cable colors 2 Starter motor BL Blue P Pink BN Brown R Red 2 Alternator GN Green SB Black 4 Main relay GR Gray VO Violet OR Orange W White 5 Stop switch LBL
125. ning in DCU display CIU Flash code Flash code Electrical fault 5 4 Value fault None Symptom Preheat relay never activated White smoke for cold start Start problems in cold climate Conditions for fault code The current through pin B25 or through pin B7 on the EMS2 deviates from normal current value Possible reason Open circuit in cable harness between EMS2 and preheat relay Suitable action 1 Check all connections on the preheat relay and all cables between EMS2 and preheat relay 2 Check the contact pressure in socket 25 and in socket 7 in the engine connector B p0013470 A Cable description 25 OR C In cold climate the intake air might need too be pre 57 60 heated This is done by the preheater located on the 7 intake manifold The activation of the preheater is con B trolled by the EMS2 via the preheat relay EMS2 pin B25 activates the preheat relay A sense wire is con EMS2 nected between the preheater relay output and B7 p0013471 The sense wire checks that the preheat element and the preheat fuse are not damaged A Connector B B Junction point C Preheat relay Measurements Checking the wiring page 125 47701632 10 2010 51 30 2 Fault Tracing MID 128 PID 94 Fuel Delivery Pressure FMI 1 Data valid but below operational range Fault code explanation Fuel pressure is too low Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electri
126. njector Sensor air inlet pressure intake manifold temper ature Oil pressure sensor Crankcase pressure sensor IEGR valve Water in fuel sensor AUX stop Main fuse 47701632 10 2010 10 11 12 13 14 15 16 30 0 General Main relay Engine control unit ECU Connector for diagnostic tool 6 pin Engine interface 8 pin connector Oil level temperature sensor Fuel pressure sensor Alternator Pressure drop indicator air temperature sensor 25 30 0 General TAD1350 1355GE P0013973 17 Coolant level sensor 21 Starter motor 18 Coolant temperature sensor 22 Flywheel position and rotation speed sensor 19 Piston cooling oil pressure sensor 23 Camshaft position sensor 20 Starter motor relay 24 Air filter indicator 26 47701632 10 2010 TWD1643GE P0013954 oO ON Oo P Coolant level switch Unit injector one for each cylinder Sensor air inlet pressure intake manifold temper ature Sensor air filter pressure air temperature Wastegate regulator Main fuse Preheat relay AUX stop 47701632 10 2010 10 11 12 13 14 15 16 30 0 General Main relay Water in fuel sensor Sensor oil level oil temperature Fuel pressure sensor Alternator Crankcase pressure sensor Diagnosis tool connector Oil pressure sensor 27 30 0 General TWD1643GE P0013955 17 Coolant temperature sensor 18 Exhaust temperature 19 Cold start valve 20 Camshaft position sensor
127. nlet manifold air warms up the resistance in the thermistor falls and the voltage drop across it falls b Intake manifold temperature Please refer to the table resistance temperature in this fault code chapter Measurements Checking signal cable voltage inlet manifold pres sure temperature sensor page 134 Checking negative cable inlet manifold pressure tem perature sensor page 135 Checking the sensor cable for open circuit or shortcir cuit page 136 Checking inlet manifold temperature sen sor page 137 47701632 10 2010 63 30 2 Fault Tracing MID 128 PID 106 Air inlet pressure FMI 0 Data valid but above normal operational range Fault code explanation Air inlet pressure is too high Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 4 Value fault 3 5 Symptom Power is reduced due to error torque map if the engine protection parameter is activated Conditions for fault code Air inlet pressure exceeds the set value of the engine protection parameter Possible reason e The wastegate does not function properly Faulty air inlet pressure sensor Wrong turbo compressor unit according to the engine specification Suitable action Check the wastegate functionality see workshop manual Group 21 26 Check the air inlet pressure sensor by control measuring the air inlet pressure using a measuring tap see workshop manual Group 21 26 Check that the
128. nsor Possible reason e Open circuit in the sensor signal cable Open circuit in the sensor negative cable Faulty sensor Suitable action Check the cable harness between the sensor and the EMS2 Check the contact pressure in socket 18 and 44 in the engine connector B Check the sensor 82 47701632 10 2010 30 2 Fault Tracing Cable description Exhaust temperature sensor consists of a Pt 200 sen sor where the resistance changes depending on exhaust temperature The resistance increases with rising exhaust temperature Pin 44 on the engine control unit EMS2 connector B provides pin 2 on the sensor with an operating voltage of 5 Volt Pin 1 on the sensor is connected to battery negative via pin 18 on the EMS2 The voltage drop across the sensor changes as exhaust temperature changes A Connector B B Exhaust temperature sensor Measurements Checking signal cable exhaust gas temperature sen sor page 148 Checking negative cable exhaust gas temperature sensor page 149 Checking exhaust gas temperature sensor page 149 47701632 10 2010 83 30 2 Fault Tracing MID 128 PID 175 Engine oil temperature FMI 0 Data valid but above normal operational range Fault code explanation Engine oil temperature too high Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 7 Value fault 5 8 Symptom Power is reduced due to error torque map if the engine pro
