2003 SSANGYONG MUSSO wiring

M162 ENGINE CONTROLS 1F1-67
CAMSHAFT POSITION SENSOR
1 Bolt (M6 X 14)......................................... 9-11Nm
2 Camshaft Position Sensor
Removal & Installation Procedure
1. Disconnect the wiring connector from the camshaft position sensor.
2. Unscrew the bolt (2) and remove the camshaft position sensor. Installation Notice 3 Shim
5 O-ring
Tightening Torque 9 - 11 Nm
3. Check the clearance and replace the shim if necessary.
4. Check the O-ring for damage and replace it if necessary.
5. Installation should follow the removal procedure in the
reverse order.

M162 ENGINE CONTROLS 1F1-71
If the measured value is not within the specified value, the possible cause may be in cable or HFM sensor in itself.Perform the 5V power supply inspection procedures.
HFM Sensor 5V Power Supply Inspection 1. Measure the voltage between the HFM sensor No.108 (+) and
No.105(-) after removing the HFM sensor connector.
HFM Sensor Input Voltage Inspection
1. Measure the HFM sensor signal voltage between the ECU
terminal No.103 and No.104.
Specified Value (coolant temperature is over 70 °C)
If the measured value is not within the specified value, the possible cause may be in cable or ECU coupling.
Iginition"ON ” 0.9 - 1.1 V
Engine at Idle 1.3 - 1.7 V
Specified Value 4.7 - 5.2 V
2. Measure the voltage between the HFM sensor wining connector terminal No.3 pin(-) and No.4 after removing the
HFM sensor connector.
Specified Value If the measured value is not within the specified value, the possible cause may be in cable or over voltage protection
relay. Perfrom the 12V power supple inspection procedures.
Specified Value 4.7 - 5.2 V
HFM Sensor 12V Power Supply Inspection
1. Measure the voltage between the HFM sensor wiring connector 1G No.2 pin(+) and No.104 after removing the
HFM sensor connector. If the measured value is not within the specified value, the possible cause may be in cable or over voltage protection
relay.
Specified Value 11 - 14 V

1F1-76 M162 ENGINE CONTROLS 2. Measure the resistance between the coolant temperaturesensor terminal No.1 and No.4 with the coolant temperature sensor disconnected.
Inspection 1. Measure the coolant sensor input voltage between the ECU
terminal No.79 and No.78 while the ignition switch in "ON" position. Notice Replace wiring and coolant temperature sensor if out of specified value. allowable error :
±5%
allowable error : ±5%
Voltage (V)
3.57 1.220.78
Temperature (
°C)
203040
Resistance (W) 2,500322 185
Temperature (
°C)
203040

FRONT SUSPENSION 2C-11
Removal & Installation Procedure
1. Disconnect actuator connector and unscrew bolt and remove
actuator assembly. Notice When installing the actuator to the mounting bracket, the wiring should face the front of the frame.
2. Unscrew the upper nut (6). Notice When screwing the nut, actuator contacting surface of the mounting bracket and rod end should be 0.5 - 1.5mm.
3. Remove the mounting bracket (5). Notice When installing the bracket, it should be vertical to the frame
side member.
4. Remove the bush and check for damage and replace if necessary.
5. Unscrew shock absorber lower bolt and nut and remove the shock absorber. Notice Shock absorber is filled with gas, never attempt to cut or heat.
6. Installation should follow the removal procedure in the reverse order.

2C-12 FRONT SUSPENSION
1 Axle Vertical Acceleration Sensor (wheel Gsensor)
Removal & Installation Procedure
1. Disconnect extension wiring connector (2) from the axle vertical acceleration sensor. Notice Installation of wiring connector should be as shown in the right drawing.
2. Unscrew bolts (3) and remove the axle vertical acceleration sensor (1). Notice When installing the sensor to the bracket, the sensor wiring should be upward.
3. Installation should follow the removal procedure in the reverse order. 1 Actuator Connector
2 Axle Vertical Acceleration Sensor Connector
3 Front Hose Mounting Bracket
4 Frame Side Member
AXLE VERTICAL ACCELERATION SENSOR (WHEEL G SENSOR)2 Extension Wiring
3 Bolt (M6)
............................................. 20 - 30Nm

2D-10 REAR SUSPENSION
Removal & Installation Procedure
1. Disconnect actuator connector and unscrew bolt and removeactuator assembly. Notice
When installing the actuator to the mounting bracket,
the wiring should face outward of the frame.
Actuator wiring should be fixed 40 - 50mm away from
the wiring ends when fixing it with the frame open clip.
2. Unscrew the upper nut (6). NoticeWhen screwing the nut, actuator contacting surface of the mounting bracket and rod end should be 0.5 - 1.5mm.
3. Remove the mounting bracket (5). Notice When installing the bracket, it should be parallel to the frame
side member.
4. Remove the bush and check for damage and replace if necessary.
5. Unscrew shock absorber lower bolt and nut and remove the shock absorber. Notice Shock absorber is filled with gas, never attempt to cut or heat.
6. Installation should follow the removal procedure in the reverse order.

