2003 SSANGYONG MUSSO cooling

1E3-6 OM600 ENGINE ELECTRICAL
ALTERNATOR Preceding Work : Removal of poly V-belt
1 Cooling Fan
2 Bolt............................................................ 45Nm
3 Bolt ............................................................ 45Nm4 Alternator
5 Plug Connection

OM600 ENGINE ELECTRICAL 1E3-7
Removal & Installation Procedure
1. Disconnect the negative terminal of the battery.
2. Disconnect the plug connection (5).
3. OM 662 EngineAlign the groove of cooling fan with bolt (2) (arrow).
4. Remove the bolts (2, 3) and take out the alternator.
5. Installation should follow the removal procedure in the reverse order.
Tightening Torque 45 Nm

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. Conduct a transmission fluid test procedure, refer to section 7.2.
Check the manual linkage adjustment (refer to the vehicle workshop manual).
Check engine idle speed (refer to Section 7.3).
Conduct a stall test (it is outside the scope of this publication to detail this procedure)
conduct 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 addedto the transmission.
Checking, Adding Fluid and Filling
When adding or changing transmission oil use only Castrol TQ 95 automatic transmission fluid (A TF) 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 temperaturerange).
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.

SECTION 7D
FULL AUTOMATIC TEMPERATURECONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 7D-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7D-1
Service Specifications . . . . . . . . . . . . . . . . . . . 7D-3
Schematic and Routing Diagrams . . . . . . . . 7D-4
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . 7D-4
FATC Block Diagram . . . . . . . . . . . . . . . . . . . . 7D-5
Component Locator . . . . . . . . . . . . . . . . . . . 7D-6 TABLE OF CONTENTS
Ventilation System . . . . . . . . . . . . . . . . . . . . . . 7D-6
Function Description . . . . . . . . . . . . . . . . . . . . 7D-7
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 7D-8
Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . . 7D-8
Maintenance and Repair . . . . . . . . . . . . . . 7D-11 FATC Control Panel . . . . . . . . . . . . . . . . . . . 7D-11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 7D-15
FATC (Full Automatic Temperature Control) is full automatic heater and airconditioning system that detects incar temperature, ambient temperature, sun load and coolant temperature and controls airconditioner system
blowing capacity, outlet temperature and intaking/outlet mode to maintain interior comfort.
SPECIFICATIONSSPECIFICATIONS
Application
Core Size (LxWxT)
Core Type
Expansion Valve Type Thermostat
Resister TypeCooling Capacity Description
237.0x232.0x92.0 Aluminum plate
Angle
ON:4.5±0.6 °C, OFF:1.5±0.6 °C
Aluminum plate
4,500 Kcal/h(AT 420 CMH)
Evaporator Unit
Application
Capacity
Type Description
650-750 g R134a
Refrigerant

