check engine SSANGYONG MUSSO 2003 Service Manual

5D1-4 TRANSFER CASE (PART TIME 4408)SELF-DIAGNOSIS
SYSTEM DESCRIPTION
1. TCCU detects transfer case system malfunctions and indicates malfunctioning part(s) through flashing 4H,4L indicator lights.
Using a service connector, connect it to the diagnosis box in the engine room and read the flashing of the ‘4WD
CHECK ’ indicator light.
The flashing indicator light will show you defective code(s).
2. Identify 7 defective codes after reading the flashing indicator light.
TCCU
Shift motor
Magnetic synchronizer clutch
Speed sensor
Hub solenoid
Selector switch
Motor position sensor
3. Transfer case system is malfunctioning when: 4H ,4L indicator lights are remain on after 0.6 second when turning the ignition switch ‘ON ’
4H,4L indicator lights are continuously come on during driving.
4. If only 1 part is malfunctioning, ‘4WD CHECK ’ indicator light
will display defective code 3 times continuously.
5. If more then 2 part is malfunctioning, the first malfunctioning part will be displayed 3 times and following malfunctioningparts will be displayed .
6. To read defective code, connect the service connector and turn the ignition switch 'ON'.
7. After repairing, eliminate the defective code stored in the TCCU. NoticeBefore replacing the malfunction parts with defective code, check the wires and connectors for proper condition.

TRANSFER CASE (PART TIME 4408) 5D1-5
Defective Code Reading
1. Position the ignition switch to ‘OFF ’
2. Using a service connector, connect the No.2 pin ( lgnition ) and No.6 pin (TCCU) of the diagnosis socket in the engine room.
3. Position the ignition switch to 'ON'.
4. Read the flashing ‘4WD CHECK ’ indicator light and identify
the malfunctioning part.
How to Eliminate the Falut Code
1. Position the ignition switch to ‘OFF ’
2. Using a service connector, connect the No.2 pin (GND) and No.6 pin (TCCU) of the diagnosis socket in the engine room.
3. Position the ignition switch to ‘ON ’ over 5 seconds.
4. Do defective code reading and make sure that all defective codes are eliminated.

5D1-8 TRANSFER CASE (PART TIME 4408) SELF-DIAGNOSIS TEST
Test Procedure
1. Connect the scanner harness connector to the enginecompartment diagnosis socket.
2. Turn the ignition switch to "ON" position.
3. Select "Electronic control vehicle diagnosis" from the function selection display and press "Enter".
4. Select "Musso" from vehicle model selection display and press "Enter".
5. Select "TCCU" from control system selection display and press "Enter".
6. Select "TCCU Part Time" from TCCU diagnosis selection display. Notice
Check sensor valve output display if necessary.
7 . Select "Self-diagnosis" from diagnosis items selection display.
8. Turn the ignition switch to "OFF" position and press "ENTER". Turn the ignition swtich to "ON" position again and press "ENTER".
9. Determine fault code and check the defective component.
Notice Refer to self-diagnosis list.

TRANSFER CASE (TOD) 5D2-19
ClassificationEngine Type
Transmission/Vehicle Type Axle Ratio
Tire Size
Coding Required
1. Replacement of TOD control unit.
2. Adjustment by input error.
3. Change of tire specification.
Items
Gasoline Engine (E32) 661 Diesel Engine
661LA Diesel Turbo Engine
662 Diesel Engine
662LA Diesel Turbo Engine Manual Transmission
Automatic Transmission MUSSO
KORANDO 3.734.554.895.38 5.86
P215 P235P255P275
Coding Method
1. Check and record engine type, axle ratio and tire size.
2. Ignition “OFF ”.
3. Connect SCANNER with diagnosis connector in engine room.
4. Ignition “ON ”.
5. Read the current memorized specification in TOD control unit.
6. Compare memorized specification with the checked record. If not matched, perform a coding.
7. Read again memorized coding specification in TOD control unit for confirmation of coding.
8. Check coding specification whether it matches with vehicle or not. If not, perform a coding again.
Coding items