129. nsor flywheel 15 Switch piston cooling 16 Unit injector Cyl 1 6 17 Relay preheating 18 Fuse preheating 19 Main circuit breaker 10 A 20 Preheater 21 Switch coolant level 22 Sensor oil level oil temperature 23 Switch water in fuel 24 Sensor oil pressure 25 Sensor fuel pressure 26 Air filter indicator 27 Connector remote stop 28 Jumper removable 29 EGR internal 30 Control unit EMS 2 2 31 Wastegate valve 47701632 10 2010 185 37 0 Wiring Diagrams TAD1341 45GE TAD1340 45VE Visco fan 6t Y YOLOANNOD g YOLOANNOD OL ULE E E P0012805 186 47 A N N a N w S N Kl A a P D w 9 Ww Ww D A O N x 8 ey R N a D N w N S N N D ba CH xX a IN 8 _ o BL GR C gt D col 1 0 i a LGN YISB g X LA N ng OR 1 0 ta D a g RW s RIBL 2 Q RBL1 5 ene S o RIBL 1 5 RIBL 1 5 EE BN 1 0 p s alSB 1 5 S IS go glsB1 5 d E eo g SB 1 5 S Ze N S S gt oyw S YW D Hp al ob S a gf SRV GRY Juj 82 a g pm SB 2 5 l 3 d Ge beens S _ eL
130. nsor oil pressure 25 Sensor fuel pressure 26 Air filter indicator 27 Aux stop 28 Jumper removable 47701632 10 2010 193 37 0 Wiring Diagrams TAD1650 51GE Visco fan 0 75 GRIOR w gt 8 8 _ 10BN 10581 SIS ghee q gt 5 5 10R 3 8 F o o 075 GN SB lo E 3 2 2 075 enw a 0 75 BLIGN R 0 75 BN OR x 0 75 BLIOR 0 75 GRIGN oz GNR N D Sep Im 0 75 OR n Ka E 0 75 BL N Ka 0 75 OR SB x N 2 ax ch ee L 0 75 GRISB x 5 ow D E 0 5 GRIW o 2 aN L 0 75 OR SB gt BINS g 1 0 Y D 10Y x Ki N 1 0Y a Y kad N 1 0Y E gluo Y IER Ka g GA a N S N G amp e 2 8 0 75 SB 0 75SB a 2 Klak Ho N 0 75 Y lL E a a Q amp e G x l N ol TS BLIW R G CAN2 gt i _ o 0 75 BLIGR wl A mak a D HNI S 0 75 GN loo S N S 0 75 Y SB Ke n 10 OR SEX OD a N 0 75 RIW K E 0 75 RIBL s 1 5 RIBL N 10Ylo 1 5 RIBL 1 5 RIBL CH 1 0 BN S 0 75 YISB 1 5 SB ep DO 0 75 wegl WEE
131. oduct and is able to carry out mechanical and electrical work to trade standard Volvo Penta continually develops its products we therefore reserve the right to make changes All infor mation in this manual is based on product data which was available up to the date on which the manual was printed New working methods and significant changes introduced to the product after this date are communicated in the form of Service bulletins Spare Parts Spare parts for the electrical and fuel systems are subject to various national safety standards Volvo Penta Original Spare Parts meet these standards No damage of any kind caused by the use of spare parts not approved by Volvo Penta will be compensated by any warranty undertaking About this Workshop manual Certified engines When carrying out service and repair on emis sion certified engines it is important to be aware of the following Certification means that an engine type has been inspected and approved by the relevant authority The engine manufacturer guarantees that all engines of the same type are manufactured to correspond to the certified engine This places special demands on service and repair work namely e Maintenance and service intervals recom mended by Volvo Penta must be complied with e Only spare parts approved by Volvo Penta may be used e Service on injection pumps pump settings and injectors must always be carried out by an authorized Volvo Penta w
132. oo high Possible reason e High surrounding temperature e Fault in sensor Suitable action 1 Check if the surrounding temperature is high or if the EMS 2 unit is exposed to heat radiation 2 Change EMS 2 unit FMI 4 Voltage below normal or short circuit to lower voltage Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 8 4 Value fault None Suitable action 1 Change EMS 2 unit FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 8 4 Value fault None Suitable action 1 Change EMS 2 unit Cable description The temperature sensor is installed inside of the EMS 2 unit 47701632 10 2010 97 30 2 Fault Tracing MID 128 PPID 98 Engine sync acknowledge FMI 9 Abnormal update rate Fault code explanation Communication fault Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault None Value fault None Preconditions NOTICE If the control panel ONLY communicates on the J1939 communi cation and NOT the redundancy of J1587 for start stop and throttle this fault code is active in the VODIA and that is normal Conditions for fault code Time out on the J1587 bus Possibl
133. orkshop e The engine must not be converted or modified except with accessories and service kits which Volvo Penta has approved for the engine e No changes to the exhaust pipe and engine air inlet duct installations may be made e No warranty seals where present on the prod uct may be broken by unauthorized persons The general instructions in the Operator s Manual concerning operation service and maintenance apply IMPORTANT Neglected or poorly performed care service and the use of spare parts not approved by Volvo Penta will mean that AB Volvo Penta no longer guarantees that the engine conforms to the certified model Volvo Penta accepts no responsibility for damage or costs arising as a result of failure to follow the above mentioned standards 47701632 10 2010 Introduction The working methods described in this manual are based on a workshop scenario where the product is mounted in a holding fixture Maintenance work is often carried out in situ in which case if nothing else is indicated using the same working methods as the workshop Warning symbols that occur in the service manual For significance refer to Safety Information DANGER IMPORTANT NOTICE are by no means comprehensive since not everything can be foreseen as service work is carried out in the most varied of circumstances We call attention to risks that may occur due to incorrect handling during work in a well equipped works
