2003 SSANGYONG MUSSO Service Manual

CONTENTS
1. STARTING & CHARGING CIRCUIT ........................................................................................... 5-8
1) GSL E23 MB A/T ............................................................................................................... ...................................... 5-8
2) GSL BTRE A/T, GSL E32 MB A/T ................................................................................................. ........................5-10
3) DSL NA BTRE A/T, M/T ......................................................................................................... .................................5-12
4) DSL LA BTRE A/T, M/T ......................................................................................................... .................................5-14
2. PREHEAT'G UNIT CIRCUIT ...................................................................................................... 5-16
3. EGR CONTROL CIRCUIT.......................................................................................................... 5-18
4. ECM (E23, MSE) ............................................................................................................... .......... 5-20
1) OVPR, FUEL PUMP, CCP SOLENOID CIRCUIT ........................................................................................ ....... 5-20
(1) W/O EURO III ............................................................................................................... ..................................................................... 5-20
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-22
2) IGNITION COIL, SENSOR (CAM SHAFT, MAP, CKP), CAM SHAFT ACTUATOR, CPS CIRCUIT .............. 5-24 (1) W/O EURO III ............................................................................................................... ..................................................................... 5-24
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-26
SECTION 5
ELECTRICAL WIRING DIAGRAMS

3) PEDAL MODULE, THROTTLE MOTOR & SENSOR, CTS, SENSOR(KNOCK, INTAKE AIR TEMP',HEATED O 2) CIRCUIT ...................................................................................................................... ......................5-28
(1) W/O EURO III ............................................................................................................... ..................................................................... 5-28
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-30
4) VSS, CLUTCH SWITCH, IMMOBILIZER CIRCUIT ...................................................................................... .........5-32
(1) W/O EURO III ............................................................................................................... ..................................................................... 5-32
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-34
5. ECM (E32, MSE) ............................................................................................................... .......... 5-36
1) OVPR, FUEL PUMP, CCP SOLENOID CIRCUIT ........................................................................................ ....... 5-36
(1) W/O EURO III ............................................................................................................... ..................................................................... 5-36
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-38
2) IGNITION COIL, SENSOR (CAM SHAFT POSITION, HFM, CKP), CAM SHAFT ACTUATOR, RESONANCE FLAP CIRCUIT ............................................................................................................................... . 5-40
3) PEDAL MODULE, THROTTLE MOTOR & SENSOR, SENSOR(KNOCK, ECT, HEATED O 2) CIRCUIT ....... 5-42
(1) W/O EURO III ............................................................................................................... ..................................................................... 5-42
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-44
4) VSS, CLUTCH SWITCH, IMMOBILIZER CIRCUIT ...................................................................................... ....... 5-46
5) HEATED O 2 SENSOR(1,2,3,4) ............................................................................................................... ............... 5-48
6. ECM (E20, HFM).............................................................................................................. ........... 5-50
1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT ............................................................................ 5-50
2) CCP SOLENOID, SENSOR (MAF, CKP) CIRCUIT ...................................................................................... ...... 5-52
3) THROTTLE MOTOR & SENSOR, ECT SENSOR, VSS, HEATED O 2 SENSOR CIRCUIT ............................ 5-54
7. ECM(E23, HFM) ............................................................................................................... ........... 5-56
1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/ IMMOBILIZER) ........................................... 5-56
2) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/O IMMOBILIZER) ........................................ 5-58
3) SENSOR (CKP, CMP, KNOCK, MAF), CAM SHAFT ACTUATOR CIRCUIT ...................................................... 5-60
4) THROTTLE MOTOR & SENSOR, ECT SENSOR, VSS, HEATED O 2, SENSOR CIRCUIT ............................. 5-62

