charging SSANGYONG MUSSO 2003 Service Manual

1E1-12 M162 ENGINE ELECTRICALUNIT REPAIR
BATTERY
Inspection Notice
When charging the battery, do not leave the inflammable
objects around it.
When checking the electrolyte of battery, put on
an eye protector and gloves.
1. Inspect the surface of the battery and replace if any defects were found on it.
2. Check if the specific gravity of the electrolyte is within the specified value. Notice
Replace the battery if the maximum tolerance of the
electrolyte between cells is out of the specified value.
Measure the specific gravity in the approx. 20 °C
of ambient temperature.
3. Replenish the electrolyte if necessary. Battery capacity(Ah)Battery specific gravity Max. tolerance between cells
85
1.24
0.04

1E2-12 M161 ENGINE ELECTRICALUNIT REPAIR
BATTERY
Inspection Notice
When charging the battery, do not leave the inflammable
objects around it.
When checking the electrolyte of battery, put on
an eye protector and gloves.
1. Inspect the surface of the battery and replace if any defects were found on it.
2. Check if the specific gravity of the electrolyte is within the specified value. Notice
Replace the battery if the maximum tolerance of the
electrolyte between cells is out of the specified value.
Measure the specific gravity in the approx. 20 °C
of ambient temperature.
3. Replenish the electrolyte if necessary. Battery Capacity(Ah)Battery Specific Gravity
Max. Tolerance between Cells
75
1.24
0.04

M162 ENGINE CONTROLS 1F1-53
3. If there is no change in fuel pressure and maintain thefollowing pressure over 30 minutes, it is normal.
Internal Leakage Test
1. Connect the fuel pressure gauge to the fuel pressure test
connector.
2. Stop the engine for approx. 30 minutes and then check the fuel pressure changes.
Fuel pressure
drops slowly 
Fuel leakage at the injector
 Faulty fuel pressureregulator'sdiaphragm and O- ring.
Fuel pressure
drops rapidly 
Faulty check valve in the fuel pump.
Possible Cause
Pressure Change
Fuel Pressure(bar) 2.5
Discharging the pressure in fuel system
1. Remove the fuel pressure test connector. Installation Notice
2. Remove the fuel pressure in fuel system by pressing the service valve with a clean, pointy tool. Notice Place a cloth so that the fuel doesn't stain around.
Tightening Torque 22.5 - 27.5 Nm

1F1-62 M162 ENGINE CONTROLS
PURGE SWITCHOVER VALVE
1 Purge Switchover Valve
2 Line to Engine
3 Line to Canister
4 Canister
Functions The fuel vaporization control system is installed to inhibit the fuel vaporized gas from discharging into the atmosphere. Thefuel vaporized gas that is accumulated in the canister abstractsthrough the purge switchover valve purification during the engine combustion (except the decreasing mode) and coolant temperature of over 80 °C. For this reason, the ECU transacts
the engine speed, air inflow quantity, coolant temperature, andintake temperature. The purge switchover valve is activated by the ECU frequency according with the engine rotating speed to adjust the purification rate. The purification rate is determined by the continuous valve opening interval. The purge switchover valve is activated by the ECU for the following conditions :
Coolant temperature of over 80 °C
Engine speed of over 1000rpm
2 Minutes after starting
When the fuel cut-off mode is not activated

