2003 SSANGYONG MUSSO sensor

1A-12 MUSSO-SPORTS
SUPPLEMENT
KAA5A020
KAA5A020
KAA5A020 EXHAUST GAS RECIRCULATION MODULE Removal and Installation Procedure
1. After releasing fixing screw of door scuff to the
passenger seat , remove the door scuff.
KAA5A020 2. After releasing fixing bolt of cowl side trim, remove
cowl side trim.
3. Remove pin of connector from the EGR module.
4. After releasing the fixing nut(3ea) of EGR module, remove the the EGR module.
5. Installation should follow the removal procedure in the reverse order.
THROTTLE POSITION SENSOR Removal Procedure 1. Disconnect the TPS connector from the TPS.
2. After releasing the fixing bolt, remove the TPS. Installation Procedure
1. Install temporary fixing bolt of TPS.
2. Install connector of TPS on the TPS.
3. Check the voltage of TPS by using SCAN-100.
4. Install completely fixing bolt of TPS.

MUSSO-SPORTS 1A-13
SUPPLEMENT
KAA5A020
KAA5A020
KAA5A020VACUUM MODULATOR 1, 2 Removal and Installation Procedure
1. Disconnect vacuum hose and connector from vacuum
module.
2. After releasing fixing bolt from bracket of intake manifold, and then remove vacuum modulator.
3. Installation should follow the removal procedures in the reverse order.
KAA5A020 EGR VALVE AND LIFT SENSOR Removal and Installation Procedure
1. Disconnect vacuum hose and connector from the
EGR valve.
2. After releasing the clamping bolt/nut of EGR Valve pipe and then remove the clamp.
3. After releasing fixing bolt of EGR Valve of Intake Manifold, remove the EGR Valve assembly.
4. Installation should follow the removal procedure in the reverse order.
COOLANT TEMPERATURE SENSOR Removal and Installation Procedure
1. Disconnect the coolant temperature sensor from the coolant temperature sensor.
2. After releasing the coolant temperature sensor from cylinder block and then remove the coolant tempera- ture sensor.
3. Installation should follow the removal procedure in the reverse order.
SOLENOID VALVE Removal and Installation Procedure
1. Disconnect vacuum hose(3ea) and connector from the solenoid valve.
2. Remove the solenoid valve from the fixing bracket of injection pump.
3. Installation should follow the removal procedure in the reverse order.

1A-34 MUSSO-SPORTS
SUPPLEMENT
15 IGN1
31
* ( ) : A/T
* A/T TPS, RPM Signal : TCU A5
30
GND
F24
LW A/T
TCU A5 Clutch SW
"1" TPSM/T
41 2
2 RPM Sensor
S201
1 3
LW GrW HUBER EGR ECU (K2004) BG
C R G BrB BrWLRG
10A
BAT+
F17
RY RY 3 9 28 62 61 81 10 29
1
4 6 0798 05 675 4 324 3 332 3 736
WR W WB BrW GR
WR W WB BrW GR BG BrG GL LG YL LB
WR Lift Sensor
EGR Valve Water Sensor
Temp EGR Modulator Exhanst Gas
RecirculationModulator Sol Valve
W WB BrW GR BG BrG GL LG YL LB
S201
8
12 10A
213 7 8
B
13(11) 14(12) 11(9) 12(10) 9(7) (10)8
C901 (C902)
C901
C108
C105
C104
G204
Ef 2 Ef 8
80A60A
C103
2
56 7 2 1
16 15 1411 10
4. HUBER EGR CIRCUIT(MUSSO SPORT)

USAGE AND CAPACITY OF FUSES IN FUSE BOX 4-3
2. I/P FUSE BLOCK
1) POSITION OF RELAY AND FUSE 2) USAGE OF FUSE IN PASSENGER ROOM FUSE BOX
* 30 : BAT(+) Power Supply Through Ef1.
15A10A
10A15A10A
20A10A10A
10AST F110AIG1 F210AIG1 F3
ACC10AF4 B+30AF5
B+
(1) F6
F13
IG1
F20
15AF730AF1410AF21
F8F15F22
20AF915AF1610AF23
F10
B+
(2)
F17
F24
20AF1115AF1810A 15A
20AF1210AIG2 F19
30A
F25 F26
F27
85
87a3087
86
85
-3087
86
BE
L
85-
30
87
86
2) RELAY BOX
FRONT WIPERRELAY DEFOGGER
RELAY TURN SIGNAL
RELAY GSL : FUEL PUMP RELAYDSL : CIGAR LIGHTER, P/SOCKET RELAY A/T SHIFT LOCK
RELAY
8730
8685
8730
8685
8730
8685
8730
8685
A/T:PNP RELAY M/T:CLUTCH INTER LOCK RELAY SUNROOF
RELAY 'B' S/W
INTERLOCK RELAY POWER WINDER
RELAY 10A 10A10A10A30A15A15A10A20A20A20A20A30A15A15A10A 15A 10A10A10A10A10A10A10A15A30A
F1F2F3F4F5F6F7F8F9
F10 F11F12F14F15F16F17 F18 F19F20F21F22F23F24F25F26F27
Fuse No Capacity Usage
Starter Motor Relay Air BagABS/ABDOutside Mirror, AudioCigar Lighter, Power SocketStop LampHazard SwitchInteriorFuel Pump (Only GSL)TCCU/TOD, Power seatOVPR 1 (Only GSL)OVPR 4 (Only GSL)Heated GlassSun RoofRear Fog Lamp, Power ANT., ECSDLCFront Wiper & WasherRear Wiper & WasherTCCU/TCMBack Up Lamp, Turn Signal LampHead Lamp, Cluster OVPR 3 (Only GSL) Speed Sensor, Unit, Relay CoilNot UsedNot UsedNot Used
Power Supply
30 BAT(+)
ACC (15C) IGN2 (15A)
30 BAT (+)
IGN1 (15)
IGN1 (15)
SPARE
8730
8685
8730
8685
ECS
RELAY ABS WARNING
LAMP RELAY
8730
8685

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