key SSANGYONG MUSSO 1998 Workshop Owner's Manual

OM600 ENGINE CONTROLS 1F3-5
VACUUM CONTROL SYSTEM TEST
2 Engine Cut-Off Valve (Ignition Key Switch)
3 Auto-locking Hub Solenoid Valve
4 Engine Stop Valve Unit
5 PLA Vacuum Unit (Idle Speed Adjustment)
6 Engine
7 Vacuum Pump8 30° Thermovalve
9 Fuel Injection Pump
10 Filter with Restriction
11 Check Valve
12 Modulating Pressure Line (Automatic T/M)
Test Data
Idle Speed Increase
Permissible Pressure Drop of SystemAt least 100 rpm at approx. 500mbr
400 - 500mbar approx. 1 min.

AUTOMATIC TRANSMISSION 5A-77
Action
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck voltage between terminal 4 and 11 of TCU.
- Standard value : when the A/C compressor is ON : 12V
when the A/C compressor is OFF : 0V
lCheck cable for open / short,
lCheck connection of other connectors.
lCheck voltage between terminal 1 and 12 of TCU.
- Standard value : when the kick down switch is ON : 12V
when the kick down switch is OFF : 0V
lFully depress accelerator pedal for 5 seconds(ignition key is ON).
lRelease accelerator pedal.
lDepress brake pedal and start the engine in ‘P’ position.
lDepress brake pedal and idle the engine for 5 seconds in ‘D’
position.
lShift into ‘D’ position and determine fault code for throttle initial-
ization.
lComplete the initialization.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck resistance between terminal 1 and 34 of TCU(when the
connector is disconnected).
- Standard value : 26 - 30
W
lCheck solenoid.
lCheck cable for open / short.
lCheck connection of other connectors,
lCheck resistance between terminal 1 and 40 of TCU (when the
connector is disconnected).
- Standard value : 26 - 30
W
lCheck solenoid.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck resistance between terminal 1 and 41 of TCU (when the
connector is disconnected).
- Standard value : 26 - 30
W
lCheck solenoid.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck resistance between terminal 1 and 33 of TCU (when the
connector is disconnected),
- Standard value : 26 - 30
W
Possible Cause
Air conditioner switch
Kick down switch
Pedal
Vehicle ID
VPS offset
Throttle position sensor
initialization
Solenoid 1
Solenoid 2
Solenoid 3
Solenoid 4 Symptom
P1710
P1712
P1713
P1714
P1715
P1716
P1733
P1734
P1735
P1736

5B-28 MANUAL TRANSMISSION
7. Using a screwdriver, remove the spiral retaining ring.
8. Remove the thrust washer and three-piece 2nd speed
blocking ring assembly.
9. For correct reassembly, place an alignment mark on the
1-2 synchronizer hub and sleeve.
10. Remove the 1-2 synchronizer sleeve from the hub with
following parts :
lThe anti-rattle ball and spring.
lThe three keys.
lOne of the 3 springs.
11. Using a hydraulic press and puller plate, remove the 5th
speed driven gear from the main shaft.

5B-30 MANUAL TRANSMISSION
Assembly Procedure
1. When assemble the synchronizer, make sure that the hubs
and sleeves are matched and the 3 keys are installed
properly. Also align blocking rings with keys during
installation.
Notice
Before assembly, coat all parts with lubricant. In case of the
paper-lined blocking rings, soak them in DexronII/III before
installation.
2. Assemble the following parts :
l1st speed blocking ring.
lAlignment pin and 1st speed gear bearing race.
l1st speed gear and its bearing.
3. Install the rear bearing assembly to the main shaft.
4. Using a hydraulic press and installer, press the 5th driven
gear onto the main shaft. While the main shaft is still on the
press bed, install the 5th driven gear snap ring. If the snap
ring does not fit completely, continue pressing the 5th driven
gear.
5. Install the following parts :
l2nd speed blocking ring assembly.
lThrust washer for the blocking ring inner cone.
lSpiral retaining ring (Use special tools).
l2nd speed gear spacer, bearing and gear.
l2nd gear thrust washer and snap ring.
l3rd speed gear spacer, bearing and gear.
l3rd speed blocking ring.

MANUAL TRANSMISSION 5B-31
6. Using a hydraulic press and installer, install the 3-4
synchronizer hub onto the main shaft.
Notice
Align the blocking ring with the synchronizer keys while
installing the hub.

5D2-20 TRANSFER CASE (TOD)
ELIMINATE THE MEMORIZED FAULT
CODE
When diagnose by SCANNER, it is required that you make
adequate service on defects against all fault codes. And then
you should delete the memorized fault codes in TOD control
unit using SCANNER as follows;
1. Connect SCANNER with diagnosis connector.
2. Select “trouble code clear” in SCANNER.
3. In “trouble code clear” screen, press “enter” key to erase
the fault code.
4. Confirm deletion of fault code and, if not, repeat 2.-3.
process.