TRANSFER CASE (TOD) 5D2-25
Error in electro - magnetic clutch : fault code “1721 ”, “1722 ”
Phenomenon
1. Upon diagnosis by SCAN-100, it displays on fault
codes “1721,1722 ”.
Cause
1. Defect in electro - magnetic clutch
2. Defect in connector or wiring
- Open or short from EMC to the supply : 1721
- Short EMC to ground : 1722
Ye sNo
C1
Ye sNo
Ye s
No
11-15Vdc Ye s
No
C2
Ye sNo
Test Stage / ContentsResult
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check relevant connector connection status.
1. Check relevant connector connection status with TOD
control unit.
- Does it connect correctly ?
2. Check connection status of speed sensor and clutch coil connector (7 pin) in transfer case.
- Does it connect correctly ?
3. In case of bad connection, connect it correctly then perform the follows :
a. Delete the memorized fault code in control unit withScan - 100.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by SCAN-100
- Does it display on fault codes “1721,1722 ” ?
Check supply voltage into electro-magnetic clutch.
1. Ignition “ON ”
2. Measure voltage between pin 4/19(+) and 17/18(-) in TOD control unit connector.
- Specified value
- Measured value is within specified range ?
3. If the specified value would not be measured, perform the follows :
a. Check battery voltage (charging condition)
b. Check open circuit on No.13 fuse (20A)
c. Check relevant wires.
- Is the above 3a, 3b, 3c normal ? Perform C1-2 stage Perform C1-3 stage Perform C2 stage Normal system
Perform C2 stage Perform C1-3 stage Perform C3 stage Perform C2-3 stage Perform C3 stage

Charging/ Replace battery
Replace fuse
Repair wires

8B-8 SUPPLEMENTAL RESTRAINT SYSTEM(SRS) Energy Reserve System Energy reserve system is consisted of condensor and energy switch and will check following items continuously during system operation.
- High voltage
- Low voltage
- Low rating capacity
- Function of the energy reserve switchIf there is fault in the energy reserve system, warning lamp will turn on. And defects are found by continuouschecking of the condenser voltage, the system will enter overall shutdown status for safety reason. Shutdown Switch There is 1 energy shutdown switch in the system and it will be checked during start-up. And it also checks that
condenser is discharging properly. If shutdown switch is short, it will be detected during condensor voltage test. If squib line fault is obvious, the warning lamp will turn on and the module will enter overall shutdown status. Accelerometer Check Accelerometer function will be checked during start-up. During operation, accelerometer off-set signal will be checked, If there is fault, module will enter overall shutdown status. ASIC Overheat
Module monitors upper side ASIC overheats continuously. If overheated, the module will enter overall shutdown status. Microprocessor Fault Module checks EEPROM, ROM checksum and RAM during start-up. EEPROM tests checksum operation.If RAM or ROM checksum is defective, module will not allow start-up continuously but will be re-set,If EEPROM is defective, warning lamp will turn on and the module will enter overall shutdown status.During operation, RAM will continuously verify the proper operation of temporary memory program data usage. If there is fault, the module will enter overall shutdown status and the warning lamp will turn on.
Watchdog Test
Watchdog function will be tested in start-up. If there is fault during the test, warning lamp will turn on and the module will enter overall shutdown status.

8B-14 SUPPLEMENTAL RESTRAINT SYSTEM(SRS)
Fault
CodeDefects Service HintAppli-
cation
42 Over heat
4 3 SENS
44 Standard band gap
45 Temperature sensor
46 Warning lamp
47 Battery voltage
49 Fault code list
5 0 USA communication
51 LSA communication
52 No EEPROM program
53 EEPROM checksum
5 4 EEPROM map
55 External watchdog 1
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
Open/short in the warning lamp circuit.
Check related circuits for open/short.
Check connection of connector.
Check the ECU.
Power wire voltage is out of standard voltage (9 - 16V).
Check the battery for voltage and charging.
Check related circuits for open/short.
Check connection of connector.
Check the ECU.
Air bag control unit internal defects.
Check the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
56 Arming sensor-no close
57 RAM check
5 8 System
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.
59 External watchdog 2
60 Pulse
Air bag control unit internal defects.
Check and replace the ECU.
Air bag control unit internal defects.
Check and replace the ECU.

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

BODY WIRING SYSTEM 9A-3
STARTING & CHARGING (GASOLINE HFM)

9A-4 BODY WIRING SYSTEM
STARTING & CHARGING (DIESEL)