1998 SSANGYONG MUSSO level switch

M162 ENGINE MECHANICAL 1B1-93
OIL PAN
1 Gasket ................................................... Replace
2 Bolt (M6 x 22, 6 pieces)............................ 10 Nm
3 Drain Plug (M6 x 20)................................. 25 Nm
4 Bolt (M6 x 20, 22 pieces).......................... 10 Nm5 Bolt (M6 x 85)............................................ 10 Nm
6 Bolt (M8 x 40)............................................ 25 Nm
7 Bolt (M10)................................................. 40 Nm
8 Oil Pan
Removal & Installation Procedure
1. Remove the drain plug and drain the oil completely.
2. Disconnect the electric connector from oil level switch.
3. Unscrew the bolts (10) for oil level switch and check the O-
ring (11) for wear or damage. And replace it if necessary.
4. Unscrew the bolts and remove the oil pan and gasket.
Notice
Arrange the bolts according to each size.
5. Clean the inside of oil pan and sealing surface, then apply
the sealant.
6. Replace the gasket with new one.
7. Install the oil pan with gasket, and tighten each bolt in
specified torque.
8. Check for oil leaks while running the engine.
M8 X 40, 4 pieces
M6 X 85, 3 pieces
M6 X 35, 3 pieces
M6 X 20, 28 pieces the rest

5A-28 AUTOMATIC TRANSMISSION
Table 3.4 - Solenoid States and Functions
Table 3.5 - Solenoid Logic for Static Gear States
Solenoids 1 and 2
Solenoids 3 and 4
Solenoid 5
Solenoid 6
Solenoid 7S1 and S2 are normally open On/off solenoids that set the selected gear.
These solenoids determine static gear position by operating the shift valves.
Refer to table 3.5. Note that S1 and S2 solenoids also send signal pres-
sure to allow or prohibit rear band engagement.
S3 and S4 are normally open On/off solenoids that combine to control
shift quality and sequencing. S3 switches the clutch regulator valve off or
on. S4 switches the front band regulator valve off or on.
S5 is a variable force solenoid that ramps the pressure during gear
changes. This solenoid provides the signal pressure to the clutch and
band regulator, thereby controlling the shift pressures.
S6 is a normally open On/off solenoid that sets the high/low level of line
pressure, Solenoid off gives high pressure.
S7 is a normally open On/off solenoid that controls the application of the
converter clutch. Solenoid on activates the clutch.
S2
ON
ON
OFF
OFF
OFF
OFF
OFFS1
ON
OFF
OFF
ON
OFF
OFF
OFF Gear
1st
2nd
3rd
4th
Reverse
Neutral
Park

AUTOMATIC TRANSMISSION 5A-67
Table 6.1.3 - Diagnostic Trouble Messages
Description / Cause
There have been no faults recorded since the TCU was last cleared. If
the fault history has never been cleared, then there have been no
faults recorded since the TCU was originally powered up.
There is an internal fault within the TCU.
The voltage measured by the TCU corresponding to the battery sup-
ply voltage has been outside the range of the maximum operating
voltage of 16.5 volts.
The minimum operating voltage depends on the transmission tem-
perature but is typically between 8-9 V for a warm transmission.
The voltage measured by the TCU from the throttle potentiometer has
been outside acceptable levels.
This would typically indicate a loose connection in the wiring to, or
within, the throttle sensor which has caused the signal at the TCU to
read 0V or 5V.
The voltage measured by the TCU across the temperature Input ter-
minals has been outside acceptable levels.
This would typically be caused by a loose connection or short to ground
in the wiring to, or within, the temperature sensor which has caused
the signal at the TCU to read 0V or 5V.
The voltage measured by the TCU across the shift lever input termi-
nals has been outside acceptable levels for a significant length of
time. This would typically be caused by a loose connection or short to
ground in the wiring to, or within, the inhibitor switch which has caused
the signal at the TCU to read 0V or 5V.
The signal from the ignition, of ignition pulses, has either been non-
existent or has been unreliable.
There are two reasons this fault could occur. The first is due to a lack
of ignition pulses when other TCU inputs would indicate that the en-
gine is running, that is the gear lever is in a driving position, the throttle
is applied and vehicle speed increasing.
The second cause of this (aunt is the frequency of the pulses of the
ignition pulse input to the TCU indicate an unachievable engine speed.
The pulses from the shaft speed sensor have either been non-exis-
tent or have been unreliable.
There are three reasons this fault could occur. The first is due to a
sudden loss of speedometer pulses at a time when they were fre quent,
thus indicating an unachievable degree of deceleration of the drive
line. The second cause of this fault is that the frequency of the pulses
on the shaft speed sensor input to the TCU indicate an unachievable
propeller shaft speed. The third is the presence of a high engine speed
in a driving gear with no speedometer pulses. Condition
Test Pass
Transmission Control
Module Fault
Battery Voltage Input
Fault
Throttle Input Fault
Temperature Input Fault
Shift Lever Position
Input Fault
(Inhibitor/PRNDL Switch)
Engine Speed Sensor
Fault
Shaft Speed Sensor
Fault
(Speedo Sensor)Solenoid
1
2
3
4
5
6
7
8