134. planation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 5 4 Value fault None Symptom Preheat relay never activated White smoke for cold start Start problems in cold climate Conditions for fault code The voltage on pin B25 or on pin B7 on the EMS2 deviates from normal voltage value Possible reason Short circuit to battery voltage in cable harness between EMS2 and preheat relay Suitable action 1 Check all connections on the preheat relay and all cables between EMS2 and preheat relay FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 5 4 Value fault None Symptom Induction air is hot Preheat relay is impossible to turn off Preheat fuse will break Conditions for fault code The voltage on pin B25 or on pin B7 on the EMS2 deviates from normal voltage value Possible reason Short circuit to battery negative in cable harness between EMS2 and preheat relay Suitable action 1 Check all connections on the preheat relay and all cables between EMS2 and preheat relay 50 47701632 10 2010 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine war
135. pter cable 885675 to the cable har ness connector to the engine control unit 4 Use multimeter 9812519 to do resistance meas urement against the engine control unit Checking signal cable crankcase pressure sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit 4 Use multimeter 9812519 to do resistance meas urement against the engine control unit NOTICE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit 47701632 10 2010 30 2 Fault Tracing Checking supply cable crankcase pressure sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Turn ignition off 2 Remove the connector from the sensor Connect adapter cable 885675 between the sensor and engine control unit Use multimeter 9812519 for voltage measurement 4 NOTICE Turn ignition on SS E f 885 675 P0001355 Ch Vodia logging throttle signal To verify the throttle signal on the J1587 bus do as fol low 1 Choose Log test under the Service and mainte nance menu 2 Choose MID 128 Accelerator Pedal Position and MID 144 Throttle Calibrated Position and press play 3 Verify that booth throttle values displayed in per centage by Vodia changes simultaneous while movi
136. r 0 700 kPa Supply voltage 5 00 0 25 VDC Nominal output voltage at 25 C and at supply voltage 5 00 VDC 0 5 VDC 0 bar 0 kPa 4 5 VDC 7 bar 700 kPa Measurements Checking supply cable fuel sensor page 125 Checking negative cable fuel sensor page 126 Checking the signal cable for interruption or shortcir cuit page 127 Checking fuel pressure sensor page 128 47701632 10 2010 30 2 Fault Tracing MID 128 PID 97 Water in fuel indicator FMI 0 Data valid but above normal operational range Fault code explanation Water in fuel Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 9 Value fault 2 1 Symptom None Possible reason e Water in the fuel trap has been detected e Short circuit between both cables to the water in fuel switch Suitable action 1 Empty the water trap 2 Check the water in fuel switch 3 Check the cable harness between water in fuel switch and EMS2 FMI 3 Voltage above normal or shorted high Fault code explanation Faulty monitor Faulty monitor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 9 Value fault 2 1 p0013478 47701632 10 2010 55 30 2 Fault Tracing EMS2 p0013479 A Connector B B Water in fuel 56 Cable description A sensor is located in the water trap under the fuel filter Its t
137. r flywheel 28 Sensor camshaft 29 Sensor air inlet pressure inlet manifold tem perature 30 Air filter indicator 31 Sensor oil pressure 32 Thermostat by pass valve 33 Wastegate valve 34 Sensor exhaust temperature 35 Connector A 36 Connector B 37 Control module EMS 2 47701632 10 2010 189 37 0 Wiring Diagrams TAD1650VE Q OO SIS XS In al a S S18 T S Jeunes S GNW BL OR g GNIR N o d B D SB 1 0 vd in ja D w N _ N or IM ES w N a D n GRIR x 3 BN OR z y LBN lt GRIR BI A N E z ka d N 3 S E Hd Vd 8 SB 1 0 D D Se x aR HN de Y Sjo Gi a a a o S Ka z X g BLw nela g BLIGR enz WK a Lis D Vis St Rb w GN GG amp yy VSB Ge pa pfOR 1 0 Y NIS o RW N g RIBL o RIBL 1 5 Y1 0 g RIBL 1 5 y RIBL 1 5 i BN 1 0 L B E WISB o Zesis be w Ka S Wis SO GRISB Ins YW YW N gt 99 ISo D gt 5 g GRIY GRY Juj BZ 2 ee dA AT Y ads ot o 1 E D BB D Ye EH L ZS lee Si a N R BL 1 5 2 E S n A S R L met T o 92 EE NEE g 38 W SB Daa 2 Na DSS X in RIBL 1 0 g g UI EIS Z R 8 R Ik Ni GEI Wel op Fb sB 1 1 ws TL E a Ki R25 P0012803 190 GLY SL In gS A
138. rcuit Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Conditions for fault code The voltage on pin B38 on the EMS2 deviates from normal voltage value Possible reason Open circuit in wastegate regulator signal cable Open circuit in wastegate regulator battery negative cable Faulty wastegate regulator Suitable action Check all cable and connectors between EMS2 and wastegate regu lator Check contact pressure in socket 38 engine connector B Change wastegate regulator P0007171 P0013528 TAD1350 52 GE TWD1643 GE 112 47701632 10 2010 2 1 H 7 C B A EMS2 TWD 1643 GE P0013529 A Connector B B Junction points C Wastegate TWD1643 GE EMS P0007253 a Wastegate b Connector B TAD1350 52 GE 47701632 10 2010 30 2 Fault Tracing Cable description The engine is equipped with a turbocharger with a wastegate valve The wastegate valve controls the amount of exhaust gas flow which should pass through the exhaust turbine An electronically controlled regu lation valve wastegate regulator which is controlled by the engine control unit controls the air pressure supplied to the wastegate valve Air pressure taken from the inlet manifold is used to control the amount that the wastegate opens As the air pressure supplied by the control valve to the wastegate valve increases the valve opens