TRANSFER CASE (TOD) 5D2-21
DIAGNOSIS Malfunction interior TOD control unit ; fault code 1714
Phenomenon
1. When ignition “ON ”, “4WD CHECK ” lamp illuminates
continuously.
2. On diagnosis by SCAN-100, it displays fault code “1714 ”.
Cause ; Error of EEPROM checksum in TOD control unit
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check power supply for TOD control unit. 1. Disconnect 30 pin connector from TOD control unit.
2. Ignition “ON ”.
3. Using multi-tester, measure voltage between pin 5(+)
and 17/18 (-). - Specified value - Measured value is within specified range ? 11-14 Vdc
Ye sNo Perform A2 stagePerform A3 stage
Check connection status in TOD control unit connector.
1. Check connection status.
- Is it connected exactly?
2. In case of mal-connection, connect tightly then perform the follows.
a. Delete fault code using Scan-100.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by Scan-100.
- Does it display fault code “1714 ”? Ye s
No
Ye s No
Check short of 10A fuse (fuse No.20).
1. Detach No.20 fuse from engine room fuse box.
2. Check the existence of short.
- Is fuse normal? Yes
No
Check ground of TOD control unit.
1. Ignition “ON ”.
2. Check voltage between 4/19 (+) pin and 17/18 (-)
using multi-tester (keep connection status).
- Specified value (battery is good)
- Measured value
3. Check short between 17/18 pin and body after disconnect 30 pin connector.
- Is resistance " "? 12Vdc (battery
voltage)
Ye s
No
Ye sNo
A1 A2 A3 A4
Perform A3 stage Perform A2 stage Perform A3 stage Normal system Perform A4 stage Replace fuse, then perform A1 stage Perform A4-3 stage Replace TOD controlunit Repair ground wiring Ground is O.K., perform A5 stage

TRANSFER CASE (TOD) 5D2-23
Error of signal in engine throttle position ; fault code 1715, 1716
Phenomenon
1. Upon diagnosis by SCAN-100, it display on 1715,
1716 codes.
Cause
1. Bad communication line between E/G ECU and CAN.
2. Defect of TOD control unit.
3. Defect of E/G ECU.
Check connection status of connector through CAN communication line.
1. Check connection of connector.
- Does connector connect correctly between TOD
control unit and E/G ECU?
2. In case of bad connection, connect correctly then
perform the follows ;
a . Delete the memorized fault code using SCANNER.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by SCANNER.
- Does it display fault codes “1715 ” or “1716 ”. Ye s
No
B1
Ye sNo
Check connection status of CAN communication line towards E/G ECU.
1. Ignition “OFF ”.
2. Disconnect 30 pin connector towards TOD control unit.
3. Measure resistance between pin No.22 and 23 in wiring connector using multi-tester.
- Specified value
- Measured value is within specified range?
B2
115-125
Ye s
No
Check connection status of CAN communication line towards TOD control unit.
1. Ignition “OFF ”.
2. Disconnect coupling of E/G ECU (gray, 1-60 pin).
3. Measure resistance between pin No.37 and 38 in coupling using multi-tester.
- Specified value
- Measured value is within specified range?
B3
115-125
Ye s
No
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Perform B2 stage Perform B1-2 stage Perform B2 stage Normal system
Perform B3 STAGE Perform B4 stage, check and replace E/ G ECU
Perform B5 STAGE Replace TOD control unit

POWER STEERING SYSTEM 6A-5
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE INSPECTION Steering Wheel Freeplay Inspection Procedure
1. Start the engine and set the wheels in straight ahead position.
2. Slightly move the steering wheel to the left and right andmeasure steering wheel free play when the front wheel is
start to move. Notice
If exceeds specification, the steering column shaft
connections and steering linkage .clearance. Replace orrepair if necessary.
Steering Angle Inspection Procedure
1. Place the front wheel on a measuring tool.
2. Rotate steering wheel all the way right and left and measure steering angle Notice If out of standard, check or adjust toe-in.
Standard 33°37'
31°50'Inner
Outer
Steering Effort Inspection Procedure
1 Place a vehicle on the paved flat ground with front wheels in a straight ahead position.
2 Start the engine and run it at 1,000rpm.
3 Using a scale, measure the steering effort in both directions.
NoticeThe difference in steering effort of left and right should be within 0.6 kg.
Standard Max. 3.0kg
StandardMax. 30mm