AUTOMATIC TRANSMISSION 5A-79
ADJUSTMENTS
HYDRAULIC SYSTEM
The procedures detailed below should be followed in the event that the self test procedure detailed in section 6, or a
defect symptom, indicates that there is a fault in the hydraulic system.
When making adjustments to the transmission, select the appropriate procedures from the following preliminary
checks.
lConduct a transmission fluid test procedure, refer to section 7.2.
lCheck the manual linkage adjustment (refer to the vehicle workshop manual).
lCheck engine idle speed (refer to Section 7.3).
lConduct a stall test (it is outside the scope of this publication to detail this procedure)
lconduct a road test (it is outside the scope of this publication to detail this procedure).
TRANSMISSION FLUID TEST PROCEDURE
Checking Transmission Fluid Level
This procedure is to be used when checking a concern with the fluid level in a vehicle. A low fluid level will result in
gearshift loss or delay if driven when the vehicle is cold.
The vehicle is first checked for transmission diagnostic messages (refer to section 6). If the vehicle has a speedo fault
it is possible for the oil level to be low.
The vehicle is to be test driven to determine if there is an abnormal delay when selecting drive or reverse, or loss of
drive. One symptom of low oil level is a momentary loss of drive when driving the vehicle around a comer. Also when
the transmission fluid level is low, a loss of drive may occur when the transmission oil temperature is low.
If there is no loss of drive when the vehicle is driven warm and a speedo fault is registered, then fluid should be added
to the transmission.
Checking, Adding Fluid and Filling
When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid (ATF) or other approved
fluids. The use of incorrect oil will cause the performance and durability of the transmission to be severely degraded.
Do not underfill the transmission. Incorrect tilling may cause damage to the transmission. The fluid level setting
procedure is detailed below.
Notice
When a transmission is at operating temperature hot transmission fluid may come out of the case if the fill plug is
removed. 9 the transmission is at operating temperature allow two hours for cooling prior to removing the plug.
1. If the vehicle is at operating temperature allow the vehicle to cool down for two, but no greater than four hours
before adding transmission fluid (this will allow the transmission to be within the correct temperature
range).
While hot the ATF level is higher and removing the plug may result in oil being expelled from the filler hole. This
will result in the level being low.
2. The transmission selector is to be in Park.
Switch the engine off.
3. Raise the vehicle on a hoist (or leave over a service pit).
4. Clean all dirt from around the service fill plug prior to removing the plug. Remove the oil service fill plug.
Clean the fill plug and check that there is no damage to the ‘O’ ring.
Install the filler pump into the filler hole.
5. Lower the vehicle with the filler pump still connected and partially fill the transmission.
Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.

