4WD SSANGYONG MUSSO 2003 Owner's Guide

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

5D2-22 TRANSFER CASE (TOD)
Check function of TOD control unit.
1. Even A1, A2, A3 and A4 test, if you could not find defect,it is required to replace TOD control unit on basis of below phenomena.
a. ”4WD CHECK ” lamp illuminates continuously when
ignition “ON ”.
b. Shift is not possible even 4H/4L switch operation.
c. Upon diagnosis by Scan-100, it displays on “impossible communication with TOD control unit ”
or fault code “1714, 1715, 1716 ”.
- Do occur the above defects? Ye s
No Replace TOD control unit Normal system
A5 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure

5D2-26 TRANSFER CASE (TOD)0Vdc
11 - 15Vdc
Ye s
No
2.5
Ye s No
C3 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check resistance of electro-magnetic clutch.
1. Disconnect 30 pin connector from TOD control unit.
2. Measure resistance between pin 3 and 7 in wiring
connector using multi-tester.
- Specified value
- Measured value is within specified range? Perform C4 stage

0 : short
: open
C4 Check operational voltage of elector-magnetic clutch.
1. Ignition "ON"
2. Measure voltge between pin 3(+) and 17(-)in TOD control unit connector.
- Specified value 4WD high 4WD low
- Measure value is within specified range ? Replace TODcontrol unit Replace wire

TRANSFER CASE (TOD) 5D2-27
Defect in speed sensor : fault code 1731, 1732, 1733, 1734, 1735,1736
Phenomenon
1. Upon diagnosis by SCANNER, it displays on fault code
1731, 1732, 1733, 1734, 1735 and 1736.
2. “4WD CHECK ” lamp illuminates continuously when
ignition “ON ”.
Cause
1. Defect of speed sensor (front, rear).
2. Defect of power supply.
4.75-5.25Vdc
Ye sNo
D1
Ye s
No
D2
Ye s
Ye s
Ye sNo
D3 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check power supply of speed sensor.
1. Ignition
“ON ” or driving mode
2. Measure supply voltage between pin 16 (+) and 13 (-) in
TOD control unit connector using digital multi-tester.
- Specified value
- Measured value is within specified range ?
Check connection status of connector.
1. Check connection status of speed sensor/clutch coil connector and TOD control unit connector.
- Does it connect correctly ?
2. In case of bad connection, connect it correctly then perform the follows:
a. Delete the memorized fault code in control unit by
SCANNER.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by SCANNER.
- It does not display fault code.- It displays one or more fault code among 1731 to1736.
Check output wave of front and rear speed sensor.
1. Upon driving mode.
2. Check output wave of each speed sensor by SCANNER.
3. Is it normal on output wave ? Perform D3 stage Perform D2 stage
Perform D3 stagePerform D2-2 stage Normal system Perform D3 stage Perform D4 stage Replace speed sensor then perform D2-2 stage

TRANSFER CASE (TOD) 5D2-29
Shift motor malfunction : Fault code ® 1741,
1742, 1743
Phenomenon
1. When change the 4H/4L switch from 4H to 4L, ‘4L ’
indicator lamp turn off after blinking for a time and then ‘ 4WD CHECK ’ indicator lamp turn on.
2. Fault codes display by diagnosis of SCAN-100 : 1741, 1742, 1743
3. The shifting operation is not occurred when 4H / 4L switch, is operating.
Cause
Defect in shift motor, improper voltage provided, incorrect
connection in connector, short of wiring.
11-14 V
(Battery voltage) Ye s
No
E1
11-14 V
(Battery voltage)
Ye sNo
Ye sNo
E2
Ye sNo
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check the input voltage of shift motor.
1. Turn the ignition switch to
“ON ” position.
2. Measure the Hi/Low voltage of motor which is located between No.1/No.14 and No.2/No.15 connector of TOD control unit with digital Multi-tester or which is locatedbetween No.G connector and body after detaching T/C
motor connector.
- The specified value (When operates 4H/4L switch)
- Measured value is within specified range ?
3. Measure the Hi/Low voltage of motor which is located between No.2/No.5 and No.1/No.14 connector or which is located No.B connector and body after detaching T/C motor connector
- The specified value (When operates 4H/4L switch)
- Measured value is within specified range ?
Check the fault condition of the relevant connector.
1. Check the installation condition of TOD control unit 30pin connector and T/C shift motor connector.
- Is it installed properly ?
2. If the connector installation is improper, install properly and then perform follows :
a. Delete the fault code of control unit by scan scope
b. Turn off the ignition switch
c. Turn on the ignition switch
d. Re-diagnosis of system
It displays one or more fault code among 1741 to 1743. Perform E1-3 stagePerform E2 stage Perform E4 stage Perform E2 stage Perform E3 stage Perform E2-2 stage Perform E3 stage Normal system