139. re disconnected or connected Remove the two connectors from the engine control unit Turn the locking arm down at the same time as the connector is pulled outwards Change the engine control unit If the new engine control unit has recently been programmed Start the engine and check whether any fault codes related to the engine control unit occur 37 30 0 General Reprogramming a control unit IMPORTANT The CHASSIS ID number must be readily available to allow the software to be downloaded Action 1 Log in to Volvo Penta Partner Network s website www vppn com 2 Choose VODIA in the left hand menu Choose ECU programming in the left hand menu 4 Follow the instructions under Download software Choose the control units to be reprogrammed and click the Download button The software for the control units is now downloaded to the PDA P0006430 5 Take a look under Settings Software information in VODIA to check that the software has been downloaded 6 Connect the VODIA to the engine control unit to be programmed 7 Start with the engine control unit Select Engine with mounting and equipment in the VODIA menu Select MID 128 Control unit programming VODIA will guide you through the entire programming process 8 The next control unit is the vehicle ECU Select Electrical system and instruments in the VODIA menu Select MID 144 ECU programmin
140. s than 0 07 Volt Possible reason Open circuit in the air pressure switch signal cable Short circuit between the air pressure switch signal cable and battery negative Short circuit between the switch supply cable and the switch negative cable Faulty monitor Suitable action Check the cable harness between the air pressure switch and EMS2 Check the contact pressure in socket 15 and 29 in engine connector A Check the switch Cable description Air filter pressure and air filter temperature are meas ured by a combined switch sensor placed above the air filter The air filter pressure switch measures abso lute pressure the sum of air filter pressure and atmos pheric pressure The switch activates when the air pressure in the air filter becomes too low the vacuum between the air filter and the turbo is too high The engine control unit measures the voltage drop over the pressure switch to detect when the switch has been activated P0013493 a Connector A b Connector B c Air filter pressure and temperature 68 47701632 10 2010 P0013492 47701632 10 2010 30 2 Fault Tracing Component specification Supply voltage max 24 VDC Switching point 5kPa 500Pa 50 5 mbar Measurements Checking supply cable air filter pressure switch page 139 Checking negative cable air filter pressure switch page 153 Checking air pressure switch page 140 69 30 2 Fault Tracing MID 128 PID 108 Barom
141. ses 31 30 0 General P0013492 p0001348 p0013478 P0013504 32 Air filter pressure temperature sensor Air filter pressure and air filter temperature are meas ured by a combined sensor placed above the air filter The air filter pressure sensor measures absolute pres sure the sum of air filter pressure and atmospheric pressure The sensor consists of a monitor that sends a signal to the control unit when the pressure in the air filter becomes too high The air filter temperature sensor consists of a non lin ear resistor where the resistance is dependant on the temperature of the resistor body The resistance drops as temperature rises Crankcase pressure sensor The sensor is located on top of the engine in the middle of the valve cover on the engine s left side The pressure signal is a voltage signal proportional to the pressure The sensor reference voltage is 5 Volts Switch water in fuel The switch is located in the lower part of the fuel pre filter It s purpose is to detect water in the fuel system The switch comprises two copper electrodes between which the resistance is measured When the resist ance drops below a certain limit which indicates that there is water in the fuel a warning message is sent to the control unit Exhaust temperature sensor The exhaust temperature sensor consists of a Pt 200 sensor where the resistance changes depending on exhaust t
142. ses only crankshaft sensor Possible reason e Incorrectly mounted cam speed sensor Suitable action Check wiring between cam spped sensor and EMS2 Check the installation of the cam speed sensor Attempt to localize the source of interference Check and clean the cam speed sensor Check the contact pressure in socket 45 and 46 in engine connector A Cable description The camshaft sensor is an inductive sensor The cam shaft sensor is used in the first instance to determine the cylinder which is next in line for injection A toothed wheel installed on the camshaft is used to determine the cylinder which is next in line for injection The EMS2 toothed wheel has 7 teeth one for each cylinder plus P0007250 an extra tooth for cylinder 1 When the camshaft with toothed wheel rotates impulses are generated in the sensor The impulses generated by in the sensor is used by the engine control unit to determine the cyl b Engine speed sensor camshaft inder which is next in line for injection a Connector A Measurements Checking camshaft sensor wiring page 164 Checking camshaft sensor page 165 P0008694 P0002860 TAD950 952VE TAD1350 1352GE TAD1250 1252VE 108 47701632 10 2010 30 2 Fault Tracing MID 128 SID 22 Timing sensor crank FMI 2 Data erratic intermittent or incorrect Fault code explanation Fault indication Faulty sensor Faulty sensor circuit DCU Engine warning in DCU display CIU Fla
143. sh code Flash code Electrical fault 2 4 Value fault None Symptom Engine is difficult to start uses only cam sensor Conditions for fault code Incorrect signal Possible reason Suitable action e Short circuit between the cables to the flywheel sensor e Polarity fault The cables to the flywheel sensor is shifted 1 Check the cable harness between the flywheel sensor and EMS2 2 Check that the flywheel sensor is connected as in the circuit description 3 Check the flywheel sensor FMI 3 Voltage above normal or shorted high No signal Fault code explanation Faulty sensor Faulty sensor circuit Fault indication Symptom DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 2 4 Value fault None Engine is running with imprecise timing causing risk of high fuel consumption and smoke Cylinder balancing not working with risk of uneven running Conditions for fault code No cranksignal when expected or permanent loss of sensor signal Possible reason Suitable action 47701632 10 2010 Open circuit in any or both of the cables to the flywheel sensor Incorrectly mounted flywheel sensor Faulty flywheel sensor Check the cable harness between the flywheel sensor and EMS2 Check the installation of the flywheel sensor Check the flywheel sensor Check the contact pressure in socket 37 and 38 in engine connector A 109 30 2 Fault Tracing FMI 8
