fuel SSANGYONG MUSSO 2003 Service Manual

MUSSO-SPORTS 1A-3
SUPPLEMENT
HUBER EGR
SYSTEM DESCRIPTION The following chart shows the relationship between the input and the output in Huber EGR control unit. Compared to traditional system that only operates theEGR valve with RPM sensor and Micro switch, the HuberEGR control unit bring big differences that of traditionalsystem on the functions.
Input Signal
RPM sensor (CPS)
EGR valve lift sensor
Throttle position sensor (TPS) - M/T
Shift lever position
Throttle position sensor (TPS)
Vehicle speed sensor(VSS) Basic input signal for EGR operation Engine cold or hot signal
Position signal of EGR valve that is triggered by vacuum modulator 1 Transfer the engine load signal to the control unit directly (manual transmission)
TCU (A/T)
EGR
Control
Unit
Coolant temperature sensor (CTS)
Solenoid valve (Control forvacuum modulator 2)
If the control unit determines it is in no-load sharp accel- eration mode after analyzing the input signals, this conver- sion type switch reduces the fuel consumption by cutting off the intake air pressure from
fuel injection ALDA and gen- erating the vacuum pressure. In no-load sharp acceleration
mode, Duty Control ( continu- ous precise control) is acti- vated according to the varia- tions of the input signals when the solenoid valve generates the vacuum pressure in ALDA.
Vacuum modulator 2
The opening value of the modulator is precisely con- trolled by input signals and programmed MAP, and the opening value of EGR valve is also changed by the varia- tions of vacuum pressure to EGR valve. The changed opening value is transferred to the control unit as input signal.
Vacuum modulator 1
TCU in automatic transmission equipped vehicle transfers the information such as driving conditions and speeds into the EGR control unit. EGR control unit uses the shift lever position and vehicle speed as important information for operating the solenoid valve during no-load sharp acceleration mode. In manual transmission, the signal of vehicle speed is transferred into the EGR control unit directly.
Clutch switch
In manual transmission, the clutch switch is the one of core elements to determine driving condition. Output Signal
EGR Control Unit

MUSSO-SPORTS 1A-7
SUPPLEMENT
Throttle Position Sensor (TPS)
1. EGR unit receives TPS signal from TCU (A/T) or input
signal from pin 61 of EGR unit (M/T). The load value of engine is important signal because Huber EGRsystem make EGR valve operate in extended rangeexcept no-load sharp acceleration mode.
2. Resistance check


 Disconnect the TPS sensor connector from fuelinjection pump and measure the entire resistancebetween pin 1 and pin 4. Specified value: 5 k ± 20 %


 Measure the resistance between pin 1 and pin 2 at no-load and full-load. Approx. 10 ~ 20 % of full resistance at no-load Approx. 70 ~ 85 % of full resistance at full-load
3. Voltage check


 The supplied voltage to TPS from EGR unit (for
M/T) or TCU (for A/T) is approx. 5 V. 0.60 ± 0.2 V at no-load 3.85 ± 0.3 V at full-load
VACUUM LINE Installation of modulator and vacuum line (on-vehicle)
E GR n

1A-10 MUSSO-SPORTS
SUPPLEMENT
Test Step 2: Exhaust gas control mode with no-load sharp acceleration (between vacuum pump and ALDA)
Condition:
1. At idling, monitor the changesof boost pressure while changing the accelerator pedalposition slowly.
2. Remove the inlet port from ALDA on fuel injection pump,then install the pressure tester.
Before checking the generation of vacuum pressure, Check whether the boost
pressure from intake manifold can be applied to ALDA or not in the range beyond no-load sharp acceleration mode. Check whether the boost pressure can be generated between intake manifold and ALDA. Boost pressure at idling: approx. 5 ~ 7 mbar. While depressing the accelerator pedal slowly, does the boost pressure of 220 ~ 270 mbar generate at 4,000 ~ 4,500 rpm?
At idling, install the pressure tester into inlet port of vacuum modulator2 and read the negative pressure(specified value: approx. -900mbar) on tester. Install the vacuum tester into inlet port of solenoid valve, and checkwhether the negative pressure isgenerated in no-load sharp accel-eration mode or not, and read thechanges of vacuum pressurewithin specified ranges.
NO
If the boost pressure is not within specified value, appropriatepressure line should be replaced. Check the solenoid valve with the same method in no-load sharpacceleration mode.
YES
YES
Check the vacuum circuit in no-load sharp acceleration mode. Is the approx. -900 mbar of negative pressure generated between vacuum pump line and inlet port of vacuum modulator 2?
In vacuum modulator 2, check the vacuum circuit between inlet port and outlet port. Is the approx. -300 ~ 650 mbar of negative pressure generated in no-load sharp acceleration mode?
Check the vacuum circuit between outlet port of vacuum modulator 2 and inlet port of solenoid valve. Is the approx. -300 ~ 650 mbar of negative pressure generated in no-load sharp acceleration mode?
Install the vacuum tester into outlet port of vacuum modulator, andcheck whether the negativepressure is generated or not in no-load sharp acceleration mode.
Check the intake boost pressure by ranges