TRANSFER CASE (TOD) 5D2-31
Position incoder and position 1,2,3,4 malfunction :Fault code®1750,1751,1752,1753, 1754
Phenomenon The ‘4WD check ’ lamp can not go out when the ignition
switch positioned to ‘ON ’.
The fault code display 1750, 1751, 1752, 1753, 1754 by diagnosis of SCAN-100.
Cause The portion of position incoder malfunction, each wiring is shorted with ground.
Ye s
No
F1
Ye s No
Ye s
No
F2 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check the installation condition of connector.
1. Check the installation condition between 30 pin connector
of TOD control unit and motor connector of T/C portion.
- Is it installed properly ?
2. If the connector installation is improper, install properly and then execute follow procedure.
a. Delete the all fault code from memory by scan scope.
b. Turn off ignition switch.
c.Turn on ignition switch.
d. Rediagnosis the system.- Does the fault codes display one or more among
1750 ~ 1754. Check the each wiring whether it is shorted or not.
1. Turn off the ignition switch
2. Detach the 30 pin connector of TOD control unit.
3. Perform short test each connector, No.27 (Position 1), No.10 (Position 2), No.28 (Position 3),No.30 (Position
4), No.6 with body.
- Is there resistance of 0 ? Perform F2 stagePerform F1-2 stage Perform F2 stage Normal system Repair or replace due to wiring short
1. Replace the
motor Ass ’y due
the defectiveposition incoder portion.
2. And then, perform F1-2 stage.

9A-8 BODY WIRING SYSTEM1 Fuse Box
2 Door Lock Relay
3 Relay Box
3.1 Front Wiper Relay
3.2 ABS Warning Lamp Relay ....................................ABD 5.0
3.3 Flasher Unit
3.4 Fuel Pump Relay ................................................. Gasoline E/G
3.5 Shift Lock Relay ................................................... Automatic Transmission
3.6 Clutch Interlock & Neutral Relay ...........................Manual Transmission or Automatic Transmission
3.7 Sun Roof Relay
3.8 Automatic T ransmission ‘B’ Switch Interlock ....... Automatic Transmission
3.9 Power Window Relay
3.10 Rear Fog Lamp Relay .......................................... Rear Fog Lamp
3.11 ECS Relay 4 Defogger Relay
5 Ground 1
6 Roof Wiring Connector
7 Diode 1
8 Front Door Wiring Connector
9 Front Door Wiring Connector
10 Front Door Wiring Connector 11 Front Door Wiring Connector
12 Kick Down Relay .................................................. Automatic Transmission
13 Floor Wiring Connector
14 Floor Wiring Connector
15 Floor Wiring Connector
16 ABD Floor Wiring Connector ................................ABD 5.0
17 ECS Floor Wiring Connector
18 Rear Iper & Washer Switch
19 Clutch Switch ........................................................ Manual Transmission
19-1 Clutch Switch ........................................................ E32 Gasoline E/G with Manual Transmission
20 Stop Lamp Switch
21 Outside Mirror Switch
22 Ignition Switch
23 Multi Function Switch
24 Multi Function Switch
25 Black Out Switch .................................................. Black Out Lamp
26 Black out switch ................................................... Black Out Lamp
27 Joint Connector (Tail)
28 Joint Connector (Ignition)
29 Cluster
30 Cluster ................................................................. Automatic Transmission
31 Cluster
32 Cluster
33 4WD Switch .......................................................... Except TOD
33-1 4WD Switch .......................................................... TOD
3 4 Hazard Switch
35 Ground 2
36 Pedal Module ....................................................... Gasoline E/G with MSE ECU
37 Audio Switch
3 8 Immobilizer ........................................................... Crypto Type, Gasoline E/G with MSE ECU or Diesel E/G
39 Ignition Switch
40 Multi Function Switch
4 1 STICS
4 2 STICS
4 3 REKES ................................................................. Remote Keyless