144. splay CIU Flash code Flash code Electrical fault 3 3 Value fault 6 1 Symptom Engine is derated if the engine protection parameter is activated Conditions for fault code Coolant water temperature exceeds the set value of the engine protection parameter Possible reason Coolant level too low Dust or dirt on the outside of the radiator Drive belt is not properly adjusted Worn impeller in the coolant pump There is air in the coolant water system Faulty thermostat Faulty temperature sensor Clogged cooling water system Suitable action Check the coolant level Check the outside of radiator for dust and dirt Check the drive belt adjustment Check the impeller in the coolant pump Bleed the coolant water system If low coolant level check the coolant water system for leakage by a pressure test Check the pressure valve in the coolant cup Check the coolant water thermostat or change the coolant water ther mostat Check the coolant temperature sensor 10 Clean the coolant water system 47701632 10 2010 71 30 2 Fault Tracing FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Faulty sensor Faulty sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 3 Value fault 6 1 Conditions for fault code The voltage on pin B18 on the EMS2 is less than 0 07 Volt Possible reason e Short circuit between bot
145. sure monitor The output signal from the pressure monitor can only have two distinct positions on off in the same way as a relay output The monitor is supplied with current from the engine control unit A pre set pressure limit of 150 kPa 21 8 PSI determines when the mon itor switches on The monitor opens if the pressure exceeds this value At idle the monitor can be closed without a fault code being set Fuel pressure sensor The sensor measures fuel pressure and is located on the fuel filter bracket The sensor is an active sensor i e the sensor requires a supply voltage of 5 Volt The sensor provides an output signal whose voltage is pro portional to the pressure that the sensor measures 35 30 0 General P0013966 36 Repair Instructions General advice on working with EMS engines The following advice must be followed to avoid damage to the engine control unit and other elec tronics IMPORTANT The system must be disconnected from system volt age by cutting the current with the main switch and the starter key s must be in the 0 position when the engine control unit connectors are disconnected or connected e Never disconnect the current with the main switches when an engine is running e Never undo a battery cable when the engine is run ning e Turn the main switches off or disconnect the battery cables during quick charging of the batteries NOTICE During normal trickle charging it is
146. t code explanation Communication fault J 1939 Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 6 5 EMS Value fault None EMS Electrical fault 6 4 CIU Value fault None CIU Symptom Engine can not be started or if engine is running it can only be stopped by pushing the aux stop Instruments and warning lamps stop working Conditions for fault code CAN communication is missing Possible reason CAN H and CAN L short circuited to eachother CAN H or CAN L short circuited to battery negative on pin 3 CAN L short circuited to power supply on pin 4 CAN H or CAN L short circuited to any of the J1708 links Suitable action Check all data links between DCU CIU and EMS2 Check the contact pressure in socket 51 and 55 in the engine connector B Check that the socket 11 and 12 in the CIU connector is undamaged Cable description A CAN H Engine connector B CAN L Engine connector C Power supply 0 V D Power supply input E Ignition F Stop EMS2 a DCU CIU G J1708A Engine connector P0013534 H J1708B Engine connector a Engine connector Measurements Checking CAN bus cable page 171 47701632 10 2010 117 30 2 Fault Tracing MID 128 SID 232 5 V supply FMI 3 Voltage above normal or shorted high Fault code explanation Fault in circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electric
147. t pressure inlet manifold tem perature 10 VODIA input diagnosis conn 11 Connector development tool not used 12 Sensor crankcase pressure 13 Sensor camshaft 14 Sensor flywheel 15 Switch piston cooling 16 Unit injector Cyl 1 6 17 Relay preheating 18 Fuse preheating 19 Main circuit breaker 10 A 20 Preheater 21 Switch coolant level 22 Sensor oil level oil temperature 23 Switch water in fuel 24 Sensor oil pressure 25 Sensor fuel pressure 26 Air filter indicator 27 Connector remote stop 28 Jumper removable 29 EGR internal 30 Control unit EMS 2 2 31 Wastegate valve 47701632 10 2010 37 0 Wiring Diagrams Cable colors BL Blue P Pink BN Brown R Red GN Green SB Black GR Gray VO Violet OR Orange W White LBL Light blue Y Yellow LBN Light brown Cable cross section 0 75 mm unless otherwise stated 183 37 0 Wiring Diagrams TAD1353 55GE EL FL 1 0 CLD Y 1 0 Y 1 0 Y 1 0 Y 1 0 Lz SE TD CET Lz E T Ekt Y 1 0 Y1 0 Y1 0 Y 1 0 L Y YOLOANNOD g YOLOANNOD Qe LLLE E BZ GL ZZ Lb as ZL 9t St 8E LE ELEZ ZZ 8 ZE 87 9G 2G Brrr OF IE A as Aas e202 9L ZL L9OGSPEZL z9 6S ZE SZ BC