8. ECM(E32, HFM) .......................................................................................................................... 5-64
1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/ IMMOBILIZER) ........................................... 5-64
2) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/O IMMOBILIZER) ........................................ 5-66
3) SENSOR (CKP, CMP, KNOCK, MAF), CCP SOLENOID, CAM SHAFT ACTUATOR CIRCUIT ....................... 5-68
4) THROTTLE MOTOR & SENSOR, SENSOR (IAT, ECT, HEATED O 2), VSS, CIRCUIT (UNLEAD) ................. 5-70
5) THROTTLE MOTOR & SENSOR, SENSOR (IAT, ECT), CO POTENTIO METER, VSS CIRCUIT(LEAD) ..... 5-72
9. DLC CIRCUIT ................................................................................................................. ............. 5-74
10. TCM(GSL, BTRE) .............................................................................................................. ......... 5-76
1) POWER SUPPLY, GROUND, INDICATION LAMP CIRCUIT ............................................................................. 5- 76
2) KICK DOWN SWITCH, SELECT LEVER POSITION SENSOR, TRANSMISSION CIRCUIT ........................ 5-78
11. TCM(DSL, BTRE) .............................................................................................................. ......... 5-80
1) POWER SUPPLY, GROUND, INDICATION LAMP, SENSOR (TR, ENGINE SPEED) CIRCUIT .................... 5-80
2) KICK DOWN SWITCH, SELECT LEVER POSITION SENSOR, TRANSMISSION CIRCUIT ........................ 5-82
12. KICK DOWN RELAY, 'B' SWITCH CIRCUIT (MB A/T) ........................................................... 5-84
13. TCCU-PART TIME .............................................................................................................. ........ 5-86
1) POWER SUPPLY, GROUND, INDICATION LAMP, PNP RELAY, CLUTCH SWITCH CIRCUIT ..................... 5-86
2) 4WD SWITCH, T/C SPEED SENSOR, T/C MOTOR CIRCUIT ........................................................................ 5-88
14. TCCU-FULL TIME .............................................................................................................. ........ 5-90
1) POWER SUPPLY, GROUND, INDICATION LAMP, NEUTRAL RELAY, CLUTCH CIRCUIT ............................ 5-90
2) 4WD SWITCH, T/C SPEED SENSOR, T/C MOTOR CIRCUIT ........................................................................ 5-92
15. TOD(TORQUE ON DEMAND)-E32,MSE .................................................................................. 5-94 1) POWER SUPPLY, GROUND, WARNING LAMP, 4WD SWITCH, T/C MOTOR CIRCUIT .............................. 5-94
2) T/C SPEED SENSOR, PNP RELAY, CLUTCH SWITCH, CAN CIRCUIT .......................................................... 5-96
16. ECS ......................................................................................................................... ..................... 5-98
1) POWER SUPPLY, GROUND, SENSOR(WHEEL'G, VERTICAL, LATERAL) CIRCUIT ................................... 5-98
2) ECS SWITCH, DAMPER CIRCUIT ...................................................................................................................... 5-100

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

2 ) GSL BTRE A/T ..................................................................................................................................................... 5-140
30. CLUSTER ............................................................................................................................... ... 5-142
1) SPEED METER, TACHO METER, TEMP GAUGE, FUEL GAUGE CIRCUIT ................................................ 5-142
2) WARNING LAMP(BA TTERY CHARGE, BRAKE, OIL PRESSURE, SEAT BELT, AIR BAG) CIRCUIT ....... 5-144
3) WARNING LAMP(ABS, EBD, TCS, 4WD, ECS), INDICATOR LAMP(4H, 4L, POWER)CIRCUIT ................. 5-146
4) WARNING LAMP(PREHEA T’G, DOOR OPEN), INDICATOR LAMP(ECONOMIC, DEFROSTER, WINTER,
T/SIGNAL, FOG, HIGH BEAM) CIRCUIT .............................................................................................. ..............5-148
5) ILLUMINATION, PRND INDICATOR LAMP CIRCUIT(BTRE A/T) ..................................................................... 5-150
6) ILLUMINATION, PRND INDICATOR LAMP CIRCUIT(E23 MB A/T) .................................................................. 5-152
7) ILLUMINATION, PRND INDICATOR LAMP CIRCUIT(E32 MB A/T) .................................................................. 5-154
31. STICS ....................................................................................................................... .................. 5-156
1) POWER SUPPLY, GROUND, CHIME BELL, BUZZER, WARNING LAMP(PARK'G BRAKE, SEAT BELT)
CIRCUIT ...................................................................................................................................................................... 5-156
2) FRONT WIPER CIRCUIT ...................................................................................................................................... 5-158
3) LAMP(ROOM, MAP, LUGGAGE), DOOR SWITCH CIRCUIT ............................................................................ 5-160
4) CENTRAL DOOR LOCK CIRCUIT ....................................................................................................................... 5-162
5) DEFROSTER,DLC CIRCUIT ............................................................................................................................... ..5-164
6) POWER WINDOW CIRCUIT ............................................................................................................................... .5-166
32. REKES, AUTO-DIMMING ROOM MIRROR CIRCUIT ............................................................ 5-168
33. SUN ROOF CIRCUIT ............................................................................................................ .... 5-170
34. REAR WIPER CIRCUIT .......................................................................................................... .. 5-172
35. ELECTRIC OSRV MIRROR CIRCUIT ..................................................................................... 5-174
36. DIGITAL CLOCK, SEAT BELT TENSION REDUCER CIRCUIT ........................................... 5-176
37. HORN, CIGAR LIGHTER CIRCUIT ......................................................................................... 5-178
38. POWER SEAT CIRCUIT ........................................................................................................... 5-180