4-2 USAGE AND CAPACITY OF FUSES IN FUSE BOX
60A 80A 80A30A30A40A40A60A60A10A10A15A15A15A15A10A10A30A
Ef1Ef2Ef3Ef4Ef5Ef6Ef7Ef8Ef9
Ef10Ef11Ef12Ef13Ef14Ef15Ef16Ef17Ef18
1. ENGINE ROOM FUSE & RELAY BOX
1) ENGINE ROOM FUSE BLOCK
2) USAGE OF FUSE IN ENGINE ROOM FUSE BOX
* 30 : Battery(+) Power Supply
Front
fog
Lamp
Head
Lamp
(LOW)
Head
Lamp (HI)
Illumination
Relay
Horn
Relay
A/CON C101
C102 C103 S101
Cooling fan-2
Cooling fan-1
Ef10 10ATAIL LAMP LH
Ef11 10ATAIL LAMP RH
Ef12 15AHEAD LAMP LH
Ef13 15AHEAD LAMP RH
Ef14 15AFRT FOG LAMP
Ef15 15ADOOR LOCK
Ef16 10AHORN
Ef17 10AA/CON COMP
Ef18 30ABLOWER
DSL GSL
COMP RESIS
TOR
109876 5432121 20 19 18 17 16 15 14 13 12 11
21
123
12
Ef9 60A
BATT1
Ef8 60ABATT2
Ef7 40AIGNITION SWITCH
Ef6 40A
FUSIBLE LINK
HEADLAMP
Ef5 30ACOOLING FAN
Ef4 30APOWER
WINDOW
2) FUSIBLE LINK FUSE BOX
80A 80A 60A
E
f3Ef2Ef1
3) RELAY TERMINAL NUMBER
8687
8530
S
BL8587a
30
87
86
4PIN RELAY 3PIN RELAY 5PIN RELAY ABS & ABD
Generator
Preheating
Power Window
Cooling FanHead Lamp
Ignition Switch Battery 2 Battery 1
Tail Lamp LH
Tail Lamp RH
Head Lamp LH
Head Lamp RH
Front Fog Lamp Door LockHorn
A/C Compressor
Blower
Fuse No Capacity UsagePower Supply
30 BAT(+)
Illumination(58)
30 BAT(+)

4-4 USAGE AND CAPACITY OF FUSES IN FUSE BOXSDM Chime BellImmobilizer UnitSticsRekesEBCM
4 Pin 4 Pin 4 Pin4 Pin4 Pin4 Pin4 Pin 4 Pin 3 Pin3 Pin
82330-05000 84190-05100 84150-0130084150-0130084150-0130084150-0130084150-01300 84150-01300 84130-0500084130-05000
Part Name Part Number
Remarks
Resistor W/Diode (GSL) A/C Compressor Relaly (DSL)A/C RelayCooling Fan - 1 RelayCooling Fan - 2 RelayFront Fog Lamp Relay Head Lamp Relay (Low) Head Lamp Relay (Hi)Illumination RelayHorn Relay
3. POSITION OF RELAY, CONTROL UNIT AND PARTS NUMBER
1) ENGINE ROOM FUSE BLOCK
2) RELAY BOX ABOVE I.P FUSE BLOCK
5 Pin 5 Pin 3 Pin5 Pin5 Pin4 Pin4 Pin 4 Pin 4 Pin 4 Pin 4 Pin 4 Pin
84210-05001 84210-05001 84410-05100
66182253386618225338
84150-0130084150-01300 84150-01300 84150-01300 84150-0130084150-0130084190-05100
Part Name Part Number Remarks
Front Wiper Relay Defogger RelayTurn Signal Lamp RelayFuel Pump Relay (GSL)Cigar Lighter, P/socket Relay (DSL)A/T Shift lock Relay PNP Relay Sun Roof RelayA/T "B" Switch Interlock Relay Power Window Relay ECL RelayABS Warning Lamp Relay
3) CONTROL UNIT
Below The Audio
Beside The SDM
Behind the Wiper Switch Upper The Accelerator Upper The Stics
I/P Center Console Floor Panel
8690005800 8661005000869500580087110058008716105000
4891005000X
Part Name Part Number Remarks