148. tage above normal or shorted high Fault code explanation Faulty sensor Fault in sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 6 8 Value fault 6 7 Conditions for fault code The voltage on pin B14 in the engine control unit exceeds normal voltage value Possible reason Short circuited piston cooling signal cable to battery voltage Suitable action 1 Check cable harness between EMS2 and the piston cooling switch p0001348 92 47701632 10 2010 EMS2 P0013511 A Connector B B Piston cooling pressure 47701632 10 2010 30 2 Fault Tracing Cable description A valve is installed in the oil filter bracket which opens or closes the oil supply for piston cooling depending on oil pressure If the oil pressure is below 250 kPa TAD950 952VE or 300 kPa TAD1250 1252VE the valve closes the oil supply for piston cooling The piston cooling pressure is monitored by a pressure switch The output signal from the pressure switch pin 1 to the engine control unit can only have two distinct positions on off The switch is supplied with current from the engine control unit pin 10 A pre set pressure limit of 150 kPa determines when it switches on The switch opens if the pressure exceeds this value At idle the switch can be closed without a fault code being set Component specification Switching point 150kPa 1 5bar Supply voltage 12 24 VD
149. tection parameter is activated Conditions for fault code Engine oil temperature is too high 1 Suitable action 2 3 4 5 Check the oil level in the engine Check the coolant level and the engine temperature Check that no leakage occurs Check the sensor Clean the oil cooler system and check the bypass valve for the oil cooler Please refer to more detailed instructions in the Workshop manual group 22 Lubrication system FMI 4 Voltage below normal or shorted to lower voltage Fault code explanation Faulty sensor Fault in sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code Electrical fault 3 7 Value fault 5 8 Conditions for fault code The voltage on pin A31 in the engine control unit is less than 0 07 Volt Possible reason N e e e Short circuit between the oil temperature signal cable to the sensor negative cable Short circuit between the oil temperature signal cable and the sensor 5V supply cable Short circuit between oil temperature signal cable and oil level signal cable Fault in sensor Suitable action 1 Check the cable harness between the sensor and the EMS2 2 Check the sensor 84 47701632 10 2010 30 2 Fault Tracing FMI 5 Current below normal or open circuit Fault code explanation Faulty sensor Fault in sensor circuit Fault indication DCU Engine warning in DCU display CIU Flash code Flash code
150. temperature The EMS 2 system processor is located in the control unit where it is protected from moisture and vibration The processor receives information continuously about e engine speed e camshaft position e boost pressure e boost temperature e coolant temperature e oil pressure e oil temperature e oil level e crankcase pressure e piston cooling pressure e water in fuel e fuel pressure e coolant level e air filter pressure e air filter temperature Information from the sensors provides exact informa tion about current operation conditions and allows the processor to calculate the correct fuel volume check engine status etc Coolant temperature sensor The sensor is located in the left rear part of the cylin der head The sensor senses the coolant temperature and sends the information to the control unit The sensor comprises a non linear resistor where the resistance is dependant on the temperature of the resistor body The resistance drops as temperature rises 47701632 10 2010 p0001348 p0001348 47701632 10 2010 30 0 General Switch piston cooling A valve is installed in the oil filter bracket which opens or closes the oil supply for piston cooling depending on oil pressure If the oil pressure is below 250 kPa 36 3 PSI TAD950 952VE or 300 kPa 43 5 PSI TAD1250 1252VE the valve closes the oil supply for piston cooling The piston cooling pressure is monitored by a pres
151. ter cable 885675 to the sensor Do not connect the other end of the adapter cable 3 Use multimeter 9812519 to do resistance meas urement 1 2 R 9426Q 470 Q vid 10 C 1 2 R 5896 Q 332 Q vid 0 C 1 2 R 2511Q 109 Q vid 20 C Ss 12000 i 47 Q vid 40 C IS lt R 6120 Ch 22 Q vid 60 C P0013486 R 329 O 11 Q vid 80 C 1860 ia 5 Q vid 100 C 885675 47701632 10 2010 137 30 2 Fault Tracing P0013488 138 885675 Checking supply cable inlet manifold pressure sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Turn ignition off 2 Remove the connector from the sensor Connect adapter cable 885675 between the sensor and engine control unit Use multimeter 9812519 for voltage measurement Turn ignition on Checking signal cable inlet manifold pressure sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the sensor Connect adapter cable 885675 to the cable har ness connector to the engine control unit 4 Use multimeter 9812519 to do resistance meas urement against the engine control unit NOTICE Measurement is done to eliminate short cir cuiting or breaks in the cable to the engine control unit 47701632 10 2010 30 2 Fault Tracing Checking air inlet pressure sensor Tools 885675 Break out cable 9812519 Multimeter 1 NOTI
