2003 SSANGYONG MUSSO electrical

SECTION 1F1
M162 ENGINE CONTROLS
TABLE OF CONTENTS
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cablewill help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwisenoted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1F1-2
Fastener Tightening Specifications . . . . . . . . 1F1-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 1F1-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . 1F1-3
Schematic and Routing Diagrams . . . . . . . 1F1-4 E32 ECU (HFM) . . . . . . . . . . . . . . . . . . . . . . 1F1-4
E32 ECU (MSE) . . . . . . . . . . . . . . . . . . . . . . 1F1-5
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-6
Self Diagnosis Socket Pin Numbers andDescriptions . . . . . . . . . . . . . . . . . . . . . . . . 1F1-6
Self Diagnosis Failure Code . . . . . . . . . . . . . 1F1-7
Test Box Connection . . . . . . . . . . . . . . . . . . 1F1-10
Fuel Injection System Test (MSE3.62) . . . . . 1F1-11
Ignition System Test . . . . . . . . . . . . . . . . . . 1F1-21
Idling Control and Electronic Pedal System Test . . . . . . . . . . . . . . . . . . . . . . . 1F1-26
Air Conditioner Control System Test . . . . . . 1F1-28
Fuel Pressure and Internal Leakage Test . . 1F1-29
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . 1F1-31Injector Test . . . . . . . . . . . . . . . . . . . . . . . .
1F1-33
Maintenance and Repair . . . . . . . . . . . . . 1F1-35
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F1-35
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-35
Fuel Pressure Regulator . . . . . . . . . . . . . . 1F1-46
Fuel Distributor . . . . . . . . . . . . . . . . . . . . . . 1F1-50
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-54
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-57
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1F1-58
Purge Switchover Valve . . . . . . . . . . . . . . . 1F1-62
Vacuum System . . . . . . . . . . . . . . . . . . . . . 1F1-64
Crankshaft Position Sensor . . . . . . . . . . . . 1F1-65
Camshaft Position Sensor . . . . . . . . . . . . . 1F1-67
Hot Film Air Mass (HFM) Sensor . . . . . . . . . 1F1-69
Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . 1F1-72
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . 1F1-74
Coolant Temperature Sensor . . . . . . . . . . . 1F1-75
Accelerator Pedal Module . . . . . . . . . . . . . . 1F1-78

SECTION 1F3
OM600 ENGINE CONTROLS
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1F3-1Fastener Tightening Specifications . . . . . . . . 1F3-1
Maintenance and Repair . . . . . . . . . . . . . . 1F3-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-2
Fuel Injection Pump Coding . . . . . . . . . . . . . 1F3-3
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-4
Vacuum Control System Test . . . . . . . . . . . . 1F3-5
Vacuum Pump(Sectional View) . . . . . . . . . . 1F3-10
Vacuum Pump Test . . . . . . . . . . . . . . . . . . . 1F3-11
Vacuum Pump . . . . . . . . . . . . . . . . . . . . . . 1F3-13
Vacuum Unit Replacement . . . . . . . . . . . . . 1F3-15Idle Speed Adjustment . . . . . . . . . . . . . . . .
1F3-16
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . 1F3-18
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . 1F3-21
Injection Nozzle Test . . . . . . . . . . . . . . . . . . 1F3-22
Injection Nozzles . . . . . . . . . . . . . . . . . . . . . 1F3-25
Injection Nozzle Repair . . . . . . . . . . . . . . . . 1F3-27
Removal and Installation of Injection Timing Device . . . . . . . . . . . . . . 1F3-30
Injection Timing Device . . . . . . . . . . . . . . . . 1F3-35
Start of Delivery Test (Position Sensor, RIV Method) . . . . . . . . . 1F3-37
Fuel Injection Pump . . . . . . . . . . . . . . . . . . 1F3-46
TABLE OF CONTENTS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwisenoted.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Fuel Tank Mounting Nut Fuel Pump Pressure Line Fuel Injection NozzleFuel Injection Pipe
Nozzle Tensioning NutScrew Plug Left-Hand Thread Bolt
N· m
28 - 47 13
35 - 40 18 8030 46

