2003 SSANGYONG MUSSO lock

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
+-

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-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.

MUSSO-SPORTS 1A-15
SUPPLEMENT
KAA5A020
KAA5A020
KAA5A020Removal and Installation of Luggage Deck Preceding work: Removal of tail lamp assembly
1. After removing the tail lamp assembly, release upper
two screw and one lower. Screw of the side bumper cover.
KAA5A020 2. Carefully remove the cover of bumper side.
Note: Due to the opposite fixing section of the cover
screw of bumper side is the locking fastener, so it is fragile part careful remove this one.
3. After releasing four fixing bolt of rear bumper, and then remove the bumper.
4. Remove the wiring of tail lamp and the operation cable of fuel filler.

MUSSO-SPORTS 1A-29
SUPPLEMENT
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
Main - Engine Main - Engine Engine - MainMain - Floor Floor - FRAME FRAME - DECKMain Engine EngineMain Main Floor
C101 (21Pin, Colorless) C103 (2Pin, White) C108 (16Pin, Black)C206 (Colorless) C904 (10Pin, Black) C905 (12Pin, Black)S101 (Black) G101 G102G201 G204 G301
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 Under The Coolant Reservoir Tank Inside Co-Driver Side Cowl PanelBehind The Left FRAME Behind The Left FRAME Inside The Engine Room Fuse BlockBehind The Left Lamp Behind The Right Head Lamp Right The I/P Fuse BlockUpper The ECM Center The Left 'B' Pillar
123 456
HEAD LAMP
MULTI-FUNCTION SWITCH
C1C2
C3 C4
B1 B2 B3 B4
B5 B6 B7 B8 B9
B10
A1 A2 A3 A4 A5 A6
A7 A8 A9
A10 A11 A12 A13 A14
123456789101112
29 30 31 32 33 34 35 36 37 38
28 13 2714261525162417231822
19 2021
39 43 40
44 45 46 4147
48
42
CLUSTER C108
W/H ENGINE
1234 5678
9 101112
13 14 15 16
C103
W/H MAIN
12
5678910 34
HAZARD
SWITCH
2
1
TAIL
LAMP
123 456
1234 5678
9 101112
C905
W/H DECK
5432
109871 6
C904
W/H FLOOR

MUSSO-SPORTS 1A-31
SUPPLEMENT
C101
W/H MAIN
12345 678910
11 12 13 14 15 16 17 18 19 20 21
Main - Engine Main - Floor Floor - FRAMMEFRAME - DECK DECK - DECK LID MainEngine Engine MainFloor
C101 (21Pin, Colorless) C206 (Colorless) C904 (10Pin, Black)C905 (12Pin, Black) C906 (2Pin, Black) S101 (Black)G101 G102 G201G301
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block Inside Co-Driver Side Cowl Panel Behind The Left FRAME Behind The Left FRAMEBehind The Left DECK LID Inside The Engine Room Fuse Block Behind The Left The LampBehind The Right Head Lamp Right The I/P Fuse Block Center The Left 'B' Pillar
12
TAIL LAMP
LICENCE
LAMP
123 456
HEAD LAMP
MULTI-FUNCTION SWITCH
C1C2
C3 C4
B1 B2 B3 B4
B5 B6 B7 B8 B9
B10
A1 A2 A3 A4 A5 A6
A7 A8 A9
A10 A11 A12 A13 A14
123456789101112
29 30 31 32 33 34 35 36 37 38
28 13 2714261525162417231822
19 2021
39 43 40
44 45 46 4147
48
42
CLUSTER
123 456
C206
W/H MAIN
12 45
78 3
9 10111213 6
14
1234 5678
9 101112
C905
W/H DECK
5432
109871 6
C904
W/H FLOOR
2
1
C906
W/H DECK

MUSSO-SPORTS 1A-33
SUPPLEMENT
a. CONNECTOR INFORMATION
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
C351
W/H DRIVER
DOOR
C103
W/H MAIN
C101
W/H MAIN
C361
W/H CO-DRIVER
DOOR TWEETER
12345 678910
11 12 13 14 15 16 17 18 19 20 21
68 9
34
5 2
1
11 7
12 13 14
10
16 1720 21 22 18 19
15
68 9
34
5 2
1
11 7
12 13 14
10
16 1720 21 22 18 19
15
Main - Engine Main - Engine Main - Driver DoorMain - Co-Driver Door Main MainMain
C101 (21Pin, Colorless) C103 (2Pin, White) C351 (22Pin, Blue)C361 (22Pin, White) S201 (Black) S202 (Black)G203 Inside The Engine Room Fuse BlockInside The Engine Room Fuse BlockUpper The I/P Fuse Block Inside Co-Driver Side Cowl Panel Behind The ClusterUnder Right The Audio Right The I/P Fuse Block
CONNECTOR(NUMBER)
CONNECTING. WIRING HARNESSCONNECTOR POSITION
12
1234 5678
9 101112
13 14 15 16

MUSSO-SPORTS 1A-35
SUPPLEMENT
Main - Engine Engine - Engine Genertor - EngineMain - T/M Main - T/M MainMain
C103 (2Pin, White) C105 (8Pin, Black) C108 (16Pin, Black)C901 (16Pin, Black) C902 (12Pin, Black) S201 (Black)G204
b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION
a. CONNECTOR INFORMATION
C902
W/H T/M
C101
W/H MAIN C102
W/H MAIN C108
W/H ENGINE
CONNECTOR(NUMBER) CONNECTING. WIRING HARNESSCONNECTOR POSITION
Inside The Engine Room Fuse Block
Beside Pre-Heating Unit (DSL):MUSSO SPORT
Under The Air Cleaner Housing (DSL, N/Turbo) Upper The T/C(M/T)Upper The T/C(A/T) Behind The Cluster Upper The Huber EGR
1
2
1234
5678
1234 5678
9 101112
13 14 15 16
1234 5678
9 101112
13 14 15 16
C901
W/H T/M
1234
5678
9101112
HUBER EGR
CONTROL UNIT
24
43
23
42
22
41
21
40
20
39
19
38
18
37
17
36
16
35
15
34
14
33
13
32
12
31
11
30
10
29
9
28
8
27
7
26
6
25
62
81
61
80
60
79
59
78
58
77
57
76
56
75
55
74
54
73
53
72
52
71
51
70
50
69
49
68
48
67
47
66
46
65
45
64
12 45 3
44
63