 Boost pressure line
between intake manifold and solenoid valve


 Boost pressure line
between ALDA and solenoid outlet valve
NO
Check the voltage supplying and vacuuming
Check whether the EGR control unit can supply the battery voltage tovacuum modulator 2. If can, in no-load sharp acceleration mode,check whether the negative pressuremay vary within specified ranges. Ifthere are not any vacuuming or if thenegative pressure will not be varied,replace the modulator with new one. YES
YES
NO
Replace the vacuum hose in the range.

MUSSO-SPORTS 1A-15
SUPPLEMENT
KAA5A020
KAA5A020
KAA5A020Removal and Installation of Luggage Deck Preceding work: Removal of tail lamp assembly
1. After removing the tail lamp assembly, release upper
two screw and one lower. Screw of the side bumper cover.
KAA5A020 2. Carefully remove the cover of bumper side.
Note: Due to the opposite fixing section of the cover
screw of bumper side is the locking fastener, so it is fragile part careful remove this one.
3. After releasing four fixing bolt of rear bumper, and then remove the bumper.
4. Remove the wiring of tail lamp and the operation cable of fuel filler.

MUSSO-SPORTS 1A-25
SUPPLEMENT
KAA5A300
1 Rear Floor Pannel
2 Deck Floor Pannel
3 Middle Pannel of Floor
4 middle Pannel of Floor Extension
5 Reinforce Fuel Sending Cover
6 Reinforce Rear Seat Mounting (LH)
7 Reinforce Rear Seat Mounting (RH)
8 Reinforce Hinge Mounting
9 Mounting Member of Body Mounting
10 Reinforce No5. Mounting
11 Deck floor No1. Member
12 Deck floor No2. Member 13 Reinforce Deck No1. Mounting
14 Deck Floor No3. Member
15 Reinforce Deck No2. Mounting
16 Nut Holder
17 Nut (M10)
18 Deck Floor No4. Member
19 Upper Bracket of Spare tire
20 Lower Bracket Spare Tire
21 Deck Back Outer Pannel
22 Reinforce Stopper Mounting
23 Deck Floor Member
LUGGAGE DECK
14721179.8
1352
543.8

HOW TO USE ELECTRICAL WIRING DIAGRAM 1-3
Connector DiodeFuse in engine room fuse & relay box Fuse in passenger room fuse box Ground Joint - Inline wire connected point Splice pack(Junction connector)
C D
Ef F
G J
S
2. CIRCUIT IDENTIFICATION SYMBOL
3. FUNCTION OF POWER SUPPLY LINE (NUMBER)
IDENTIFICATION SYMBOL MEANING
Power supply No Power supply condition
Battery Voltage(B+) supply in Ignition Switch "ON" and "ST" (IGN 1)
Battery Voltage(B+) supply in Ignition Switch "ON" (IGN 2) Battery Voltage(B+) supply in Ignition Switch "ON" and "ACC"Battery Voltage(B+) supply directly regardless of Ignition Switch Ground connected to battery(
–)
Battery Voltage(B+) supply in Head Lamp Switch 1st and 2nd step
(Illumination circuit)
15
15A 15C
30 31 58
Abbreviation Color
BrownGreen Violet Pink
White
Orange
Light Green
Br
GV P
W
Or
LgAbbreviation Color
Sky BlueRed
Blue
Yellow
Gray
Black
Sb
RL Y
Gr B
4. WIRING HARNESS COLOR IDENTIFICATION 5. HOW TO CHECK
TERMINAL NUMBER OF CONNECTOR
- Terminal number is given based on Female Terminal Connector ex) Terminal Number 4 of C901 connection
Locking Terminal Number 4
of total 6 pins
Male Connector
(W/H Fuel Tank)
4 C901
Female Connector (W/H Floor)
C901
W/H Floor 13
2
46 5

