battery location SSANGYONG MUSSO 2003 Service Manual

GENERAL ENGINE INFORMATION 1A1-13
GENERAL INFORMATION
CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces withtolerances that are measured in the ten-thousanths ofan inch. When any internal engine parts are serviced,care and cleanliness are important. A liberal coating of enigne oil should be applied to friction areas during
assembly, to protect and lubricate the surfaces on initialoperation. Proper cleaning and protection of machinedsurfaces and friction areas is part of the repairprocedure. This is considered standard shop practice even if not specifically stated. Whenever valve train components are removed for
service, they should be kept in order. They should beinstalled in the same locations, and with the same matingsurfaces, as when they were removed. Battery cables should be disconnected before any majorwork is performed on the engine. Failure to disconnectcables may result in damage to wire harness or other electrical parts. ON-ENGINE SERVICE 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 personalinjury and damage to the vehicle. The ignition mustalso be in LOCK unless otherwise noted. Notice:
Any time the air cleaner is removed, the intake
opening should be covered. This will protect against accidental entrance of foreign material, which could follow the intake passage into the cylinder and cause extensive damage when the engine is started.

1F1-36 M162 ENGINE CONTROLS
Location Engine ECU is located at the inside of cowl side trim in right bottom of instrument panel of passenger side. Removal & Installation Procedure
1. Turn the ignition switch to "OFF" position.
2. Disconnect the battery negative cable
3. Remove the cowl side trim form passenger side.
4. Unscrew four securing nuts for ECU from mounting bracket.Installation Notice
5. Pulling out the ECU from bracket.
6. Disconnect the vehicle side coupling(B).
7. Installation should follow the removal procedure in the reverse order.
Tightening Torque 9 - 11 Nm

4F-16 ANTILOCK BRAKE SYSTEM
Description
Check terminals for open or short. (When connector is removed)
Replace the hydraulic modulator.
Check each valve by using SCANNER's solenoid valve overriding function.
Check connection of connector and terminals in the
ECU hydraulic modulator.
Check terminals for open or short. (When connector is removed)
Replace the hydraulic modulator
Check solenoid internal resistance of the prime(ASV) valve and pilot valve(USV) : 8.04 - 9.04
Check each valve by using SCANNER's solenoid valve overriding function.
Check connection of connector and terminals in the
ECU and hydraulic modulator.
Check terminals for open or short.(When connector is removed)
Replace the hydraulic modulator
Check solenoid internal resistance of the prime(ASV)valve and pilot valve(USV) : 8.04 - 9.04
Check each valve by using SCANNER's solenoid valveoverriding function.
Check connection of connector and terminals in the
ECU and hydraulic modulator.
Check terminals for open or short.(When connector is removed)
Replace the hydraulic modulator
Check each valve by using SCANNER's pump motoroverriding function.
Check resistance between pump motor ground ter-minal and battery negative terminal : total resistanceshould be less than 15 m
Check body ground location.
Check relay supply voltage : IGN on : 11 - 14 V
Relay coil internal resistance : 70 - 80
Replace the hydraulic modulator
Check by using SCANNER's stop lamp switch diag-nosing function from sensor value output function.
Check connection of ECU connector side stop lamp switch terminal.
Check resistance of the stop lamp, switch.
- Each end resistance value of the switch
Application
Rear / Right OUTLET Valve Function and Response of The
Valve Function and Response of The
Valve Motor Relay / Circulation Pump Stop Lamp SwitchDefect Code
20 21 2224 27

AUTOMATIC TRANSMISSION 5A-27
Shift Lever Position
Manual 1 Manual 2Manual 3Drive Netural ReverseParkResistance (OHMS) 1k - 1.4k
1.8k - 2.2k
3k - 3.4k
4.5k - 4.9k 6.8k - 7.2k
10.8k - 11.2k 18.6k - 19k
Table 3.3 - Readings for Resistance/Shift Lever Positions Diagnostics Inputs
The diagnostics control input or K-line is used to initiate the outputting of diagnostics data from the TCU to a diagnostic
test instrument. This input may also be used to clear the stored fault history data from the TCU’s
retentive memory. Connection to the diagnostics input of the TCU is via a connector included in the vehicle’s wiring
harness or computer interface. Refer to the vehicle manufacturer’ s manual for the location of the self test connectors.
Battery Voltage Monitoring Input
The battery voltage monitoring input connects to the positive side of the battery. The signal is taken from the main supply to the TCU.
If operating conditions are such that the battery voltage at the TCU falls below 11.3V the transmission will adopt a ‘low
voltage’ mode of operating in which shifts into first gear are inhibited. All other shifts are allowed but may not occur
because of the reduced voltage. This condition normally occurs only when the battery is in poor condition.
When system voltage recovers, the TCU will resume normal operation after a 3 second delay period. TCU Outputs
The outputs from the TCU are supplied to the components described below: Solenoids
The TCU controls seven solenoids. Solenoids 1 to 6 (S1 to S6) are mounted in the valve body, while Solenoid 7 (S7)
is mounted in the pump cover. The normal state (OPEN/CLOSED) and the functions associated with the solenoids
are detailed in table 3.4. Table 3.5 details the S1 and S2 logic for static gear states. The logic during gear changes for
S1 to S4 and S7 is detailed in table 3.6.

SECTION 9A
BODY WIRING SYSTEM
Schematic and Routing Diagrams . . . . . . . . 9A-2
Power Distribution . . . . . . . . . . . . . . . . . . . . . . 9A-2
Starting & Charging (Gasoline HFM) . . . . . . . 9A-3
Starting & Charging (Diesel) . . . . . . . . . . . . . . 9A-4
Fuse Box and Relay . . . . . . . . . . . . . . . . . . . 9A-5
Location of Connectors by
Wiring Harness . . . . . . . . . . . . . . . . . . . . . 9A-7
Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-7
Engine Room . . . . . . . . . . . . . . . . . . . . . . . . 9A-11
Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-13
Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-14
Driver's Door . . . . . . . . . . . . . . . . . . . . . . . . . 9A-15
Passenger's Door . . . . . . . . . . . . . . . . . . . . . 9A-15
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.
Rear Left Door . . . . . . . . . . . . . . . . . . . . . . . 9A-16
Rear Right Door . . . . . . . . . . . . . . . . . . . . . . 9A-16
Tail Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-17
Semi Automatic Air Conditioner . . . . . . . . . . 9A-18
Full automatic Air Conditioner . . . . . . . . . . . . 9A-19
Gasoline Engine (MSE) . . . . . . . . . . . . . . . . 9A-20
Gasoline Engine (HFM) . . . . . . . . . . . . . . . . 9A-21
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . 9A-22
Manual Transmission . . . . . . . . . . . . . . . . . . 9A-23
Automatic Transmission (BENZ) . . . . . . . . . . 9A-24
Automatic Transmission (BTRA) . . . . . . . . . . 9A-25
Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . 9A-26

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
+-