6A-6 POWER STEERING SYSTEM
OIL PUMP PRESSURE CHECK Oil Pump Pressure Check
1. Disconnect the pressure hose from the oil pump connect apressure gauge between the oil pump and pressure hose
2. Bleed the system . Start the engine and turn the steering wheel form lock several times until oil temperature is up to
50°C
3. Run the engine at 1,000 rpm.
4. Close the pressure gauge valve and check oil pressure.
NoticeDo not keep the valve closed for more than 10 seconds.
5. Remove the pressure gauge and connect the pressure hose.
6. Do bleeding procedure. BLEEDING OF POWER STEERING SYSTEM Bleeding of Power Steering System
1. Disconnect the fuel line. Using a starter motor, crank the engine and turn the steering wheel from lock to lock 5 or 6 times. Notice Do bleeding with engine cranking. If bleed with idling, there can be a air contact with oil.
2. Connect the fuel feed line and start the engine at idle speed.
3. Turn the steering wheel from lock to lock until there is no more air in oil reservoir.
4. Connect the oil level is within specification.
5. By turning the steering wheel left to right, check the oil level change. Notice
If oil is not changes more than 5mm, do bleeding again.
If oil level rises suddenly when stopped engine, again.
Relief Pressure
75 - 82 kg/cm2

FATC-HAVC 7D-17
7b7a
Water sensor connector
3

0.5RB
Airconditioner control unit connector
V
5

0.5BL
Water Sensor
Water sensor is a thermistor that detects engine coolant temperature to operate the blower speed to LO when water temperature is less than 50.
1. Check that there are water sensor fault code (15,16) by
using self-diagnosis function.
3. Check that measured resistance value among water sensor terminals is as shown in the right side graph. Notice Measure resistance value by soaking the sensor in the ice water and check changes in resistance values after soaking
it in the very hot water.
4. If resistance value is out of specification, replace the water sensor.
5. Install the sensor and turn the ignition switch to ON position and check that voltage between No. 7a terminal of the water
sensor and body (-) is 5V.
6. Check current between the No. 7a and 7b connector terminals of the water sensor and the No. 3 and 5 connector terminals of the airconditioner control unit and repair the wire if defective.
2. Disconnect water sensor 2-pin connector that installed on
the heater unit of inner instrument panel and remove the
water sensor.

SUPPLEMENTAL RESTRAINT SYSTEM(SRS) 8B-3
CAUTIONS
Failure to follow the correct service procedure can cause air bag damage or personal injury due to unexpected air
bag deployment. Before service (removal and installation of part, check for replacement), please be weal noticed offollowing items for your correct service.
1. For service, turn the ignition switch to ‘LOCK’ position and wait for 30 seconds after disconnecting the negative battery cable.
2. If the vehicle collapsed, remove the air bag ECU first to reserve the crash records.
3, Never use other vehicles’ air bag components and replace with specified new part.
4. Never disassemble or repair the air bag module, air bag unit and wiring harness to re-use.
5. Replace the air bag module and air bag unit with new if it dropped, cracked or damaged.
6. Only qualified technicians in service shop should check or repair the air bag,
7. Before service, should be well noticed of warning labels on the vehicle.
A. Sun Visor Side
[Warning] Pull down the sun visor and see SRS air bag warning lamp on the head lining. B. Head Lining
[Warning]
1 . This vehicle is equipped with air bag. Air bag is supplemental device for the seatbelt. Fasten your seatbelt.
2. This air bag should be replaced by authorized supplier within replacement intervals.
3. When the ignition key is turned to ON position, SRS warning lamp will turn on for 6 sec. and go off. In this case, the system is normal. For the following cases, see service manual. - SRS warning lamp does not turn on. - SRS warning lamp does not go off.- SRS warning lamp continues to blink.
C. Steering Wheel Body Inner
[Warning] Before removing the steering wheel, read service manual first. Set the front wheels straight forward
and align the center position marks of SRS clock spring. Improper removal or installation of the steering wheel can damage the SRS components. D. Engine Compartment
[Warning] This vehicle is equipped with air bag. Before checking the engine compartment, read servicemanual first. Faultuy check and service can cause SRS air bag deployment and system defects that can be led to severe damage. E. Battery Cable
[Warning]
Before disconnecting the battery power, read service manual first.