POSITION OF CONNECTORS AND GROUNDS 2-9
S204 (DSL/GSL)
S101 (DSL/GSL)
11) SPLICE PACK S202 (DSL/GSL)
S201 (DSL/GSL)
S205 (DSL/GSL)
3 2 1Ef2
80A Ef6
40A
Ef14
15A
WFusible Link Box
Head Lamp Relay (Low) '30' Fog Lamp Relay '30'
Tail Lamp Relay '30'GL
GL
GL GL
GL
1 2 3 4
5 6 7 8
5C204
LW
LW
DLC '2' Stics '29'
EGR Control unit '3' (DLC) Clock '3'VSS '3' F24 (10A)
Seat Warmer Control unit '9'
Stop Lamp Switch '3' (GSL)
LW LW LW LW LW
1 2 3 4
5 6 7 8RY RY RY RY
RYRY RY RYStics '1'
F17 (10A)
Seat belt Switch '3'
Chime Bell '2', Buzzer '3' DLC '14'
Key Reminder Switch '3' Clock '1'
C212 '10' Audio '5'
S203 (DSL/GSL)
1 2 3 4
5 6 7 8
16
Thermo AMP '3'(DSL)
Thermo AMP '4'(GSL)
Rear Wiper/WasherSwitch '8'LW
LW LW
C212
LWF19 (10A)
Blower Relay 'S1'A/C Switch '3'
S401 (DSL/GSL)
1 2 3 4
5 6 7 84
7
Ef10
10A
C212 C101ECS Switch '4'
Rear Wiper/Washer Switch '6'
A/C Control Panel '11' Tail Lamp Relay '87'
Door unlock Switch '4' Defroster Switch '4'
Audio '3', 4WD Switch '7'
Front Cigar Lighter '2'
Seat Warmer Switch '6' Fog Lamp Switch '4'
Hazard Switch '2'Clock '4'GW GW
GW
GW GW
GW
GW GW
1 2 3 4
5 6 7 8BrW BrW BrB YW
BrBBrB BrW LYECM '38'
'37' ECM
TCM 'A23' 'A24' TCM
TOD 'A10' 'A11' TOD
RESISTOR (M/T)
1 2 3 4
8 9
10 11B B
BRear RH Combi Lamp '4' Rear LH Combi Lamp '4'
5 6 7
12 13 14
2
Door lock Actuator '2'
G302B
B B
C402 BRear Wiper Motor '3' High Maunted Stop Lamp '2'
BLicense Lamp '2'
License Lamp '2'