5A-80 AUTOMATIC TRANSMISSION
6. Switch off the engine and raise the vehicle on the hoist, if applicable, ensuring that the vehicle is level.
7. Three minutes after the engine has stopped, but no longer than one hour, remove the filler pump, The correct
level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATF to the correct level.
8. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle.
9. Tighten the transmission filler plug to specification.
Checking, Adding Fluid and Filling - Drained or Dry Transmission
To set the correct fluid level proceed as follows.
1. Set the transmission selector to Park and switch the engine off.
2. Raise the vehicle on a hoist (or leave over a service pit).
3. Clean all dirt from around the service fill plug prior to removing the plug, Remove the oil service fill plug. Clean the
fill plug and check that there is no damage to the ‘O’ ring. Install the filler pump into the filler hole.
4. Lower the vehicle with the filler pump still connected and partially fill the transmission. This typically requires
approximately :
a. If the transmission torque converter is empty:
9.0 litres - 4WD
9.0 litres - RWD
b. If the transmission torque converter is full:
4.5 litres - 4WD
4.5 litres - RWD
5. Start the vehicle in Park with the Parking brake and foot brake applied with the engine idling, cycle the transmission
gear selector through all positions, adding ATF until gear application is felt.
6. Then add an additional 0.5 litres of ATF.
7. Switch off the engine and raise the vehicle on the hoist. Remove the filler pump and replace the filler plug. The
plug shall be tightened to specification.
8. The vehicle is then to be driven between 3.5 and 4.5 kilometers at light throttle so that the engine does not
exceed 2500 rpm. This should result in the transmission temperature being in the range 50 to 60°C.
9. With the engine idling, cycle the transmission selector through all gear positions with the brake applied.
10. Stop the engine. Raise the vehicle on the hoist, if applicable ensuring the vehicle is level.
11. Three minutes after the engine has stopped, but no longer than one hour, remove the filler plug. The correct
level is reached when ATF is aligned with the bottom of the filler hole. If the correct level is not reached, then add
a small quantity of ATP to the correct level.
12. Replace the transmission filler plug and clean all remnants of ATF on the transmission and vehicle. Tighten the
transmission Filler plug to specification.
ELECTRONIC ADJUSTMENTS
Idle Speed Adjustment
Carry out the adjustments to the idle speed as detailed in the workshop manual.
Throttle Position Calibration
Should the throttle position data stored in the TCU be lost or be out of specification, as indicated by a diagnostic
trouble message, it may be re-established by the following procedure.
lCheck that the hot engine idle speed is within specification.
lAllow the engine to idle in ‘Drive’ for 60 seconds with the air conditioner (if fitted) turned off. The closed throttle
reference point in the TCU has now been set.
Switch the engine off but leave the ignition on. Hold the accelerator pedal on the floor for 60 seconds. The wide open
throttle reference point in the TCU has now been set.

BODY WIRING SYSTEM 9A-9
44 Joint Connector.................................................... Ground
45 Door Unlock Switch
46 Front Fog Lamp Switch
47 Rear Defogger Switch
4 8 ECS Switch
49 Rear Fog Lamp Switch........................................Rear Fog Lamp
50 Digital Clock
51 Thermo Amplifier
52 Glove Box Lamp Switch
53 Air Conditioner Wiring Connetor
54 Glove Box Lamp
55 Ground 6
56 Ground 6.............................................................Gasoline E/G
57 Ground 7.............................................................Gasoline E/G
58 Wheel Speed Sensor (FR)..................................ABS 5.0 or ABD 5.0
59 O
2 Sensor............................................................E32 Gasoline E/G
60 Engine Main Wiring Connector............................Gasoline E/G with MSE ECU
61 HFM .....................................................................Gasoline E/G with HFM ECU
61-1 MSE .....................................................................Gasoline E/G with MSE ECU
62 Front Door Wiring Connector (Passenger Side)
63 Front door Wiring Connector (Passenger Side)
64 Joint Connector (B+)
65 Audio
66 Audio
67 Air Bag Wiring Connector
68 Chime Bell
6 9 Buzzer
70 Kick Down Switch.................................................Automatic Transmission
71 Diode 2................................................................Manual Transmission
72 Ground 3
73 Ground 4
74 Front Cigarette Lighter
75 Diode 3................................................................Automatic Transmission, MB
76 S/E Mode Selector Switch....................................Automatic Transmission
76-1Mode Switch........................................................Automatic Transmission
77 “B” Position Switch..............................................Automatic Transmission
78 “P” Position Switch..............................................Automatic Transmission
79 Shift Lock Solenoid Valve.....................................Automatic Transmission
8 0 TCCU
81 Ground 5.............................................................Gasoline E/G
81-1Ground 7.............................................................Diesel E/G
82 Seat Extension Wiring Connector
83 Transmission Extension Wiring Connector...........E23 & E32 Gasoline E/G with Manual Transmission
83-1 Transmission Extension Wiring Connector...........Diesel E/G with MB A/T
84 Transmission Extension Wiring Connector...........Gasoline E/G with Manual Transmission
84-1 Transmission Extension Wiring Connector...........Diesel E/G with Manual Transmission or BTRE A/T
85 Transmission Extension Wiring Connector...........E23 & E32 Gasoline E/G with A/T
85-1 Transmission Extension Wiring Connector...........Diesel E/G with BTRE A/T
86 Transfer Case Motor
87 Transfer Case Motor
88 Vehicle Speed Sensor
89 Fuel Gauge
90 Acceleration Sensor.............................................ABS 5.0
91 Seat Belt Switch (Passenger)
92 Seat Heater Switch
93 Head Lamp Leveling Device Switch.....................Leveling Device