17. COOLING FAN, A/C COMPRESSURE CIRCUIT................................................................... 5-102
1) GASOLINE-HFM ................................................................................................................. .................................. 5-102
2) GASOLINE-MSE ..................................................................................................................................................... 5-104
3) DIESEL ................................................................................................................................................................... 5-106
18. MANUAL AIR CONDITIONER CIRCUIT ................................................................................. 5-108
1) BLOWER MOTOR CIRCUIT ............................................................................................................................... 5-108
2) INTAKE MOTOR, MODE MOTOR CIRCUIT ............................................................................................. ........ 5-110
19. SATC(SEMI AUTO TEMPERATURE CONTROL) CIRCUIT .................................................. 5-112 1) BLOWER MOTOR CIRCUIT ............................................................................................................................... 5-112
2) SENSOR(AMBIENT, SUN, WATER), AIR MIX DOOR MOTOR CIRCUIT ...................................................... 5-114
3) INTAKE MOTOR, MODE MOTOR CIRCUIT ............................................................................................. ........ 5-116
20. FATC (FULL AUTO TEMPERATURE CONTROL) CIRCUIT ................................................ 5-118 1) BLOWER MOTOR, MODE MOTOR, INTAKE MOTOR CIRCUIT.................................................................... 5-118
2) SENSOR(AMBIENT, SUN, WATER), AIR MIX DOOR MOTOR CIRCUIT ...................................................... 5-120
21. HEAD LAMP CIRCUIT ........................................................................................................... .. 5-122
22. HEAD LAMP LEVEL'G DEVICE CIRCUIT .............................................................................. 5-124
23. ILLUMINATION CIRCUIT ........................................................................................................ .. 5-126
24. POSITION LAMP, TAIL LAMP, LICENCE PLATE LAMP CIRCUIT ....................................... 5-128
25. HAZARD LAMP CIRCUIT ........................................................................................................ 5-130
26. BACK UP LAMP CIRCUIT ...................................................................................................... 5 -132
27. FRT FOG LAMP CIRCUIT ....................................................................................................... 5-134
28. REAR FOG LAMP CIRCUIT .................................................................................................... 5- 136
29. SHIFT LOCK SOLENOID, STOP LAMP CIRCUIT ................................................................. 5-138
1) M/T, MB A/T, DSL BTRE A/T .................................................................................................... .......................... 5-138

5-40 ELECTRICAL WIRING DIAGRAMS
2) IGNITION COIL, SENSOR (CAM SHAFT POSITION, HFM, CKP), CAM SHAFTACTUATOR, RESONANCE FLAP CIRCUIT
Main - Engine Engine - Main Engine Main - ECM Main Engine Main - ECM MainMain - ECM Main
C101 (21Pin, Colorless)C109 (16Pin, Black) C111 (40Pin, Black) C112 (6Pin, Gray) C213 (6Pin, Colorless)
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C101
W/H MAIN C109
W/H ENGINE
CAM SHAFTACTUATOR
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Under The Coolant Reservoir Tank Center The Engine Room Dash PanelCenter The Engine Room Dash Panel Beside Yhe ECM (MSE)
12345 678910
11 12 13 14 15 16 17 18 19 20 21
12
CMP
SENSOR
123
HFM SENSOR
12 345
C213
W/H ECM MAIN C112
W/H ENG. MAIN
321
654
321
654
CKP SENSOR
12
OVPR
2167
5348
C111
W/H ECM MAIN
10 1
20 11
30 21
40 31
RESONANCE
FLAP
12
ECMSIG
SIG
SIG
SIG
SIG 5V
#5
#2
#1
12 #4
#3
#2
12
71
73 97 104 106 80 105 108 81 100 99 72 70 27#6
A/C
Relay "85"
35
Cooling Fan
Motor Relay "86"
44
Thermo
Amp"1"
45
EBCM
(ABD) "32"
"F1"2
Cluster
(ABD
Warning Lamp) "4"
#1
#3
12
OVPR
"8"
C112 3
12
C101
8
C213
BW PR
PR BG B BG BW
BW
BW
BY
LB BYLW
BY
BG BY
BB WBYI
gnition
Coil
1
C112 6
C109
16
C112 4
C213 YG
RG BrGr BrG GBr RL YW Br RL BrY YG G GW GGW
YW Br BrY YG
RG GV
RG BrG GBr
GV
YG RL 1
2
3
OVPR "2" Cam Shaft
Actuator CMP Sensor HFMS CKPAIR
TEMP SIG
( - ) SIG
( + )
B+ Ref
13
21
-+2
2
1
132 5 4
Resonance Flap C111
27 25
24 29 15 28 30 16 26
11