8. ECM(E32, HFM) .......................................................................................................................... 5-64
1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/ IMMOBILIZER) ........................................... 5-64
2) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/O IMMOBILIZER) ........................................ 5-66
3) SENSOR (CKP, CMP, KNOCK, MAF), CCP SOLENOID, CAM SHAFT ACTUATOR CIRCUIT ....................... 5-68
4) THROTTLE MOTOR & SENSOR, SENSOR (IAT, ECT, HEATED O 2), VSS, CIRCUIT (UNLEAD) ................. 5-70
5) THROTTLE MOTOR & SENSOR, SENSOR (IAT, ECT), CO POTENTIO METER, VSS CIRCUIT(LEAD) ..... 5-72
9. DLC CIRCUIT ................................................................................................................. ............. 5-74
10. TCM(GSL, BTRE) .............................................................................................................. ......... 5-76
1) POWER SUPPLY, GROUND, INDICATION LAMP CIRCUIT ............................................................................. 5- 76
2) KICK DOWN SWITCH, SELECT LEVER POSITION SENSOR, TRANSMISSION CIRCUIT ........................ 5-78
11. TCM(DSL, BTRE) .............................................................................................................. ......... 5-80
1) POWER SUPPLY, GROUND, INDICATION LAMP, SENSOR (TR, ENGINE SPEED) CIRCUIT .................... 5-80
2) KICK DOWN SWITCH, SELECT LEVER POSITION SENSOR, TRANSMISSION CIRCUIT ........................ 5-82
12. KICK DOWN RELAY, 'B' SWITCH CIRCUIT (MB A/T) ........................................................... 5-84
13. TCCU-PART TIME .............................................................................................................. ........ 5-86
1) POWER SUPPLY, GROUND, INDICATION LAMP, PNP RELAY, CLUTCH SWITCH CIRCUIT ..................... 5-86
2) 4WD SWITCH, T/C SPEED SENSOR, T/C MOTOR CIRCUIT ........................................................................ 5-88
14. TCCU-FULL TIME .............................................................................................................. ........ 5-90
1) POWER SUPPLY, GROUND, INDICATION LAMP, NEUTRAL RELAY, CLUTCH CIRCUIT ............................ 5-90
2) 4WD SWITCH, T/C SPEED SENSOR, T/C MOTOR CIRCUIT ........................................................................ 5-92
15. TOD(TORQUE ON DEMAND)-E32,MSE .................................................................................. 5-94 1) POWER SUPPLY, GROUND, WARNING LAMP, 4WD SWITCH, T/C MOTOR CIRCUIT .............................. 5-94
2) T/C SPEED SENSOR, PNP RELAY, CLUTCH SWITCH, CAN CIRCUIT .......................................................... 5-96
16. ECS ......................................................................................................................... ..................... 5-98
1) POWER SUPPLY, GROUND, SENSOR(WHEEL'G, VERTICAL, LATERAL) CIRCUIT ................................... 5-98
2) ECS SWITCH, DAMPER CIRCUIT ...................................................................................................................... 5-100

2 ) GSL BTRE A/T ..................................................................................................................................................... 5-140
30. CLUSTER ............................................................................................................................... ... 5-142
1) SPEED METER, TACHO METER, TEMP GAUGE, FUEL GAUGE CIRCUIT ................................................ 5-142
2) WARNING LAMP(BA TTERY CHARGE, BRAKE, OIL PRESSURE, SEAT BELT, AIR BAG) CIRCUIT ....... 5-144
3) WARNING LAMP(ABS, EBD, TCS, 4WD, ECS), INDICATOR LAMP(4H, 4L, POWER)CIRCUIT ................. 5-146
4) WARNING LAMP(PREHEA T’G, DOOR OPEN), INDICATOR LAMP(ECONOMIC, DEFROSTER, WINTER,
T/SIGNAL, FOG, HIGH BEAM) CIRCUIT .............................................................................................. ..............5-148
5) ILLUMINATION, PRND INDICATOR LAMP CIRCUIT(BTRE A/T) ..................................................................... 5-150
6) ILLUMINATION, PRND INDICATOR LAMP CIRCUIT(E23 MB A/T) .................................................................. 5-152
7) ILLUMINATION, PRND INDICATOR LAMP CIRCUIT(E32 MB A/T) .................................................................. 5-154
31. STICS ....................................................................................................................... .................. 5-156
1) POWER SUPPLY, GROUND, CHIME BELL, BUZZER, WARNING LAMP(PARK'G BRAKE, SEAT BELT)
CIRCUIT ...................................................................................................................................................................... 5-156
2) FRONT WIPER CIRCUIT ...................................................................................................................................... 5-158
3) LAMP(ROOM, MAP, LUGGAGE), DOOR SWITCH CIRCUIT ............................................................................ 5-160
4) CENTRAL DOOR LOCK CIRCUIT ....................................................................................................................... 5-162
5) DEFROSTER,DLC CIRCUIT ............................................................................................................................... ..5-164
6) POWER WINDOW CIRCUIT ............................................................................................................................... .5-166
32. REKES, AUTO-DIMMING ROOM MIRROR CIRCUIT ............................................................ 5-168
33. SUN ROOF CIRCUIT ............................................................................................................ .... 5-170
34. REAR WIPER CIRCUIT .......................................................................................................... .. 5-172
35. ELECTRIC OSRV MIRROR CIRCUIT ..................................................................................... 5-174
36. DIGITAL CLOCK, SEAT BELT TENSION REDUCER CIRCUIT ........................................... 5-176
37. HORN, CIGAR LIGHTER CIRCUIT ......................................................................................... 5-178
38. POWER SEAT CIRCUIT ........................................................................................................... 5-180