POSITION OF CONNECTORS AND GROUNDS 2-3
C361 C371C381C401C402C403 22
88626 White
ColorlessColorlessColorlessColorlessColorless Main - Co-Driver DoorFloor - Rear Left DoorFloor - Rear Right DoorFloor - Tail GateFloor - Tail GateFloor - Tail Gate
Inside Co-Driver Side Cowl PanelCenter 'B' PillarCenter Left 'B' PillarBehind The Left LampBehind The Left LampBehind The Left Lamp
2. CONNECTOR, GROUND AND SPLICE PACK INFORMATION
1) CONNECTOR
Connector
Number Connecting Wiring HarnessConnector PositionColorPin
Number
C101 C102C103C104C105C106C107 C108 C109C110C111C112C201C203C204C205 C206
C206B C207 C208C208
C208B C209C210C211C212 C213 C251C301C302C303 C304 C305 C351212 2
15 143 2
16 6
40 6 84
10 33
4 [6]
1616121584
1417 6 3
20 1614 12 6
22 Colorless Colorless
WhiteBlackBlackBlackBlack Black BlackBlackBlack Gray
White
Colorless WhiteBlackBlack Black BlackBlackBlackBlackBlackBlackBlack
White
Colorless Black
White WhiteWhite
Colorless White
Blue Main - Engine Main - EngineMain - EngineEngine - MainEngine - EngineGenerator - EngineGenerator - Engine Genertor - Engine Engine - MainMain - Engine MainEngine Main - ECM MainEngine Main - ECM MainMain - RoofMain Air BagMain - Driver SeatMain - T/MMain - Fuel Tank Main - Fuel Tank Main - T/MMain - T/MMain - T/MMain - T/MMain - T/MMain - T/MDLC Connector - MainMain - Air ConMain - ECM Main Driver Seat - Driver Seat, AUX Main - FloorMain - Floor Main - Floor Main - FloorMain - Floor Main - Driver DoorInside The Engine Room Fuse Block Inside The Engine Room Fuse BlockInside The Engine Room Fuse BlockUnder The Engine Room Fuse BlockBeside Pre-Heating Unit (DSL)Under The Air Cleaner Housing (DSL, Turbo)Under The Air Cleaner Housing (DSL, N/Turbo) Under The Air Cleaner Housing (GSL) Under The Coolant Reservoir TankBehind The ABS Module (HFM)Center The Engine Room Dash PanelCenter The Engine Room Dash PanelUpper The I/P Fuse BlockLeft The AudioUnder The Driver SeatUpper The T/C MotorUpper The T/C (DSL) Upper The T/C (GSL) Upper The T/CUpper The T/C (GSL)Upper The T/C (DSL)Upper The T/C (GSL)Upper The T/C (DSL)Upper The T/C (GSL)Beside The Steering ColumnBehind The Glove BoxBeside The ECM (MSE) Under The Driver Seat Beside The I/P Relay BlockBeside The I/P Relay BlockBeside The I/P Relay Block Inside Co-Driver Side Cowl Panel Beside Center ConsoleUpper The I/P Fuse Block
Connector
Number Connecting Wiring HarnessConnector PositionColorPin
Number
2) GROUND
G101 G102 G103G201 G202 G203G204G205 G206 G207G208 G209 G301G302G303 Ground Position
Wiring Harness
Ground
Number
Behind The Left LampBeside The Start Motor Behind The Right Head Lamp Right The I/P Fuse BlockBeside The STICSUpper The ECM Behind The Ashtray Beside The TCCUBeside The ABS Module Beside THe ECM Under THe CO-Driver SeatBeside The EBCMCenter The Left 'B' Pillar Beside The Left Rear Speaker Beside The Right Rear Speaker
Engine Engine Engine
Main MainMain Main MainMain Main MainMain
Floor Floor Floor
* [ ] : EURO III