9A-12 BODY WIRING SYSTEM
15 LH Damper........................................................... ECS
16 Ground 1
17 Ground 2
18 Locking Hub Solenoid
19 Condenser Fan Relay.........................................Gasoline E/G
20 LH Position Lamp
21 LH Head Lamp
22 LH Head Lamp Leveling Device...........................Leveling Device
23 Thermo Switch 2..................................................Gasoline E/G with HFM
24 Thermo Switch 3..................................................Gasoline E/G with HFM & Air Conditioner
25 LH Front Fog Lamp
26 LH Horn...............................................................Black Out Driving Lamp (Domestic)
27 Condenser Fan Motor.........................................Diesel E/G
28 Black Out Driving Lamp.......................................Black Out Driving Lamp (Domestic)
29 LH Horn...............................................................Leveling Device
30 LH Condenser Fan Motor....................................Gasoline E/G with Air Conditioner
31 Thermo Switch 1..................................................Diesel E/G or Gasoline E/G with HFM
32 Resistor...............................................................Gasoline E/G with Air Conditioner
33 Thermo Switch 4..................................................Gasoline E/G with HFM & Air Conditioner
34 Ambient Censor...................................................Air Conditioner
35 RH Condenser Fan Motor....................................Gasoline E/G
36 RH Horn
37 RH Front Fog Lamp
38 RH Position Lamp
39 RH Head Lamlp
40 RH Head Lamp Leveling Device..........................Leveling Device
41 Wheeling Sensor................................................. ECS
42 Wheel Speed Sensor (FR)..................................ABS 5.0, 5.3 or ABD 5.0, 5.3
43 RH Damper.......................................................... ECS
44 Alternator Extension Connector...........................Gasoline E/G
45 Alternator .............................................................Gasoline E/G
46 Alternator Extension Joint box..............................Diesel E/G
47 Alternator Extension Connector...........................Diesel E/G
48 Ground 3
49 Fusible Link Box...................................................Gasoline E/G
49-1Fusible Link Box...................................................Diesel E/G
50 Receiver Dryer.....................................................Gasoline E/G with Air Conditioner
50-1Receiver Dryer.....................................................Diesel E/G with Air Conditioner
51 Hood Switch.........................................................Diesel E/G with Black Out Driving Lamp
52 Front Washer Motor.............................................Gasoline E/G
53 Main Wiring Connector

INSTRUMENTATION/DRIVER INFORMATION 9E-3
COMBINATION METER
COMPONENT LOCATOR
1. Speedometer
2. Odometer
3. Trip odometer
4. Tachometer
5. Coolant temperature gauge
6. Fuel gauge
7. Low fuel level warning light
8. Turn signal indicator (left)
9. Turn signal indicator (right)
10. Outside rearview mirror & tailgate heating switch
11. Reset button
12. Auto shift indicator*
13. Door open warning light
14. TCS indicator (equipped with ABD)*
21. ABS warning light*22. EBD warning light*
23. ECS / SPORT warning light*
24. 4 - wheel warning light*
25. 4 - wheel high indicator
26. 4 - wheel low indicator
27. WINTER indicator
28. POWER indicator
29. High beam indicator
15. Alternator warning light
16. Engine oil pressure warning light
17. Brake system warning light
18. Glow indicator light (For Diesel engine)
19. Airbag warning light*
20. Seat belt reminder