152. the customer s own control panel This unit has two serial communication links one fast and one slow The fast one is a CAN link that features a bus speed of 250 Kbit s All data regarding instruments indicator lamps contacts and potentiometers are controlled by this bus The slower J1708 J1587 link handles diagnostic infor mation for among other things the flashing code The VODIA diagnosis tool also uses the J1708 J1587 link to communicate with the system DCU Display Control Unit DCU is a digital instrument panel that communicates with the engine control unit via the CAN link DCU has several functions such as Engine control Start stop speed control pre heating etc Monitoring Engine speed boost pressure boost temperature coolant temperature oil pressure oil temperature engine hours battery voltage instantaneous fuel consumption and fuel consumption trip fuel Diagnostics Shows fault codes in text Lists previous faults Parameter setting Idling speed alarm limit for oil temperature coolant temperature droop Preheating for ignition Information Information about hardware software and engine identification 47701632 10 2010 VOLVO PENTA SOO OO P0002061 47701632 10 2010 30 0 General DU Display Unit The DU is an instrument panel which shows engine working values graphically on an LCD screen It con sists of an computerised unit for perma
153. the circuit Check the following e Disconnect the relevant connector at each end of the cable harness e Use 9812519 Multimeter to measure the resistance between the ends of the cable Nominal value 0 Q e f possible shake the cables and pull the connectors during measurement to discover whether the cable harness is damaged e Check the next cable system in the wiring schedule if no fault has been found 41 30 0 General P0007179 P0007180 42 Joining electrical cables for connectors Tools 88890003 Press tool 88890028 Pin tool 88890058 Pliers Repair kit 1078054 1 Disconnect the connector from the engine control unit or from the power supply unit please refer to Engine Control Unit ECU Replace page 37 Undo the connector to gain access to the cable leading to the pin which is to be changed 2 Undo the pin catch 3 Remove the pin with 88890028 Pin tool NOTICE Only remove one pin at a time 4 Cutoff the cable and the pin which is to be changed Join the cable with the new one using repair kit no 1078054 Use 88890003 Press tool with 88890058 Pliers 5 Carefully heat the joint with a hot air gun to make the insulation shrink and seal tightly 6 Put the pin back in the right place in the connector before removing the next pin if several pins are to be changed Check that the locking tongue locks the pin in the connector 7 Install the cables with insulation and tie wraps in t
154. tion 00 0 General Torque angle tightening When torque angle tightening the fastener is tight ened to a specified torque and tightening then con tinues through a pre determined angle Example For 90 angle tightening the fastener is turned a further 1 4 turn in one sequence after the specified tightening torque has been achieved Lock nuts Removed locknuts may not be re used they must be replaced by new ones as locking properties are impaired or lost with re use In the case of lock nuts with plastic inserts the tight ening torque indicated must be reduced if the nut has the same nut height as a standard all metal hexag onal nut Reduce the torque by 25 for bolt sizes of 8 mm or larger In the case of lock nuts with plastic inserts with a high nut height where the all metal thread is as high as a standard hexagonal nut the indicated torque applies Strength classes Nuts and bolts are subdivided into different strength classes The classification is shown by a marking on the bolt head Markings of a higher number indicate stronger material For example a bolt marked 10 9 is stronger than one marked 8 8 For this reason it is important that when bolts are removed they are returned to their original locations on re assembly When replacing bolts check the applicable Spare parts catalogue to ensure the cor rect bolt is used Sealing compounds etc To ensure service work is correctly carried out it is
155. tion Controller Area Network for diesel engine con trol The system has been developed by Volvo and includes fuel control and diagnostic function The system consists of a control unit six unit injectors a number of sensors that supply the control unit with measurements sockets for diagnosis and functional checks The engine can be connected to a communi cations interface consisting of a CAN link and a serial link CAN Controller Area Network The J1939 CAN link is responsible after all communi cation between the engine control unit EMS 2 anda communication interface such as CIU DCU except for diagnostics Diagnostics are managed by the so called J1708 J1587 link The CAN link is much faster than the J1708 J1587 link and has been designed to connect to other components that support the SAE J1939 protocol such as instrument panels and trans missions If a fault develops on the CAN link signals for the engine speed potentiometer and the start and stop knobs are taken over by the J1708 J1587 link How ever instrument and indicator lamps are completely turned off If faults occur in both links the engine starts to idle The only way to shut off the engine in this case is to use the auxiliary stop AUX STOP placed on the engine s left side 47701632 10 2010 17 30 0 General P0002060 P0002932 18 CIU Control Interface Unit The CIU is a translator between the CAN bus and
156. urement Also do a continuity test between 1 4 to verify that the coil inside the valve is intact P0013522 160 47701632 10 2010 30 2 Fault Tracing 47701632 10 2010 Trimming the injector The electronic trim strategy is used to ensure that all injectors run with nominal timing and fuel delivery This is achieved by adjusting the beginning and end of the electronic drive waveform for each actuator to com pensate for spread in actuation and deactuation times of the two actuators in each injectors and to correct for variations in fuelling due to nozzle flow variations NOTICE Write down the new injector s code before installation The code consists of 9 characters and is on the injector s electric connector under the SN num ber 1 Connect Vodia and switch on the current for the engine 2 Go into the Service and maintenance menu in Vodia Select Parameter programming Press Play Select the cylinder number corresponding to the injector which has been changed 6 Enter the new injector s code Click OK 7 Close Parameter programming 8 Vodia will ask you to Turn off the main switch then follow the instructions 9 Report the parameters back as in items 10 13 in Programming the control unit 161 30 2 Fault Tracing Checking the injector wiring Tools 9812519 Multimeter 1 NOTICE Turn the starter key to the stop position
