SSANGYONG MUSSO 2003 Service Manual

9U-6 CONTROL UNITS AND SYSTEM
5. Rear defogger timerT1 : 12±2 min.
T2 : within 10±1 min.
T3 : 6±1 min.
6. Seat belt warning timer T1 : 6±1 sec.
T2 : 0.3±0.1 sec.
T3 : 0.6±0.1 sec.
7. Parking brake warning T1 : 0.3±0.1 sec.
T2 : 0.3±0.1 sec. V1 : 3km/h - 5km/h
8. Tail lamp lighting warning
When the driver ’s door is opened after removing the IGN
key while the tail lamp switch is still ON, the buzzer should be operated.
T1 : 0.3±0.1 sec.
T2 : 0.3±0.1 sec.

CONTROL UNITS AND SYSTEM 9U-7
After 1), the driver ’s or passenger ’s door should be
unlocked when it locked.
T1 : within 0.2±5 sec.
T2 : 5±0.5 sec.
9. Door ajar warning T1 : 0.3±0.1 sec.
T2 : 0.3±0.1 sec.V1 : 3 - 5km/h
10. IGN key reminder warning T1 : within 0.2 sec.
T2 : 5±0.5 sec.
T3 : 0.3±0.1 sec.
T4 : 0.3±0.1 sec.
T5 : 0.5±0.1 sec.

9U-8 CONTROL UNITS AND SYSTEM
11. Central door lockT1 : within 0.2 sec.
T2 : 0.5±0.1
12. Coupled with REKES mode T1 : 0.0 5±0.02 sec. (lock signal)
T2 : 0.1±0.02 sec. (unlock signal)
T3 : within 0.2±5 sec.
T4 : 0.5±0.1 sec.T5 : within 0.3 sec.
T6, T7 : 0.5±0.1 sec.
T8 : 1±0.25 sec.
13. Ignition key hole illumination

CONTROL UNITS AND SYSTEM 9U-9
14. Auto door lockV1 : 50±5km/h
T1 : 0.5±0.1 sec.
15. Auto door unlock T1 : 0.5±0.1 sec. V1 : 15km/h

MUSSO-SPORTS 1A-3
SUPPLEMENT
HUBER EGR
SYSTEM DESCRIPTION The following chart shows the relationship between the input and the output in Huber EGR control unit. Compared to traditional system that only operates theEGR valve with RPM sensor and Micro switch, the HuberEGR control unit bring big differences that of traditionalsystem on the functions.
Input Signal
RPM sensor (CPS)
EGR valve lift sensor
Throttle position sensor (TPS) - M/T
Shift lever position
Throttle position sensor (TPS)
Vehicle speed sensor(VSS) Basic input signal for EGR operation Engine cold or hot signal
Position signal of EGR valve that is triggered by vacuum modulator 1 Transfer the engine load signal to the control unit directly (manual transmission)
TCU (A/T)
EGR
Control
Unit
Coolant temperature sensor (CTS)
Solenoid valve (Control forvacuum modulator 2)
If the control unit determines it is in no-load sharp accel- eration mode after analyzing the input signals, this conver- sion type switch reduces the fuel consumption by cutting off the intake air pressure from
fuel injection ALDA and gen- erating the vacuum pressure. In no-load sharp acceleration
mode, Duty Control ( continu- ous precise control) is acti- vated according to the varia- tions of the input signals when the solenoid valve generates the vacuum pressure in ALDA.
Vacuum modulator 2
The opening value of the modulator is precisely con- trolled by input signals and programmed MAP, and the opening value of EGR valve is also changed by the varia- tions of vacuum pressure to EGR valve. The changed opening value is transferred to the control unit as input signal.
Vacuum modulator 1
TCU in automatic transmission equipped vehicle transfers the information such as driving conditions and speeds into the EGR control unit. EGR control unit uses the shift lever position and vehicle speed as important information for operating the solenoid valve during no-load sharp acceleration mode. In manual transmission, the signal of vehicle speed is transferred into the EGR control unit directly.
Clutch switch
In manual transmission, the clutch switch is the one of core elements to determine driving condition. Output Signal
EGR Control Unit

1A-4 MUSSO-SPORTS
SUPPLEMENT
from vacuum pump
EGR valve
EGR control unit
KAA5A020
KAA5A020
KAA5A020
KAA5A020 EGR COMPONENTS EGR Unit
1. Location: behind passenger's side panel
2. Arrangement: 81-pin connector
3. Integrated self-diagnostic function (Scan-100: not
fixed)
4. Part number For automatic transmission: 28800-07100 For manual transmission: 28800-07000
Vacuum Modulator
1. Location: in front of intake manifold
2. Continuous precise control with the signals from EGR unit (PWM-Pulse With Modulation Control)
3. Rated voltage: 12 V
4. Operating voltage: 8 ~ 16 V
5. Resistance (at 20 °C): 15.4 ± 0.7
6. Operating range of vacuum (Duty control)


 Vacuum modulator 1: 0 ~ 600 mbar


 Vacuum modulator 2: 300 ~ 600 mbar
7. Modulator control


 Vacuum modulator 1: for controlling EGR valve


 Vacuum modulator 2: for controlling no-load sharp
acceleration (ALDA control)
not used connector
Vacuum modulator 1
(for controlling EGR valve)Vacuum modulator 2
(for controlling ALDA)
from vacuum pump
Vacuum modulator 1
Vacuum modulator 2
Solenoid valve
ALDAIntake
manifold
EGR control unit

MUSSO-SPORTS 1A-5
SUPPLEMENT
KAA5A020
KAA5A020
KAA5A020EGR Valve and Lift Sensor
1. EGR valve: The output signals from EGR unit controls
the vacuum modulator 1 through step 1 to step 16 precisely, accordingly the opening value of EGR valvewill be changed.
2. Lift sensor (potentiometer): EGR unit converts the position of EGR valve into electrical signal to detectthe opening value of the valve (Lift sensor). In additionto, this compensates the opening value of EGR valveby controlling the vacuum modulator 1 when thereare some differences between the output signal fromvacuum modulator 1 and the input value ofpotentiometer from EGR valve. If the closing or opening value EGR valve is different from the output value due to the carbon and paticlematerial in exhaust gas, the opening value of EGRvalve is compensated by adjusted the vacuum levelof vacuum modulator.
Measured EGR valve opening value Step 1 2
Vacuum(mbar)
approx. -370 approx. -690 Valve opening
value (mm)
approx. 0.2approx. 6.0 Output
voltage (V)
approx. 1.7 ~ 2.1
approx. 9.6 ~ 11.6
1. The opening value of the valve is the internal moving distance of EGR valve by vacuum pressure. The valve starts to move when the vacuum pressurereaches approximately -370 mbar. If the EGR valveis fully opened, the moving distance will be 6 mmdue to -690 hpa of vacuum pressure.
2. The output voltage may vary according to the battery voltage in vehicles. These values have been convertedinto percentage from battery voltage in each step.


 Step 1: 15% of battery voltage


 Step 2: 64% of battery voltage
Location of EGR valve EGR valve arrangement
Vacuum modulator 1 Connector (potentiometer)
Circuit of potentiometer
312

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.