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 of
following 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 service
manual 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.

9A-8 BODY WIRING SYSTEM
1 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 Transmission ‘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
19-1Clutch 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
33-14WD 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

9A-10 BODY WIRING SYSTEM
94 Seat Belt Switch (Driver)
95 Seat Belt Switch (Dirver)
96 Parking Brake Switch
97 Rear Cigarette Lighter
9 8 OVPR.................................................................Gasoline E/G
99 LH Side Repeater...............................................Rear Fog Lamp
100 Engine Wiring Connector
101 Engine Joint Connector
102 Engine Joint Connector......................................Gasoline E/G
103 ECS Engine Wiring Connector...........................Diesel E/G & Gasoline E/G with HFM ECU
104 ABD Engine Wiring Connector...........................ABD 5.0
105 ABD Engine Wiring Connector...........................ABD 5.0
105-1ABS Engine Wiring Connector............................ABS 5.0
106 Canister Purge Solenoid Valve...........................Gasoline E/G with MSE ECU
106-1Canister Purge Solenoid Valve...........................E20 & E23 Gasoline E/G with FHM ECU
107 Econo/Standard Solenoid Valve.........................Gasoline E/G with Automatic Transmission
108 CO Potentio Meter..............................................Gasoline E/G with HFM ECU & CO Potentio Meter
109 Front Wiper Motor
11 0 O
2 Sensor...........................................................E20 or E23 Gasoline E/G
111 RH Side Repeater
112 Engine Wiring Connector
113 Vertical Sensor
114 Lateral Sensor
115 Diagnosis
11 6 Joint Box.............................................................Gasoline E/G (E32)
117 Canister Purge Solenoid Valve...........................E32 Gasoline E/G with HFM ECU
118 Led Antenna......................................................Rolling code type Immobilizer
119 E-key Connector................................................Gasoline E/G with Rolling Code Type Immobilizer
120 Receiver Unit......................................................Gasoline E/G with Rolling Code Type Immobilizer
121 Receiver Unit......................................................Gasoline E/G with Rolling Code Type Immobilizer
122 Receiver Antenna..............................................Gasoline E/G with Rolling Code Type Immobilizer
123 Receiver Connector...........................................Gasoline E/G with Rolling Code Type Immobilizer
124 ICU Connector....................................................Gasoline E/G with Rolling Code Type Immobilizer
125 ICU .....................................................................Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
126 CAN Line............................................................Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
127 TOD ...................................................................Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
128 TOD ...................................................................Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
129 Transfer Case Speed Sensor.............................Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
130 Engine Main Wiring Connector...........................Gasoline E/G with MSE ECU
131 Remote Engine Start..........................................Diesel E/G with A/T & Black Out Lamp
132 Remote Engine Start..........................................Diesel E/G with A/T & Black Out Lamp
133 TCU ....................................................................Diesel E/G with BTRE A/T
134 TCU ....................................................................Diesel E/G with BTRE A/T
135 Ground 5............................................................Diesel E/G
136 Start Protection Relay.........................................Diesel E/G with Rolling Code Type Immobilizer
137 EGR control unit.................................................Diesel E/G
1 3 8 ICU 1..................................................................Diesel E/G with Rolling Code Type Immobilizer
1 3 9 ICU 2..................................................................Diesel E/G with Rolling Code Type Immobilizer
140 Injection Pump Valve Extension..........................Diesel E/G with Rolling Code Type Immobilizer
141 Injection Pump Valve Extension..........................Diesel E/G with Rolling Code Type Immobilizer
142 EGR Solenoid....................................................Diesel E/G
143 ICU led................................................................Diesel E/G with Rolling Code Type Immobilizer
144 Immobilizer Solenoid Valve..................................Diesel E/G with Crypto Type Immobilizer
147 Immobilizer Unit...................................................Diesel E/G with Crypto Type Immobilizer

SECTION 9T
REMOTE KEYLESS ENTRY AND
ANTI-THEFT SYSTEM
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 otherwise
noted.
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 9T-1
REKES Specifications . . . . . . . . . . . . . . . . . . . 9T-1
Schematic and Routing Diagrams . . . . . . . . 9T-2
REKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T-3
SPECIFICATIONS
REKES SPECIFICATIONS
Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . . 9T-3
Maintenance and Repair . . . . . . . . . . . . . . . 9T-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9T-5
REKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9T-5
Transmitter
Description
DC 3V
-10°C - 60°C
Changeable Coin Type LITHIUM Battery
(CR2032)
Above 2 years (10 times/day) Application
Rated Voltage
Rated Range of Operating Temperature
Model
Durability
Description
DC 12V
DC 8V - 16V
-30°C - +80°C
Above 5M W
Maximum 3mA Application
Rated Voltage
Rated Range of Operating Voltage
Rated Range of Operating Temperature
Insulating Resistance
Arm Current
Receiver