4F-20 ANTILOCK BRAKE SYSTEM
Removal & Installation Procedure ABS Hydraulic Unit
1. Release the ABS wiring connector locking lever in arrowdirection and remove the connector. Notice
Do not force the connector when releasing in arrow
direction.
For installation of the connetor, align and firmly seat
the connector of the hydraulic unit and wiring connector while keeping the locking lever upward and then push it down.
2. Remove the hydraulic lines of the hydraulic unit. During removal, be careful not to drip brake fuid on the
body. Installation Notice
3. Unscrew hydraulic unit mounting nuts (2EA) and remove the unit from the bracket.Installation Notice
Tightening Torque 9 - 12 Nm
Removal of the ABS / ABD Unit Location : Under the front passenger's seat.
1. Remove the wiring connector of the ABS/ABD(or ABS:attached type) ECU.
2. Remove the ground wire.
3. Unscrew the mounting bolts and remove the ECU.
4. Installation should follow the removal precedure in reverse order.
Tightening Torque 12 - 16 Nm
Notice When carrying a new unit, never recline it over 30 °.

5A-24 AUTOMATIC TRANSMISSION
Transmission Control Unit(TCU)
The TCU is an in-vehicle micro-processor based transmission management system. It is usually mounted in the
vehicle cabin, under the instrument panel, under the seat, behind the side kick panels or under the floor in the
footwell on the passenger side. Different control units are supplied for different vehicle applications.The TCU contains:
Processing logic circuits which include a central microcontroller and a back-up memory system.
Input circuits.
Output circuits which control external devices such as the variable pressure solenoid (VPS), on/off solenoid
drivers, a diagnostics output and the driving mode indicator light.
The various items which make up the TCU are discussed below.
Processing Logic
Shift schedule and calibration information is stored in an erasable programmable read only memory (EEPROM).
Throttle input calibration constants and the diagnostics information are stored in electrically erasable programmable
read only memory (EEPROM) that retains the memory even when power to the TCU is disconnected. In operation the software continuously monitors the input values and uses these, via the shift schedule, to determine the required gear state, At the same time it monitors, via the solenoid outputs, the current gear state. Whenever the
input conditions change such that the required gear state is different to the current gear state, the TCU initiates a
gear shift to bring the two states back into line.
Once the TCU has determined the type of gear shift required the software accesses the shift logic, estimates the
engine torque output, adjusts the variable pressure solenoid ramp pressure then executes the shift.
The TCU continuously monitors every input and output circuit for short or open circuits and operating range. When
a failure or abnormal operation is detected the TCU records the condition code in the diagnostics memory and
implements a limp mode, The actual limp mode used depends upon the failure detected with the object to maintain
maximum driveability without damaging the transmission. In general input failures are handled by providing a default
value. Output failures, which are capable of damaging the transmission, result in full limp mode giving only third or
fourth gear and reverse. For further details of limp modes and memory retention refer to the Diagnostic Section.
The TCU is designed to operate at ambient temperatures between -40 and 85°C . It is also protected against
electrical noise and voltage spikes, however all the usual precautions should be observed, for example when arc welding or jump starting. TCU Inputs
To function correctly, the TCU requires engine speed, road speed, transmission sump temperature, throttle position
and gear position inputs to determine the variable pressure solenoid current ramp and on/off solenoid states. This
ensures the correct gear selection and shift feel for all driving conditions. The inputs required by the TCU are as follows: Engine Speed
The engine speed signal is derived from the tachometer signal line, a dedicated sensor or a Controlled Area Network (CAN).
Road Speed
4WD (Diesel) - The shaft speed signal is derived from the speedo sensor located on the transfer case. This signal is transmitted directly to the TCU.
4WD (Gasoline) - The speedo sensor sends the shaft speed signal to the engine control module (ECM). The
information is then transferred to the TCU via the CAN.
Transmission Sump Temperature
The transmission sump temperature sensor is a thermistor located in the solenoid wiring loom within the transmission.
This sensor is a typical NTC resistor with low temperatures producing a high resistance and high temperatures