5-6 ELECTRICAL WIRING DIAGRAMS
39. SEAT WARMER CIRCUIT ........................................................................................................ 5-182
40. AUDIO CIRCUIT ............................................................................................................... ........ 5-184
41. ABS 5.3 CIRCUIT ............................................................................................................. ........ 5-186
42. ABD 5.3 CIRCUIT ............................................................................................................. ........ 5-188
1) POWER SUPPLY, GROUND, WHEEL SPEED SENSOR CIRCUIT ................................................................. 5-188
2) MODULATOR CIRCUIT ......................................................................................................................................... 5-190
43. AIR BAG CIRCUIT ............................................................................................................. ...... 5-192
44. IMMOBILIZER(DIESEL-CRYPTO TYPE) CIRCUIT.................................................................. 5-194
45. IMMOBILIZER(GASOLINE HFM-ROLLING CODE TYPE) CIRCUIT ..................................... 5-196
46.TRAILER CONNECTOR CIRCUIT ........................................................................................... 5-198

5-8 ELECTRICAL WIRING DIAGRAMS
1. STARTING & CHARGING SYSTEM
1) GSL E23 MB A/TC101 (21Pin, Colorless) C102 (2Pin, Colorless) C108 (2Pin, Black) C110 (6Pin, Black) C208B (15Pin, Black)
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C108
W/H GENERA- TOR C208B
W/H MAIN
C101
W/H MAIN C102
W/H MAIN C110
W/H MAIN
START LOCK
SWITCH (MB A/T) IGNITION SWITCH
CLUSTER
CONNECTOR(NUMBER)CONNECTING. WIRING HARNESS
Main - Engine Main - Engine Genertor - Engine Main - Engine MainMain - T/M
CONNECTOR POSITION
Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Under The Air Cleaner Housing (GSL)Behind The ABS Module (HFM) Upper The T/C (GSL)
12345 678910
11 12 13 14 15 16 17 18 19 20 211212
135 2 46
1
4 52
8
14
7
93
15
13
10
11 6
12
76
12
4
38 N
P IGNR
D
3910123 456
11 2
29 38
28
13 2021
39 434842
M
+-30 (BAT +)
: M/T (HFM E20, E23)
15 (IGN 1) 15A (IGN 2)
15C (ACC)
31 GND
Cluster (Charging
WarningLamp)
G105
G104
B B
G201
BST 3
4
OFF
"12"ICU
ACC
ONST BL
BY BY BY
BL
BG
BG 162
F22
10A
F24
10A
RG
W
RGLB 18 5
2 1 YW YW YW
C108
Generator
I.C Regulator D+
B+ 1
C101
Resister 15
C101
14
Ef7
40A
E
f2 80A
BW L LW
Ignition Switch
C102
1
Battery Start LockSwitch(MB A/T)
BY StarterMotor
1
30 87
8685
2
Clutch Switch
1 2
C110
4 C208B
PNP
Relay
8
C208B
2

ELECTRICAL WIRING DIAGRAMS 5-9
• W/H T/M
c. POSITION OF CONNECTORS AND GROUNDS
 W/H MAIN (I/P)  W/H ENGINE (GSL)