157. warning in DCU display CIU Flash code Flash code Electrical fault 9 9 EMS Value fault None EMS Electrical fault 9 8 CIU Value fault None CIU Symptom Engine does not start Possible reason e Internal fault in control unit aai nr Oo Suitable action 1 Reprogram the unit which set the faultcode ee ee 47701632 10 2010 121 30 2 Fault Tracing MID 128 144 SID 254 Controller 1 FMI 3 Voltage above normal or shorted high FMI 8 Abnormal frequency pulse width or period FMI 12 Faulty device or component Fault code explanation Communication fault Fault indication CIU Flash code Flash code Electrical fault 9 9 EMS Value fault None EMS Electrical fault 9 8 CIU Value fault None CIU Possible reason If faultcode MID 144 SID 254 FMI 11 appears the CIU throttle positive and negative supply wire could be short circuited to eachother Faulty EEPROM CIU Faulty flash memory CIU Fault in control unit CIU Suitable action Check for short circuit in the supply cables to the CIU throttle potenti ometer Reprogram the unit which set the faultcode 122 47701632 10 2010 30 2 Fault Tracing MID 128 PSID 201 Data link MID144 FMI 9 Abnormal update rate Fault indication DCU Engine warning in DCU display CIU None Flash code Electrical fault None Value fault None Conditions for fault code No communication with the engine control unit
158. ween EMS 2 connector B and the IEGR 3 Use multimeter 9812519 to measure the resistance in the IEGR coil and cable harness 30 60 R 33 490 47701632 10 2010 157 30 2 Fault Tracing Checking IEGR solenoid 1 NOTICE Cut the current with the main switch IN 2 Remove the IEGR solenoid Please see workshop manual Group 21 26 for reference how to remove the IEGR solenoid 3 One part of the solenoid is spring loaded Press gently down that part with a screwdriver and hold 4 Connecta 24 volt power supply to the IEGR elec trical connection The solenoid should now make a click when alter its position and one should feel a pressure in the screwdriver P0013517 158 47701632 10 2010 30 2 Fault Tracing Checking supply cable coldstart valve Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Turn ignition off 2 Remove the connector from the valve Connect adapter cable 885675 between the valve and engine control unit Use multimeter 9812519 for voltage measurement Turn ignition on 1 4 valve activated U battery voltage 1 4 valve not activated P0013521 47701632 10 2010 159 30 2 Fault Tracing Checking negative cable coldstart valve Tools 885675 Break out cable 9812519 Multimeter 1 NOTICE Cut the current with the main switch 2 Disconnect the connector from the valve 3 Connect adapter cable 885675 to the valve 4 Use multimeter 9812519 to do resistance meas
159. ween the oil pressure sensor and EMS2 Check the contact pressure in socket 7 and 11 in the engine connector A and in socket 11 in engine connector B Check the sensor p0001348 60 47701632 10 2010 P0013480 a Connector A b Connector B c Oil pressure Utspanning V wo 0 O 100 200 300 400 500 600 700 p0013477 Oljetryck kPa 47701632 10 2010 30 2 Fault Tracing Cable description The sensor which measures the oil pressure is an active sensor i e it must have operating voltage The engine control unit connector A pin 7 supplies the sensor pin 1 with 5 Volt The sensor pin 4 is connected to battery negative via the engine control unit connector A pin 11 The output signal from the pressure sensor pin 2 to the engine control unit connector B pin 11 is a voltage signal which is proportional to the oil pressure after the oil filters The output signal is linear within the sen sors working range Component specification Working range 0 7 bar 0 700 kPa Supply voltage 5 00 0 25 VDC Nominal output voltage at 25 C and at supply voltage 5 00 VDC 0 5 VDC 0 bar 0 kPa 4 5 VDC 7 bar 700 kPa Measurements Checking supply cable oil pressure sen sor page 132 Checking negative cable oil pressure sen sor page 132 Checking signal cable oil pressure sensor page 133 Checking oil pressure sensor page 133 61 30 2 Fault Tr
160. y attention to the following when using a high pressure washer on components other than the actual engine Never direct the water jet at seals rubber hoses or electrical components 47701632 10 2010 08 2 Special Service Tools 885675 Break out cable Adapter cable for sensor test 9990136 Break out cable Adapter cable for relay test 9998699 Break out box Used with 9990014 Break out cable 88890016 Break out cable For use with 9998699 Break out box 47701632 10 2010 08 2 Special Service Tools The following special tools are used when working on the engine The tools can be ordered from AB Volvo Penta by specifying the number indicated 9812519 Multimeter Used for measurements 9998482 Measuring tool Gauge for connector on control unit 88820047 VODIA diagnostic tool Complete tool 88890053 Break out cable Used with 9812519 Multimeter to measure on the ECU 9990014 Break out cable Adapter cable EMS2 9998534 Break out cable Used with 9812519 Multimeter 88890003 Press tool Used for joining cables 88890058 88890058 Pliers Jaw used with 88890003 Press tool 15 16 08 2 Special Service Tools 88890028 Pin tool Tool is included in 88890037 Extraction tool set 47701632 10 2010 30 0 General 30 0 General Design and Function EMS 2 Engine Management System General Information EMS 2 is an electronic system with CAN communica

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