USAGE AND CAPACITY OF FUSES IN FUSE BOX 4-3
2. I/P FUSE BLOCK
1) POSITION OF RELAY AND FUSE 2) USAGE OF FUSE IN PASSENGER ROOM FUSE BOX
* 30 : BAT(+) Power Supply Through Ef1.
15A10A
10A15A10A
20A10A10A
10AST F110AIG1 F210AIG1 F3
ACC10AF4 B+30AF5
B+
(1) F6
F13
IG1
F20
15AF730AF1410AF21
F8F15F22
20AF915AF1610AF23
F10
B+
(2)
F17
F24
20AF1115AF1810A 15A
20AF1210AIG2 F19
30A
F25 F26
F27
85
87a3087
86
85
-3087
86
BE
L
85-
30
87
86
2) RELAY BOX
FRONT WIPERRELAY DEFOGGER
RELAY TURN SIGNAL
RELAY GSL : FUEL PUMP RELAYDSL : CIGAR LIGHTER, P/SOCKET RELAY A/T SHIFT LOCK
RELAY
8730
8685
8730
8685
8730
8685
8730
8685
A/T:PNP RELAY M/T:CLUTCH INTER LOCK RELAY SUNROOF
RELAY 'B' S/W
INTERLOCK RELAY POWER WINDER
RELAY 10A 10A10A10A30A15A15A10A20A20A20A20A30A15A15A10A 15A 10A10A10A10A10A10A10A15A30A
F1F2F3F4F5F6F7F8F9
F10 F11F12F14F15F16F17 F18 F19F20F21F22F23F24F25F26F27
Fuse No Capacity Usage
Starter Motor Relay Air BagABS/ABDOutside Mirror, AudioCigar Lighter, Power SocketStop LampHazard SwitchInteriorFuel Pump (Only GSL)TCCU/TOD, Power seatOVPR 1 (Only GSL)OVPR 4 (Only GSL)Heated GlassSun RoofRear Fog Lamp, Power ANT., ECSDLCFront Wiper & WasherRear Wiper & WasherTCCU/TCMBack Up Lamp, Turn Signal LampHead Lamp, Cluster OVPR 3 (Only GSL) Speed Sensor, Unit, Relay CoilNot UsedNot UsedNot Used
Power Supply
30 BAT(+)
ACC (15C) IGN2 (15A)
30 BAT (+)
IGN1 (15)
IGN1 (15)
SPARE
8730
8685
8730
8685
ECS
RELAY ABS WARNING
LAMP RELAY
8730
8685

4-4 USAGE AND CAPACITY OF FUSES IN FUSE BOXSDM Chime BellImmobilizer UnitSticsRekesEBCM
4 Pin 4 Pin 4 Pin4 Pin4 Pin4 Pin4 Pin 4 Pin 3 Pin3 Pin
82330-05000 84190-05100 84150-0130084150-0130084150-0130084150-0130084150-01300 84150-01300 84130-0500084130-05000
Part Name Part Number
Remarks
Resistor W/Diode (GSL) A/C Compressor Relaly (DSL)A/C RelayCooling Fan - 1 RelayCooling Fan - 2 RelayFront Fog Lamp Relay Head Lamp Relay (Low) Head Lamp Relay (Hi)Illumination RelayHorn Relay
3. POSITION OF RELAY, CONTROL UNIT AND PARTS NUMBER
1) ENGINE ROOM FUSE BLOCK
2) RELAY BOX ABOVE I.P FUSE BLOCK
5 Pin 5 Pin 3 Pin5 Pin5 Pin4 Pin4 Pin 4 Pin 4 Pin 4 Pin 4 Pin 4 Pin
84210-05001 84210-05001 84410-05100
66182253386618225338
84150-0130084150-01300 84150-01300 84150-01300 84150-0130084150-0130084190-05100
Part Name Part Number Remarks
Front Wiper Relay Defogger RelayTurn Signal Lamp RelayFuel Pump Relay (GSL)Cigar Lighter, P/socket Relay (DSL)A/T Shift lock Relay PNP Relay Sun Roof RelayA/T "B" Switch Interlock Relay Power Window Relay ECL RelayABS Warning Lamp Relay
3) CONTROL UNIT
Below The Audio
Beside The SDM
Behind the Wiper Switch Upper The Accelerator Upper The Stics
I/P Center Console Floor Panel
8690005800 8661005000869500580087110058008716105000
4891005000X
Part Name Part Number Remarks

CONTENTS
1. STARTING & CHARGING CIRCUIT ........................................................................................... 5-8
1) GSL E23 MB A/T ............................................................................................................... ...................................... 5-8
2) GSL BTRE A/T, GSL E32 MB A/T ................................................................................................. ........................5-10
3) DSL NA BTRE A/T, M/T ......................................................................................................... .................................5-12
4) DSL LA BTRE A/T, M/T ......................................................................................................... .................................5-14
2. PREHEAT'G UNIT CIRCUIT ...................................................................................................... 5-16
3. EGR CONTROL CIRCUIT.......................................................................................................... 5-18
4. ECM (E23, MSE) ............................................................................................................... .......... 5-20
1) OVPR, FUEL PUMP, CCP SOLENOID CIRCUIT ........................................................................................ ....... 5-20
(1) W/O EURO III ............................................................................................................... ..................................................................... 5-20
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-22
2) IGNITION COIL, SENSOR (CAM SHAFT, MAP, CKP), CAM SHAFT ACTUATOR, CPS CIRCUIT .............. 5-24 (1) W/O EURO III ............................................................................................................... ..................................................................... 5-24
(2) W/ EURO III ................................................................................................................ ....................................................................... 5-26
SECTION 5
ELECTRICAL WIRING DIAGRAMS