SECTION 1G3
OM600 ENGINE INTAKE & EXHAUST
Specifications . . . . . . . . . . . . . . . . . . . . . . . 1G3-1Fastener Tightening Specifications . . . . . . . . 1G3-1
Schematic and Routing Diagrams . . . . . . . 1G3-2 EGR Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 1G3-2
Maintenance and Repair . . . . . . . . . . . . . . 1G3-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 1G3-3 TABLE OF CONTENTS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwisenoted.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Air Cleaner Housing Cover Nut Intake Manifold Bolt (M8 x 20)Intake Manifold Bolt (M8)Exhaust Mainfold Stud BoltExhaust Pipe Nut (Engine) Exhaust Pipe Bolt
N 

 m
9 - 11
22.5 - 27.5 22.5 - 27.5 9.5 - 12.5 15 - 2828 - 47
Air Cleaner and Inlet Duct & Hose . . . . . . . . 1G3-3
Intake and Exhaust Manifold . . . . . . . . . . . . . 1G3-5
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . 1G3-8
Charge Air System Diagram . . . . . . . . . . . . . 1G3-8
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . 1G3-9
Turbocharger Assembly . . . . . . . . . . . . . . . 1G3-11

SECTION 4A
HYDRAULIC BRAKES
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
General Specifications . . . . . . . . . . . . . . . . . . 4A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Noise or Vehicle Vibration When Applied
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Pulls to One Side When Braking . . . . . . . . . . . 4A-2
Poor Braking . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-2Increasing Pedal Stroke (Pedal Goes to
Floor) or Brake Dragging . . . . . . . . . . . . . . . 4A-3
Poor Braking of Parking Brake . . . . . . . . . . . . 4A-3 TABLE OF CONTENTS
Component Locator . . . . . . . . . . . . . . . . . . . 4A-4
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-4
ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Non-ABS / ABD . . . . . . . . . . . . . . . . . . . . . . . . 4A-6
Maintenance and Repair . . . . . . . . . . . . . . . 4A-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4A-7
Bleeding the Brakes . . . . . . . . . . . . . . . . . . . . 4A-7
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-9
LCRV (Load Conscious Reducing Valve) . . . 4A-12
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Type
Pedal Ratio
Pedal Stroke
Pedal Freeplay Type
Inner Diameter Type
Ratio
Type
I.D. of Caliper Cylinder
Thickness of Brake Pad Thickness of Disc Plate Type
I.D. of Caliper Cylinder
Thickness of Brake Pad Thickness of Disc Plate
Type
Operation
Specification PBR Brake
4.3 : 1
132 mm
23.81 mm
5.0 : 1
60.4 mm

40.5 mm
9.5 mm

Suspended
1 - 4 mm
Tandem Type with Lever Sensor
Vacuum Booster Type
Ventilated Disc 10 mm 24 mm
Rear Wheel Internal Expansion Type Mechanical
SAE J1703, DOT3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Brake Pedal
Master Cylinder Brake Booster Front Brake
Rear Brake
Parking Brake Brake Fluid MANDO Brake
4.3 : 1
138 mm
25.4 mm
5.6 : 1
60 mm
Solid Disc
38.2 mm
10.0 mm 10.4 mm
Application

FrontRear
Front Rear
SECTION 4F
ANTILOCK BRAKE SYSTEM
TABLE OF CONTENTS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Model
ECUNumber of Pins
Operating TemperatureMotor Operating CurrentSolenoid Coil Resistance External Resistance Air Gap
Number of teeth Description
ABS 5.3 31
-40 ~ +120 °C
Below MAX 40A
1.28K - 1.92K
0.35 - 1.60 mm 0.15 - 1.20 mm 52 52 ABS/ABD 5.3
83
-40 ~ +85 °C
Below MAX 45A
8.04 - 9.04 except AV,
HSV 4.04 - 4.54
1.28K - 1.92K
0.35 - 1.60 mm 0.15 - 1.20 mm
52 52
Hydraulic System
Wheel Speed Sensor Impulse Ring
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4F-1
General Specifications . . . . . . . . . . . . . . . . . . 4F-1
Schematic and Routing Diagrams . . . . . . . . 4F-2 ABS 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-2
ABS/ABD 5.0 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-3
ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-4
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . 4F-5
Component Locator . . . . . . . . . . . . . . . . . . . 4F-6 ABS, ABS/ABD . . . . . . . . . . . . . . . . . . . . . . . . 4F-6
ABD System Description . . . . . . . . . . . . . . . 4F-7 Self Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 4F-9
ABS, ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . 4F-9
ABS, ABS/ABD 5.0 . . . . . . . . . . . . . . . . . . . . 4F-11
Defect Codes . . . . . . . . . . . . . . . . . . . . . . . . 4F-13
Maintenance and Repair . . . . . . . . . . . . . . 4F-19
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . 4F-19
Wheel Speed Sensor . . . . . . . . . . . . . . . . . . 4F-19
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . 4F-21 ABS 5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4F-21
ABS/ABD 5.3 . . . . . . . . . . . . . . . . . . . . . . . . 4F-24

