SSANGYONG MUSSO 2003 Service Manual

MUSSO-SPORTS 1A-9
SUPPLEMENT
Test Step 1: EGR operating range (between vacuum pump and EGR valve)
(Condition: at idling) Remove the vacuum modulator 1 and vacuum line (to the directionof vacuum pump), then installvacuum tester.
Check whether the vacuum pressure can be generated between vacuum modulator 1 and vacuum line (vacuum pump side).
Is the vacuum pressure of 900 mbar generated?
Is the vacuum pressure properly generated in the vacuum line between vacuum modulator 1 and EGR valve?
Check the EGR valve for leaks and sticking.
Remove the vacuum hose from outlet port (to the direction of vac-uum pump) of vacuum modulator.Connect the tester and checkwhether vacuum pressure changeor not when the engine rpmchanges. Install the tester into Inlet port of EGR valve and check whether thevacuum pressure changes or notwhen engine rpm changes.
1. Start the engine, then remove EGR valve hose with idling. If the valve disk snaps into position, EGR valve operates properly.
2. Install the T-connector into inlet port of EGR valve, then connects the manual vacuum pump and the vacuum tester in each connection.
3. Generate -700 mbar of vacuum pressure with manual vacuum pump. If EGR will not open (stay vacuum state), EGR valve should be replaced (due tosticks of inner valve guide and valve).Vacuum leaks from vacuum line
NO
Is the vacuum modulator 1 operated properly?

 Is the vacuum pressure varied
between 0 and 600 mbar?


 Is the constant vacuum pressure
generated in constant engine speed?
Check the battery voltage can be supplied to vacuum modulator 1through EGR control unit. With thebattery voltage supplied, check thevacuum pressure can be changedaccording to the accelerator pedalpositions. If the vacuum pressurecannot be generated or changed,the vacuum modulator should bereplaced.
NO
Vacuum modulator 1 has a problem in power supplying system.
NO
Replace the vacuum line between vacuum modulator 1 and EGR valve with new one.
YES YES
YES

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-11
SUPPLEMENT
Install the vacuum tester into out- let port of solenoid valve, andcheck whether the negative pres-sure is generated in no-load sharpacceleration mode or not, and readthe changes of vacuum pressurewithin specified ranges.
YES
In solenoid valve, check whether the vacuum pressure is generated between inlet port and outlet port. When the power is supplied, does the solenoid valve close and the intake boost pressure cut off to complete the vacuum circuit?
NO
Replace the vacuum hose in the range.
Install the vacuum tester into out- let port of solenoid valve, andcheck whether the negative pres-sure is generated in no-load sharpacceleration mode or not, and readthe changes of vacuum pressurewithin specified ranges.
YES
Check whether the vacuum pressure is generated between outlet port of solenoid valve and inlet port of ALDA. Is the approx. -300 ~ 650 mbar of negative pressure generated in no-load
sharp acceleration mode?
NO
Replace the vacuum hose in the range.

1A-12 MUSSO-SPORTS
SUPPLEMENT
KAA5A020
KAA5A020
KAA5A020 EXHAUST GAS RECIRCULATION MODULE Removal and Installation Procedure
1. After releasing fixing screw of door scuff to the
passenger seat , remove the door scuff.
KAA5A020 2. After releasing fixing bolt of cowl side trim, remove
cowl side trim.
3. Remove pin of connector from the EGR module.
4. After releasing the fixing nut(3ea) of EGR module, remove the the EGR module.
5. Installation should follow the removal procedure in the reverse order.
THROTTLE POSITION SENSOR Removal Procedure 1. Disconnect the TPS connector from the TPS.
2. After releasing the fixing bolt, remove the TPS. Installation Procedure
1. Install temporary fixing bolt of TPS.
2. Install connector of TPS on the TPS.
3. Check the voltage of TPS by using SCAN-100.
4. Install completely fixing bolt of TPS.

MUSSO-SPORTS 1A-13
SUPPLEMENT
KAA5A020
KAA5A020
KAA5A020VACUUM MODULATOR 1, 2 Removal and Installation Procedure
1. Disconnect vacuum hose and connector from vacuum
module.
2. After releasing fixing bolt from bracket of intake manifold, and then remove vacuum modulator.
3. Installation should follow the removal procedures in the reverse order.
KAA5A020 EGR VALVE AND LIFT SENSOR Removal and Installation Procedure
1. Disconnect vacuum hose and connector from the
EGR valve.
2. After releasing the clamping bolt/nut of EGR Valve pipe and then remove the clamp.
3. After releasing fixing bolt of EGR Valve of Intake Manifold, remove the EGR Valve assembly.
4. Installation should follow the removal procedure in the reverse order.
COOLANT TEMPERATURE SENSOR Removal and Installation Procedure
1. Disconnect the coolant temperature sensor from the coolant temperature sensor.
2. After releasing the coolant temperature sensor from cylinder block and then remove the coolant tempera- ture sensor.
3. Installation should follow the removal procedure in the reverse order.
SOLENOID VALVE Removal and Installation Procedure
1. Disconnect vacuum hose(3ea) and connector from the solenoid valve.
2. Remove the solenoid valve from the fixing bracket of injection pump.
3. Installation should follow the removal procedure in the reverse order.

1A-14 MUSSO-SPORTS
SUPPLEMENT
KAA5A020
KAA5A020
KAA5A020 Removal and Installation of Rear Combi-Lamp
1. After pulling the tailgate, release fixing bolt of the
tail lamp assembly.
2. Carefully remove the tail lamp assembly.
3. Remove the wiring connector of tail lamp.
4. Installation should follow the removal procedure in the reverse order.

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.

1A-16 MUSSO-SPORTS
SUPPLEMENT
j

MUSSO-SPORTS 1A-17
SUPPLEMENT
KAA5A300
REMOVAL AND INSTALLATION
TAIL GATE Preceding repair: remove trim cover of tail gate
1 Hinge Assembly of Tail Gate
2 Fixing Bolt of Tail Gate Hinge
3 Stopper of Tail Gate 4 Fixing Bolt of Tail Gate Stopper
5 Latch of Tail Gate and Rod Assembly
KAA5A020Removal
1. After pulling the tail gate, release fixing bolt of left
tail gate and right tail gate. Notice: While stopper fixing bolt of tail gate is released
not released completely, put this one on the hole of installation.

1A-18 MUSSO-SPORTS
SUPPLEMENT
KAA5A020
KAA5A020 3. Remove the wiring connector of tail lamp.
4. Remove the wiring and grommet which is linked with
tail gate.
5. Remove left and right hinge of tail gate.
6. Remove the assembly of tail gate.
KAA5A020 2. After pulling the tail gate, release fixing screw of tail
gate inside and then remove pannel.