2003 SSANGYONG MUSSO check engine

8B-10 SUPPLEMENTAL RESTRAINT SYSTEM(SRS)
1. Position the ignition switch to ‘OFF’.
2. Connect the harness connector of scanner to the diagnosissocket in engine compartment.
3. Turn the ignition switch to ‘ON’ position.
4. Select “Electronic control vehicle diagnosis” from function selection display and press ‘Enter’ .
5. Select “Musso (’98 model year)” from vehicle model selection display and press ‘Enter’ .
6. Select “Electronic air bag” from control system selection display and press ‘Enter’ .
7. Select “Self-diagnosis” from diagnosis item selection display.
Notice
Check sensor value of output display, if necessary.
8. Determine the fault code and trace defective component.
NoticeRefer to self-diagnosis list.
SELF DIAGNOSIS

9B-10 LIGHTING SYSTEM Head Lamp Focusing When using the beam setting device
1. The head lamp focus should be adjusted by using a properbeam setting device.
2. Adjust the head lamp focus by using Up/Down, Left/Right adjusting screws.
When using the screen
1. Put the vehicle on the leveling surface.
2. One person is needed to seat on the driver's seat without other loads(CVW) and check the tire pressure if it is in the specification.
3. The distance between the headlamp and the screen is 25m.
4. Draw the vertical line (crossing the center of each headlamp) on the screen.
5. Start the engine.
6. Check if the cut-off line of the headlamp on the screen is in the specification.
1 ) Left/right direction
- The degree of the cross point at the cut-off line of theheadlamp and the vertical line should be 15.
2 ) Up/down direction - The distance between the cut-off line of the headlampand the horizontal line should be 25cm.
7. Adjust the focus if the cut-off line of the headlamp is out of
the specification by using up/down, left/right adjusting screws. A : Up/down direction adjusting screwB : Left/right direction adjusting secrw

1A-6 MUSSO-SPORTS
SUPPLEMENT
Coolant Temperature Sensor (CTS)
1. Location: on cylinder block
2. Coolant temperature MAP (4 Stages) T0: 10 ~ 24 °C
T1: 25 ~ 40 °C
T2: 41 ~ 61 °C
T3: above 61 °C
3. If the EGR system is normally defective while engine is cold (or during warming up), it may be caused by incorrect input signal of the coolant temperaturesensor.
4. Resistance between pin 1 and pin 4 of the connector 20 °C: 2250 ± 159.0
50 °C: 836 ± 41.5
80 °C: 321 ± 15.0
120 °C: 113 ± 7.2
KAA5A040 KAA5A060
KAA5A060Solenoid Valve
1. This valve is used in no-load sharp acceleration mode.
2. Solenoid valve (Normal Open type)


 Normal: Solenoid valve opens, then intake
manifold pressure will operate ALDA.


 No-load sharp acceleration mode: Solenoid valve
closes, then vacuum pressure operate ALDA.
3. Operating voltage: approx. 12 V
4. Resistance: approx. 22.4 ± 1.4
5. Check the connections in each passage when supplying or cutting off the operating voltage.
The valve passage to ALDA will be changed when the battery voltage is supplied through EGR control unit.
Changed to ALDA (1 to 3) or vacuum from intake manifold
Changed to ALDA (2 to 3) from modulator 2 (Refer to exhaust gas control mode with no-load sharp acceleration)
TPS sensorSolenoid valve
Intake manifold
ALDAEGR control unit
3
12
Vacuum modulator 2
2
1
3
300
OHM
+-

MUSSO-SPORTS 1A-7
SUPPLEMENT
Throttle Position Sensor (TPS)
1. EGR unit receives TPS signal from TCU (A/T) or input
signal from pin 61 of EGR unit (M/T). The load value of engine is important signal because Huber EGRsystem make EGR valve operate in extended rangeexcept no-load sharp acceleration mode.
2. Resistance check


 Disconnect the TPS sensor connector from fuelinjection pump and measure the entire resistancebetween pin 1 and pin 4. Specified value: 5 k ± 20 %


 Measure the resistance between pin 1 and pin 2 at no-load and full-load. Approx. 10 ~ 20 % of full resistance at no-load Approx. 70 ~ 85 % of full resistance at full-load
3. Voltage check


 The supplied voltage to TPS from EGR unit (for
M/T) or TCU (for A/T) is approx. 5 V. 0.60 ± 0.2 V at no-load 3.85 ± 0.3 V at full-load
VACUUM LINE Installation of modulator and vacuum line (on-vehicle)
E GR n

1A-8 MUSSO-SPORTS
SUPPLEMENT MAINTENANCE AND REPAIR
VACUUM PUMP AND VACUUM LINE This diagnosis procedure checks for vacuum leaks and actuator's operation while performing the actual control of EGR unit through vacuum lines in vacuum pump. The following special service tools should be used for this procedure.
001 589 73 21 00
Manual Vacuum Pump
Multi-Tester 201 589 13 21 00
Vacuum Tester
KAA5A2P0
KAA5A2R0 KAA5A2Q0
VACUUM LINE TEST Check the EGR system when the vehicle produces excessive exhaust gas. Check the vacuum lines for leaks and blocks. If there are not any faults, check the actuators controlled by EGR control unit. Install the tester in position according to the vacuum circuit diagram.
To prevent personal injury, beware of moving parts of engine.