SECTION 4G
PARKING BRAKE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 4G-1General Specifications . . . . . . . . . . . . . . . . . . 4G-1
Fastener Tightening Specifications . . . . . . . . . 4G-1
Component Locator . . . . . . . . . . . . . . . . . . . 4G-2 TABLE OF CONTENTS
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-2
Maintenance and Repair . . . . . . . . . . . . . . . 4G-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 4G-3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 4G-3
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
SPECIFICATIONS
GENERAL SPECIFICATIONS
Application
Parking Brake Lever Bolt Cable Mounting Bracket Bolt
N 

 m
8 - 18 8 - 18
FASTENER TIGHTENING SPECIFICATIONS
Application
Type
Operating Type
Description
Mechanically Operated Rear Wheel Expansion Manual

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

5A-30 AUTOMATIC TRANSMISSION
Solenoid Valve Symbols (On/off Solenoids)
The solenoid symbol shown adjacent to each solenoid on the
hydraulic system schematics indicates the state of the oil flow
through the solenoid valve with the power On or 0ff. Refer to
figure 3.6 for the On/off operational details of NO solenoidvalves. Normally Open (NO) Solenoid POWER ON
Line 500 port is closed. The output port is open to exhaust at the solenoid valve. POWER OFF
The exhaust port is closed. The output port is open to line 500,Figure 3.6- Normally Open (NO) Symbols
Variable Pressure Solenoid Multiplexing System
Friction element shifting pressures are controlled by the variable pressure solenoid (VPS).
Line pressure is completely independent of shift pressure and is a function of throttle position, gear state and enginespeed.
S5 is a proportional or variable pressure solenoid that provides the signal pressure to the clutch and band regulator
valves thereby controlling shift pressures.
VPS pressure is multiplexed to the clutch regulator valve, the band regulator valve and the converter clutch regulator
valve during automatic gearshifts.
A variable pressure solenoid produces a hydraulic pressure inversely proportional to the current applied. During a
gearshift the TCU applies a progressively increasing or decreasing (ramped) current to the solenoid. Current applied will vary between a minimum of 200 mA and a maximum of 1000 mA, Increasing current decreases output (55)
pressure. Decreasing current increases output (55) pressure.
Line 500 pressure, (approximately 440 to 560 kPa), is the reference pressure for the VPS, and the VPS outputpressure is always below line 500 pressure.
When the VPS is at standby, that is no gearshift is taking place, the VPS current is set to 200 mA giving maximum output pressure.
Under steady state conditions the band and clutch regulator valve solenoids are switched off. This applies full Line
500 pressure to the plunger and because Line 500 pressure is always greater than S5 pressure it squeezes the S5
oil out between the regulator valve and the plunger. The friction elements are then fed oil pressure equal to Line 500multiplied by the amplification ratio.
When a shift is initiated the required On/off solenoid is switched on cutting the supply of Line 500 to the plunger.
At the same time the VPS pressure is reduced to the ramp start value and assumes control of the regulator valve by
pushing the plunger away from the valve. The VPS then carries out the required pressure ramp and the timed shift is
completed by switching Off the On/off solenoid and returning the VPS to the standby pressure.
This system enables either the band or clutch or both to be electrically controlled for each gearshift. Mode Indicator Light
Depending on the application, the mode indicator light may be used to indicate the mode that has been selected or
if an overheat condition exists. The mode indicator light is usually located on the instrument cluster. Communication Systems CAN
The controller area network (CAN) connects various control modules by using a twisted pair of wires, to share
common information. This results in a reduction of sensors and wiring. Typical applications include using the engine
controller to obtain the actual engine speed and throttle position, and adding these to the network. The ABS controller
(if fitted) can be used to obtain the road speed signal. This information is then available to the TCU without anyadditional sensors.