MUSSO-SPORTS 1A-9
SUPPLEMENT
Test Step 1: EGR operating range (between vacuum pump and EGR valve)
(Condition: at idling) Remove the vacuum modulator 1 and vacuum line (to the directionof vacuum pump), then installvacuum tester.
Check whether the vacuum pressure can be generated between vacuum modulator 1 and vacuum line (vacuum pump side).
Is the vacuum pressure of 900 mbar generated?
Is the vacuum pressure properly generated in the vacuum line between vacuum modulator 1 and EGR valve?
Check the EGR valve for leaks and sticking.
Remove the vacuum hose from outlet port (to the direction of vac-uum pump) of vacuum modulator.Connect the tester and checkwhether vacuum pressure changeor not when the engine rpmchanges. Install the tester into Inlet port of EGR valve and check whether thevacuum pressure changes or notwhen engine rpm changes.
1. Start the engine, then remove EGR valve hose with idling. If the valve disk snaps into position, EGR valve operates properly.
2. Install the T-connector into inlet port of EGR valve, then connects the manual vacuum pump and the vacuum tester in each connection.
3. Generate -700 mbar of vacuum pressure with manual vacuum pump. If EGR will not open (stay vacuum state), EGR valve should be replaced (due tosticks of inner valve guide and valve).Vacuum leaks from vacuum line
NO
Is the vacuum modulator 1 operated properly?

 Is the vacuum pressure varied
between 0 and 600 mbar?


 Is the constant vacuum pressure
generated in constant engine speed?
Check the battery voltage can be supplied to vacuum modulator 1through EGR control unit. With thebattery voltage supplied, check thevacuum pressure can be changedaccording to the accelerator pedalpositions. If the vacuum pressurecannot be generated or changed,the vacuum modulator should bereplaced.
NO
Vacuum modulator 1 has a problem in power supplying system.
NO
Replace the vacuum line between vacuum modulator 1 and EGR valve with new one.
YES YES
YES

HOW TO USE ELECTRICAL WIRING DIAGRAM 1-3
Connector DiodeFuse in engine room fuse & relay box Fuse in passenger room fuse box Ground Joint - Inline wire connected point Splice pack(Junction connector)
C D
Ef F
G J
S
2. CIRCUIT IDENTIFICATION SYMBOL
3. FUNCTION OF POWER SUPPLY LINE (NUMBER)
IDENTIFICATION SYMBOL MEANING
Power supply No Power supply condition
Battery Voltage(B+) supply in Ignition Switch "ON" and "ST" (IGN 1)
Battery Voltage(B+) supply in Ignition Switch "ON" (IGN 2) Battery Voltage(B+) supply in Ignition Switch "ON" and "ACC"Battery Voltage(B+) supply directly regardless of Ignition Switch Ground connected to battery(
–)
Battery Voltage(B+) supply in Head Lamp Switch 1st and 2nd step
(Illumination circuit)
15
15A 15C
30 31 58
Abbreviation Color
BrownGreen Violet Pink
White
Orange
Light Green
Br
GV P
W
Or
LgAbbreviation Color
Sky BlueRed
Blue
Yellow
Gray
Black
Sb
RL Y
Gr B
4. WIRING HARNESS COLOR IDENTIFICATION 5. HOW TO CHECK
TERMINAL NUMBER OF CONNECTOR
- Terminal number is given based on Female Terminal Connector ex) Terminal Number 4 of C901 connection
Locking Terminal Number 4
of total 6 pins
Male Connector
(W/H Fuel Tank)
4 C901
Female Connector (W/H Floor)
C901
W/H Floor 13
2
46 5

5-90 ELECTRICAL WIRING DIAGRAMS
14. TCCU-FULL TIME
1) POWER SUPPLY, GROUND, INDICATION LAMP, PNP RELAY, CLUTCH SWITCH CIRCUIT Main - Engine Main - Engine Main - Engine DLC Connector - Main MainMain
C101 (21Pin, Colorless)C102 (2Pin, Colorless)C103 (2Pin, White) C211 (14Pin, Black) G201 G207
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Inside The Engine Room Fuse Block Beside The Steering ColumnRight The I/P Fuse Block Beside THe ECM
12
11 2
29 38
28
13 2021
39 434842
CLUSTER
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
C103
W/H MAIN
141516 13 12 11 10 9
87654321
DLC
CLUTCH SWITCH
C102
W/H MAIN
C211
W/H DLC
87654321
23222120191817161514131211109
TCCU
5
C208B
"40"
Cluster (N) TCM
"A9" (E23
MB
A/T) "N"
Start Lock Switch (E32
MB
A/T) "N"
LL L L
LL
9C208B
30 15
BAT+IGN 1
31 GND
E
f2
C103 RB
LB
Cluster
YW
Full Time TCCU
YW
G201 G201
B
2
1
G207
18
4WD
Low 4WD
Check
35
80A
F22
10A
LW
B
BB
F20
10A
F10 10 15
9
20A
B+ SIG
5V
B+
IGN 1
GND
2
C211
3
GrR
LgW 31
L
W
"12" DLC
Clutch switch(M/T) 87 86
30 85
B
Y Y
PNP
Relay (A/T) (A/T)
(M/T) 22 19
11
4
C211
4
L
BrW
"13" DLC 8
14 GND
3
: M/T
910 1213
12
11
34
56
71 4
81
2